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13 pages, 5622 KiB

Open AccessFeature PaperArticle

Control the Working Process of the Rotor System with Tilting Pad Bearing

by Audrius Čereška

Processes 2024, 12(11), 2583; https://doi.org/10.3390/pr12112583 - 18 Nov 2024

Viewed by 2042

Abstract

Various processes take place in rotor systems with tilting pad bearings. It is important not only to control but also to manage these processes. Due to the instability of the oil film layer in a bearing with inclined pads, oil whirl/whip can occur. [...] Read more.

Various processes take place in rotor systems with tilting pad bearings. It is important not only to control but also to manage these processes. Due to the instability of the oil film layer in a bearing with inclined pads, oil whirl/whip can occur. Such whirl/whip destabilize the operation of the rotor system. Additional elastic elements between the tilt pads suppress oil whirl/whip and thus reduce rotor vibration excitation. By identifying the working zones of such bearings where oil whirl and whip occur, the problems of rotor rotation instability can be solved. In order to determine the effectiveness of the elastic elements between the tilting pads, research was conducted. A special stand with diagnostic equipment was used for the tests. The clearance between the rotor and the bearing was 50 μm. During the research, the rotor rotation speed was varied from 0 to 5000 rpm. After conducting the research, stable and unstable rotor working zones were determined (Zone I: 0 to 1938 rpm; Zone II: 1938–3923 rpm; Zone III: 3923–5000 rpm). Based on the obtained research results, it is possible to control the working process of the rotor system. Full article

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20 pages, 3772 KiB

Open AccessArticle

Industrial Catalytic Production Process of Erythromycin

by Theodora Adamantidi, Ellie Panoutsopoulou, Evangelia Stavrakoudi, Panagiota Tzevelekou and Nikolaos C. Kokkinos

Processes 2024, 12(7), 1533; https://doi.org/10.3390/pr12071533 - 21 Jul 2024

Viewed by 3442

Abstract

The impact of COVID-19’s unexpected outbreak forced the scientific community to seek alternative treatment methods in order to overcome the hindrance of traditional medicine in terms of alleviating the symptoms of this virus. Erythromycin, which was introduced in 1952, is an antibiotic that [...] Read more.

The impact of COVID-19’s unexpected outbreak forced the scientific community to seek alternative treatment methods in order to overcome the hindrance of traditional medicine in terms of alleviating the symptoms of this virus. Erythromycin, which was introduced in 1952, is an antibiotic that is reported to pose as an effective substitute medication for various ailments such as skin, respiratory, bone, and female reproductive conditions, and cancer, as well as the newly added COVID-19. The importance of both the erythromycin molecule and the catalyst of its production, namely P450eryF of the cytochrome P450 family, in many health-concerned and environmentally related applications, has led several countries, the World Health Organization (WHO) and the health industry to recruit and cooperate with numerous universities and institutions, in an attempt to tackle the demand for efficient antibiotics. The aim of this study is to discuss and further analyze the overall structure and catalytic mechanism of erythromycin’s synthesis and industrial production, in order to gain a better comprehension of this molecule’s significance and value in the pharmaceutical field. This was carried out through the citation of the current production rates per country and the latest statistics and published patents. As implied in this manuscript, the demand for an increase and improvement in the production of erythromycin and its antibiotic derivatives should be globally promoted to deliver more effective results against infectious diseases, such as COVID-19. Full article

(This article belongs to the Special Issue Monitoring and Control of Processes in the Context of Industry 4.0)

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15 pages, 7818 KiB

Open AccessArticle

Digital Twin for Monitoring the Experimental Assembly Process Using RFID Technology

by Jakub Demčák, Kamil Židek and Tibor Krenický

Processes 2024, 12(7), 1512; https://doi.org/10.3390/pr12071512 - 18 Jul 2024

Cited by 2 | Viewed by 1158

Abstract

Despite the considerable advances that industrial manufacturing has undergone as a result of digitalization, the real-time monitoring of assembly processes continues to present a significant technical challenge. This article presents a solution to this problem by integrating digital twin technology with radio frequency [...] Read more.

Despite the considerable advances that industrial manufacturing has undergone as a result of digitalization, the real-time monitoring of assembly processes continues to present a significant technical challenge. This article presents a solution to this problem by integrating digital twin technology with radio frequency identification (RFID) in order to improve the monitoring and optimization of assembly processes. The objective of this research is to develop a methodology that ensures synchronized data exchange between physical components and their digital counterparts using RFID for improved visibility and accuracy. The methodology entails the configuration of radio frequency identification systems to track the positions of products on conveyor belts, thereby facilitating real-time monitoring and the prompt detection of any deviations. This integration enhances remote monitoring capabilities and markedly optimizes assembly processes in comparison to traditional methods. The research findings suggest that this approach offers real-time data and monitoring capabilities, which can contribute to improved operational efficiency. This study presents an introduction to digital twins and RFID technology, a review of related research, a detailed methodology, an implementation plan, results and analysis, a discussion of the findings, and conclusions with future recommendations. This article presents a comprehensive discussion of the configuration of an RFID-based digital twin for an assembly line, highlighting the benefits and challenges of integrating these technologies into industrial processes. Full article

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23 pages, 7574 KiB

Open AccessArticle

Monitoring and Reconstruction of Actuator and Sensor Attacks for Lipschitz Nonlinear Dynamic Systems Using Two Types of Augmented Descriptor Observers

by Hao Wang, Zhi-Wei Gao and Yuanhong Liu

Processes 2024, 12(7), 1383; https://doi.org/10.3390/pr12071383 - 2 Jul 2024

Viewed by 1257

Abstract

Fault data injection attacks may lead to a decrease in system performance and even a malfunction in system operation for an automatic feedback control system, which has motive to develop an effective method for rapidly detecting such attacks so that appropriate measures can [...] Read more.

Fault data injection attacks may lead to a decrease in system performance and even a malfunction in system operation for an automatic feedback control system, which has motive to develop an effective method for rapidly detecting such attacks so that appropriate measures can be taken correspondingly. In this study, a secure descriptor estimation technique is proposed for continuous-time Lipschitz nonlinear cyber physical systems affected by actuator attacks, sensor attacks, and unknown process uncertainties. Specifically, by forming a new state vector composed of original system states and sensor faults, an equivalent descriptor dynamic system is built. A proportional and derivate sliding-mode observer is presented so that the system states, sensor attack, and actuator attack can be reconstructed successfully. The observer gains are obtained by using linear matrix inequality to secure robustly stable estimation error dynamics. Moreover, a robust descriptor fast adaptive observer estimator is presented as a complement. Finally, the efficacy levels of the proposed design approaches are validated using a vertical take-off and landing aircraft system. Comparison studies are also carried out to assess the tracking performances of the proposed algorithms. Full article

(This article belongs to the Special Issue Monitoring and Control of Processes in the Context of Industry 4.0)

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14 pages, 1782 KiB

Open AccessArticle

Signal Decomposition for Monitoring Systems of Processes

by Ivan Pavlenko, Justyna Trojanowska, Vitalii Ivanov, Svetlana Radchenko, Jozef Husár and Jana Mižáková

Processes 2024, 12(6), 1188; https://doi.org/10.3390/pr12061188 - 9 Jun 2024

Viewed by 948

Abstract

This article is devoted to the problem of signal decomposition into periodic and aperiodic components. According to the proposed approach, there is no need to evaluate the aperiodic component as a difference between the total signal of its periodic components. This research aims [...] Read more.

This article is devoted to the problem of signal decomposition into periodic and aperiodic components. According to the proposed approach, there is no need to evaluate the aperiodic component as a difference between the total signal of its periodic components. This research aims to create a general analytical approach that combines the Fourier and Maclaurin series methodologies into a single comprehensive series. As a result, analytical expressions for determining deposition coefficients were established for an aperiodic signal with a monoharmonic overlay. Recurrence relations were established to determine the coefficients of this series. These relations allow direct integrations of the obtained values of integrals to be avoided. The evaluated numerical values of the coefficients are also presented graphically and tabulated. It was proven that the values of these coefficients are universal numbers since they do not depend on the period/frequency of oscillations. The reliability of the proposed approach was confirmed by the fact that the evaluated coefficients are equal to the Fourier series coefficients in the case of a periodic signal. Also, for an aperiodic signal, these coefficients were reduced to the coefficients of the Maclaurin series. The usability of the proposed generalized analytical approach for signal decomposition is for control and monitoring systems of processes. Full article

(This article belongs to the Special Issue Monitoring and Control of Processes in the Context of Industry 4.0)

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21 pages, 5364 KiB

Open AccessArticle

IoT-Based Data Mining Framework for Stability Assessment of the Laser-Directed Energy Deposition Process

by Sebastian Hartmann, Bohdan Vykhtar, Nele Möbs, Ingomar Kelbassa and Peter Mayr

Processes 2024, 12(6), 1180; https://doi.org/10.3390/pr12061180 - 7 Jun 2024

Cited by 3 | Viewed by 1066

Abstract

Additive manufacturing processes are prone to production errors. Specifically, the unique physical conditions of Laser-Directed Energy Deposition (DED-L) lead to unexpected process anomalies resulting in subpar part quality. The resulting costs and lack of reproducibility are two major barriers hindering a broader adoption [...] Read more.

Additive manufacturing processes are prone to production errors. Specifically, the unique physical conditions of Laser-Directed Energy Deposition (DED-L) lead to unexpected process anomalies resulting in subpar part quality. The resulting costs and lack of reproducibility are two major barriers hindering a broader adoption of this innovative technology. Combining sensor data with data from relevant steps before and after the production process can lead to an increased understanding of when and why these process anomalies occur. In the present study, an IoT-based data mining framework is presented to assess the stability of processing Ti6Al4V on an industrial-grade DED-L machine. The framework employs an edge-cloud computing methodology to collect data efficiently and securely from various steps in the part lifecycle. During manufacturing, multiple sensors are employed to monitor the essential process characteristics in situ. Mechanical properties of the 160 printed specimens were obtained using appropriate destructive testing. All data are stored on a central database and can be accessed via the web for data analytics. The results prove the successful implementation of the proposed IoT framework but also indicate a lack of process stability during manufacturing. The occurring part errors can only be partially correlated with anomalies in the in situ sensor data. Full article

(This article belongs to the Special Issue Monitoring and Control of Processes in the Context of Industry 4.0)

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20 pages, 2436 KiB

Open AccessFeature PaperArticle

Modeling and Analysis of Distributed Control Systems: Proposal of a Methodology

by Milan Tkáčik, Ján Jadlovský, Slávka Jadlovská, Anna Jadlovská and Tomáš Tkáčik

Processes 2024, 12(1), 5; https://doi.org/10.3390/pr12010005 - 19 Dec 2023

Cited by 1 | Viewed by 2419

Abstract

A Distributed Control System is a concept of Network Control Systems whose applications range from industrial control systems to the control of large physical experiments such as the ALICE experiment at CERN. The design phase of the Distributed Control Systems implementation brings several [...] Read more.

A Distributed Control System is a concept of Network Control Systems whose applications range from industrial control systems to the control of large physical experiments such as the ALICE experiment at CERN. The design phase of the Distributed Control Systems implementation brings several challenges, such as predicting the throughput and response of the system in terms of data-flow. These parameters have a significant impact on the operation of the Distributed Control System, and it is necessary to consider them when determining the distribution of software/hardware resources within the system. This distribution is often determined experimentally, which may be a difficult, iterative process. This paper proposes a methodology for modeling Distributed Control Systems using a combination of Finite-State Automata and Petri nets, where the resulting model can be used to determine the system’s throughput and response before its final implementation. The proposed methodology is demonstrated and verified on two scenarios concerning the respective areas of ALICE detector control system and mobile robotics, using the MATLAB/Simulink implementation of created models. The methodology makes it possible to validate various distributions of resources without the need for changes to the physical system, and therefore to determine the appropriate structure of the Distributed Control System. Full article

(This article belongs to the Special Issue Monitoring and Control of Processes in the Context of Industry 4.0)

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18 pages, 1262 KiB

Open AccessArticle

Integration of Bayesian Adaptive Exponentially Weighted Moving Average Control Chart and Paired Ranked-Based Sampling for Enhanced Semiconductor Manufacturing Process Monitoring

by Botao Liu, Muhammad Noor-ul-Amin, Imad Khan, Emad A. A. Ismail and Fuad A. Awwad

Processes 2023, 11(10), 2893; https://doi.org/10.3390/pr11102893 - 30 Sep 2023

Cited by 4 | Viewed by 1529

Abstract

Exponentially weighted moving average (EWMA) and Shewhart control charts are commonly utilized to detect the small to moderate and large shifts in the process mean, respectively. This article introduces a novel Bayesian AEWMA control chart that employs various loss functions (LFs), including square [...] Read more.

Exponentially weighted moving average (EWMA) and Shewhart control charts are commonly utilized to detect the small to moderate and large shifts in the process mean, respectively. This article introduces a novel Bayesian AEWMA control chart that employs various loss functions (LFs), including square error loss function (SELF) and LINEX loss function (LLF). The control chart incorporates an informative prior for posterior and posterior predictive distributions. Additionally, the control chart utilizes various paired ranked set sampling (PRSS) schemes to improve its accuracy and effectiveness. The average run length (ARL) and standard deviation of run length (SDRL) are used to evaluate the performance of the suggested control chart. Monte Carlo simulations are conducted to compare the performance of the proposed approach to other control charts. The results show that the proposed method outperforms in identifying out-of-control signals, particularly under PRSS schemes compared to simple random sampling (SRS). The proposed CCs effectiveness was validated using a real-life semiconductor manufacturing application, utilizing different PRSS schemes. The performance of the Bayesian AEWMA CC was evaluated, demonstrating its superiority in detecting out-of-control signs compared to existing CCs. This study introduces an innovative method incorporating various LFs and PRSS schemes, providing an enhanced and efficient approach for identifying shifts in the process mean. Full article

(This article belongs to the Special Issue Monitoring and Control of Processes in the Context of Industry 4.0)

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15 pages, 908 KiB

Open AccessArticle

Study on Multi-Objective Optimization of Logistics Distribution Paths in Smart Manufacturing Workshops Based on Time Tolerance and Low Carbon Emissions

by Chao Wu, Yongmao Xiao, Xiaoyong Zhu and Gongwei Xiao

Processes 2023, 11(6), 1730; https://doi.org/10.3390/pr11061730 - 6 Jun 2023

Cited by 2 | Viewed by 2371

Abstract

In the Industry 4.0 environment, an ideal smart factory should be intelligent, green, and humanized, and the logistics transportation from raw materials to final products in the factory should be completed by smart logistics. In order to address the problems of low efficiency, [...] Read more.

In the Industry 4.0 environment, an ideal smart factory should be intelligent, green, and humanized, and the logistics transportation from raw materials to final products in the factory should be completed by smart logistics. In order to address the problems of low efficiency, poor workstation service satisfaction, high distribution costs, and non-greening during the logistics distribution processes in discrete smart manufacturing workshops are required. A mathematical model of optimized multi-objective green logistics distribution paths in a smart manufacturing workshop has been constructed in this study, with low costs, high efficiency, and workstation service satisfaction taken into consideration. Then, this mathematical model was solved with an improved ant colony optimization algorithm. A “time window span” was introduced in the basic ant colony optimization algorithm to prioritize the services to workstations with a relatively high urgency in material demand, with the aim of improving workstation service satisfaction. Lastly, in order to verify the effectiveness of the model and algorithm proposed in this study, a simulation experiment has been conducted on the workstation logistics distribution system in a smart manufacturing workshop to provide convincing evidence for optimizing workstation logistics distribution paths in workshops of discrete manufacturing enterprises. Full article

(This article belongs to the Special Issue Monitoring and Control of Processes in the Context of Industry 4.0)

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19 pages, 3089 KiB

Open AccessArticle

A Framework for Multivariate Statistical Quality Monitoring of Additive Manufacturing: Fused Filament Fabrication Process

by Moath Alatefi, Abdulrahman M. Al-Ahmari, Abdullah Yahia AlFaify and Mustafa Saleh

Processes 2023, 11(4), 1216; https://doi.org/10.3390/pr11041216 - 14 Apr 2023

Cited by 8 | Viewed by 2021

Abstract

Advances in additive manufacturing (AM) processes have increased the number of relevant applications in various industries. To keep up with this development, the process stability of AM processes should be monitored, which is conducted through the assessment of the outputs or product characteristics. [...] Read more.

Advances in additive manufacturing (AM) processes have increased the number of relevant applications in various industries. To keep up with this development, the process stability of AM processes should be monitored, which is conducted through the assessment of the outputs or product characteristics. However, the use of univariate control charts to monitor an AM process might lead to misleading results, as most additively manufactured products have more than one correlated quality characteristic (QC). This paper proposes a framework for monitoring the multivariate quality characteristics of AM processes, and the proposed framework was applied to monitor a fused filament fabrication (FFF) process. In particular, specimens were designed and produced using the FFF process, and their QCs were identified. Then, critical quality characteristic data were collected using a precise measurement system. Furthermore, we propose a transformation algorithm to ensure the normality of the collected data. After examining the correlations between the investigated quality characteristics, a multivariate exponential weighted moving average (MEWMA) control chart was used to monitor the stability of the process. Furthermore, the MEWMA parameters were optimized using a novel heuristic technique. The results indicate that the majority of the collected data are not normally distributed. Consequently, the efficacy of the proposed transformation technique is demonstrated. In addition, our findings illustrate the correlations between the QCs. It is worth noting that the MEWMA optimization results confirm that the considered AM process (i.e., FFF) is relatively stable. Full article

(This article belongs to the Special Issue Monitoring and Control of Processes in the Context of Industry 4.0)

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18 pages, 4242 KiB

Open AccessArticle

Turned Surface Monitoring Using a Confocal Sensor and the Tool Wear Process Optimization

by Jozef Jurko, Martin Miškiv-Pavlík, Jozef Husár and Peter Michalik

Processes 2022, 10(12), 2599; https://doi.org/10.3390/pr10122599 - 5 Dec 2022

Cited by 8 | Viewed by 1939

Abstract

Laser scanning technology has been used for several years. Nevertheless, no comprehensive study has been conducted to prove that the application of confocal chromatic sensor (CCHS) laser technology is effective and suitable to verify the integrity parameters of machined surfaces in terms of [...] Read more.

Laser scanning technology has been used for several years. Nevertheless, no comprehensive study has been conducted to prove that the application of confocal chromatic sensor (CCHS) laser technology is effective and suitable to verify the integrity parameters of machined surfaces in terms of cutting tool damage. In this paper, the optimization and effects of five factors (cutting speed, feed, depth of cut, attachment length of the workpiece, and tip radius) on the roundness deviation measured by CCHS and, at the same time, on the amount of wear on the back side of the cutting part of the tool were studied according to ISO 3685, which was measured with a microscope. The results obtained were evaluated using the gray relational analysis method (GRA), in conjunction with the Taguchi method, and the significance of the factors was demonstrated using the analysis of variance (ANOVA) method. Full article

(This article belongs to the Special Issue Monitoring and Control of Processes in the Context of Industry 4.0)

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16 pages, 3776 KiB

Open AccessFeature PaperArticle

Vapor Overproduction Condition Monitoring in a Liquid–Vapor Ejector

by Serhii Sharapov, Jana Mižáková, Danylo Husiev, Vitalii Panchenko, Vitalii Ivanov, Ivan Pavlenko and Kamil Židek

Processes 2022, 10(11), 2383; https://doi.org/10.3390/pr10112383 - 13 Nov 2022

Cited by 2 | Viewed by 1473

Abstract

We consider the influence of vapor content in the mixed flow leaving a liquid-vapor ejector on the energy efficiency of a vacuum unit. As shown by numerical studies of liquid-vapor ejectors, this issue is important as vapor overproduction, which accompanies the process of [...] Read more.

We consider the influence of vapor content in the mixed flow leaving a liquid-vapor ejector on the energy efficiency of a vacuum unit. As shown by numerical studies of liquid-vapor ejectors, this issue is important as vapor overproduction, which accompanies the process of secondary flow ejection, directly impacts the efficiency of the working process of both the liquid-vapor ejector and the vacuum unit as a whole. The greater the degree of vapor overproduction, the greater the load on the vapor phase of the separator, which is part of the vacuum unit. In addition, the liquid phase must be returned to the cycle to ensure the constancy of the mass flow rate of the working fluid of the primary flow. Our numerical study results revealed the rational value of the degree of vapor overproduction at which the efficiency of the liquid–vapor ejector was maximized, and the amount of additional working fluid that needed to enter the cycle of the vacuum unit was minimal. Experimental condition monitoring studies on the liquid–vapor ejector were carried out on plane-parallel transparent models with different flow path geometries. Through experimental studies, we confirmed and adjusted the values of the achievable efficiency of the working process of a liquid–vapor ejector, depending on the degree of vapor overproduction. Using a comparative analysis of liquid–vapor ejectors with different flow path geometries, differences were revealed in their working processes, which consisted of the degree of completion of the mixing of the working media of primary and secondary flows. To determine the feasibility of using liquid–vapor ejectors with different flow path geometries, exergy analysis was performed, resulting in achievable efficiency indicators. Full article

(This article belongs to the Special Issue Monitoring and Control of Processes in the Context of Industry 4.0)

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21 pages, 6575 KiB

Open AccessArticle

Experimental Studies and Condition Monitoring of Auxiliary Processes in the Production of Al₂O₃ by Sol–Gel Technology

by Vsevolod Sklabinskyi, Oleksandr Liaposhchenko, Ján Piteľ, Ivan Pavlenko, Maksym Skydanenko, Ruslan Ostroha, Mykola Yukhymenko, Kostiantyn Simeiko, Maryna Demianenko, Michal Volf, Oleksandr Starynskyi, Oleksandr Yurchenko and Oleksandr Mandryka

Processes 2022, 10(10), 2090; https://doi.org/10.3390/pr10102090 - 15 Oct 2022

Cited by 1 | Viewed by 1737

Abstract

Powders and granules of heavy metal oxides produced through condition monitoring are in high demand as intermediate products for obtaining fine-grained ceramics for a wide range of applications, i.e., nuclear fuel and fuel elements for nuclear power plants. Sol–gel technology to produce nuclear [...] Read more.

Powders and granules of heavy metal oxides produced through condition monitoring are in high demand as intermediate products for obtaining fine-grained ceramics for a wide range of applications, i.e., nuclear fuel and fuel elements for nuclear power plants. Sol–gel technology to produce nuclear fuel (UO₂), as well as catalysts (ThO₂) for organic synthesis in the form of granules from pressed microspheres, is a promising method to obtain powders and granules of heavy metal oxides (fine-graded ceramics). Al₂O₃ was selected as the model analog at the stages of obtaining a solution of heavy metal and sol, the formation and gelation of droplets, and the preparation of gel spheres and their further washing and drying, as well as recovery and firing of particles. In the study, the main parameters were substantiated, e.g., the diameter and angle of inclination of the axis for the holes in the perforated shell, the multiplicity of sol circulation before the holes, the coefficients of liquid (sol) flow rate, the oscillation frequency of the disperser, and the concentration of surfactant and acid in sol. All of these parameters affect the characteristics of the granules that are obtained by sol–gel technology. Moreover, recommendations to increase productivity and the energy efficiency of production were also given. In particular, it was found that oscillation frequency in a range of 70–80 Hz leads to a granulometric composition of the obtained granules of 2.0–2.2 mm. A hole of 0.85 mm and a frequency of 100 Hz slightly change this range to 1.2–2.0 mm, while maintaining monodispersity. Full article

(This article belongs to the Special Issue Monitoring and Control of Processes in the Context of Industry 4.0)

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Review

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30 pages, 6194 KiB

Open AccessReview

Modeling and Control for Beam Pumping Units: An Overview

by Zhi-Wei Gao and Shifeng Jia

Processes 2024, 12(7), 1468; https://doi.org/10.3390/pr12071468 - 13 Jul 2024

Viewed by 1589

Abstract

Beam pumping units play a key role in oil extraction. There is an increasing demand for optimal oil-extracting performance as operational environments are becoming more challenging and complex. Therefore, it is vital to create an acceptable mathematical model and develop robust control mechanisms. [...] Read more.

Beam pumping units play a key role in oil extraction. There is an increasing demand for optimal oil-extracting performance as operational environments are becoming more challenging and complex. Therefore, it is vital to create an acceptable mathematical model and develop robust control mechanisms. In the past decades, researchers have achieved fruitful results regarding modeling and control methods in this field. This article provides a comprehensive review of the research on modeling and control methods for beam pumping units, including mathematical models based on differential equations and boundary conditions, as well as the control strategies designed. Finally, future perspectives and recommendations are presented. Full article

(This article belongs to the Special Issue Monitoring and Control of Processes in the Context of Industry 4.0)

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