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Processes
Special Issues
Challenges and Advances of Process Control Systems
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Challenges and Advances of Process Control Systems

A special issue of Processes (ISSN 2227-9717). This special issue belongs to the section "Process Control and Monitoring".

Deadline for manuscript submissions: 30 June 2025 | Viewed by 8725

Special Issue Editors

Prof. Dr. Olympia Roeva

E-Mail Website
Guest Editor
Institute of Biophysics and Biomedical Engineering, Bulgarian Academy of Sciences, 1113 Sofia, Bulgaria
Interests: mathematical modelling; metaheuristic algorithms; process control; generalised nets; intuitionistic fuzzy sets; intercriteria analysis
Special Issues, Collections and Topics in MDPI journals
Prof. Tsonyo Slavov

E-Mail Website
Guest Editor
Systems and Control, Technical University of Sofia, 1000 Sofia, Bulgaria
Interests: system modelling and identification; robust control; embedded control system; process control

Special Issue Information

Dear Colleagues,

The purpose of the Special Issue, titled “Challenges and Advances of Process Control Systems”, is to provide an opportunity for researchers and practitioners to exchange their latest theoretical and technological advances and to identify critical issues and challenges addressing the application and development of various devices of different advanced control algorithms. These algorithms can be based on, but are not limited to, the approaches of robust, optimal, adaptive, predictive control, and intelligent control.

The topics include, but are not limited to, the following control system applications:

  • Manufacturing and production processes
  • Power generation and distribution
  • Robotics
  • Hydraulics
  • Medicine
  • Biotechnology

Prof. Dr. Olympia Roeva
Prof. Tsonyo Slavov
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Processes is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • real-time process control
  • application of artificial intelligence in modelling and control problems
  • robot control and modelling
  • bioprocess modelling and control
  • embedded control systems

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Further information on MDPI's Special Issue polices can be found here.

Published Papers (7 papers)

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Research

17 pages, 5518 KiB  
Article
Robustness and Scalability of Incomplete Virtual Pheromone Maps for Stigmergic Collective Exploration
by Kaloyan Dimitrov and Vladimir Hristov
Processes 2024, 12(10), 2122; https://doi.org/10.3390/pr12102122 - 29 Sep 2024
Viewed by 559
Abstract
The Swarm Guiding and Communication System (SGCS) is a decision-making and information-sharing framework for robot swarms that only needs close-range peer-to-peer communication and no centralized control. Each robot makes decisions based on an incomplete virtual pheromone map that is updated on each interaction [...] Read more.
The Swarm Guiding and Communication System (SGCS) is a decision-making and information-sharing framework for robot swarms that only needs close-range peer-to-peer communication and no centralized control. Each robot makes decisions based on an incomplete virtual pheromone map that is updated on each interaction with another robot, imitating ant colonial behavior. Similar systems rely on continuous communication with no range limitations, environment modification, or centralized control. A computer simulation is developed to assess the effectiveness and robustness of the framework in covering an area. Consistency and the time needed for 99% coverage are compared with an unbiased random walk. The pheromone approach is shown to outperfom the unbiased one regardless of number of agents. Innate resilience to individual failures is also demonstrated. Full article
(This article belongs to the Special Issue Challenges and Advances of Process Control Systems)
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20 pages, 6470 KiB  
Article
PID Controller Design for an E. coli Fed-Batch Fermentation Process System Using Chaotic Electromagnetic Field Optimization
by Olympia Roeva, Tsonyo Slavov and Jordan Kralev
Processes 2024, 12(9), 1795; https://doi.org/10.3390/pr12091795 - 23 Aug 2024
Viewed by 694
Abstract
This paper presents an optimal tuning of a proportional integral differential (PID) controller used to maintain glucose concentration at a desired set point. The PID controller synthesizes an appropriate feed rate profile for an E. coli fed-batch cultivation process. Mathematical models are developed [...] Read more.
This paper presents an optimal tuning of a proportional integral differential (PID) controller used to maintain glucose concentration at a desired set point. The PID controller synthesizes an appropriate feed rate profile for an E. coli fed-batch cultivation process. Mathematical models are developed based on dynamic mass balance equations for biomass, substrate, and product concentration of the E. coli BL21(DE3)pPhyt109 fed-batch cultivation for bacterial phytase extracellular production. For model parameter identification and PID tuning, a hybrid metaheuristic technique—chaotic electromagnetic field optimization (CEFO)—is proposed. In the hybridization, a chaotic map is used for the generation of a new electromagnetic particle instead of the electromagnetic field optimization (EFO) search strategy. The CEFO combines the exploitation capability of the EFO algorithm and the exploration power of ten different chaotic maps. The comparison of the results with classical EFO shows the superior behaviour of the designed CEFO. An improvement of 30% of the objective function is achieved by applying CEFO. Based on the obtained mathematical models, 10 PID controllers are tuned. The simulation experiments show that the designed controllers are robust, resulting in a good control system performance. The closed-loop transient responses for the corresponding controllers are similar to the estimated models. The settling time of the control system based on the third PID controller for all estimated models is approximately 9 min and the overshoot is approximately 15%. The proposed CEFO algorithm can be considered an effective methodology for mathematical modelling and achievement of high quality and better performance of the designed closed-loop system for cultivation processes. Full article
(This article belongs to the Special Issue Challenges and Advances of Process Control Systems)
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25 pages, 12203 KiB  
Article
Influence Mechanism of Ambient Air Parameters on the Rotational Stall of an Axial Fan
by Hui Ma, Guangtong Tang, Chaoyang Wang, Tianlong Wang, Xin Li, Yonghui Jia, Yulong Qiu, Wei Yuan and Lei Zhang
Processes 2024, 12(8), 1781; https://doi.org/10.3390/pr12081781 - 22 Aug 2024
Viewed by 767
Abstract
This study investigates a dual-stage axial-flow fan within a specific power plant context. Numerical simulations encompassing both steady-state and stall conditions were conducted utilizing the Reynolds-averaged Navier–Stokes (RANS) equations coupled with the Realizable k–ε turbulence model. The findings reveal that, under [...] Read more.
This study investigates a dual-stage axial-flow fan within a specific power plant context. Numerical simulations encompassing both steady-state and stall conditions were conducted utilizing the Reynolds-averaged Navier–Stokes (RANS) equations coupled with the Realizable k–ε turbulence model. The findings reveal that, under normal operating conditions, there exists a positive correlation between the mass flow rate and outlet pressure with gas density while displaying a negative correlation with dynamic viscosity. Regardless of the changes in air density, the volumetric flow rate at the maximum outlet pressure of the fan remains essentially the same. When a stall occurs, the volumetric flow rate rapidly decreases to a specific value and then decreases slowly. The analysis of the three-dimensional flow field within the first-stage rotor was performed before and after the rotational stall occurrence. Notably, stall inception predominantly manifests at the blade tip. As the flow rate diminishes, the leakage area at the blade tip within a passage expands, directing the trajectory of the leakage vortex toward the leading edge of the blade. Upon reaching a critical flow rate, the backflow induced by the blade tip leakage vortex obstructs the entire passage at the blade tip, progressively evolving into a stall cell, thereby affecting flow within both passages concurrently. Full article
(This article belongs to the Special Issue Challenges and Advances of Process Control Systems)
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9 pages, 2068 KiB  
Article
An Application of Lean Techniques to Construct an Integrated Management Systems Preventive Action Model and Evaluation: Kaizen Projects
by Matshidiso Moso and Oludolapo Akanni Olanrewaju
Processes 2024, 12(6), 1069; https://doi.org/10.3390/pr12061069 - 23 May 2024
Viewed by 1031
Abstract
The Occupational Health and Safety system enforces the continual improvement culture in industries for much safer processes and zero injuries. The Quality Management System also enforces the same philosophy of continual improvement within the processing system for zero defects, hence a high productivity [...] Read more.
The Occupational Health and Safety system enforces the continual improvement culture in industries for much safer processes and zero injuries. The Quality Management System also enforces the same philosophy of continual improvement within the processing system for zero defects, hence a high productivity rate. Good quality products always result from good Overall Equipment Effectiveness; hence, Process Re-Engineering is essential for the good functioning of machinery. This research is based on Integrated Management System requirements in terms of problem-solving, especially the opportunities that arise within Quality nonconformances, Safety Incidents, as well as Process Engineering related breakdowns. This study aims to develop a troubleshooting system that evaluates continual improvement projects. The method used to develop the troubleshooting system is based on Total Quality Management, where lean principles are combined with kaizen concepts and quality standards. The proposed troubleshooting system is separated into three development phases: the first phase is for recording the details of the fault that has been raised, where one will record full details of the nonconformance, the time and date, validation of the nonconformance by the lab test or any other form of validation depending on the nature of the problem as well as the details of the location of the problem. The second phase is for problem classification, whether it is a quality nonconformance, Safety incident, or engineering-related breakdown. The deeper root cause analysis is performed by an application of lean techniques, which are the eight types of waste, Five Whys and Ishikawa analysis. The eight types of waste identify the type of waste contributed by the problem, the Five Whys analysis assists in finding the reason for the problem occurrence, and the Ishikawa analysis classifies the problem accordingly, which assists the analyst in identifying the area to focus on for problem-solving. The third phase is for a database system and an application of the kaizen philosophy by evaluating continual improvement projects as well as status reports on the permanent solutions to the faults. The proposed troubleshooting model was applied in a case study company to upgrade the problem-solving model that the company was using which was assisting for corrective and preventive action. The study resulted in drastic improvements; hence, continual improvement projects were evaluated within the problem occurrences. Full article
(This article belongs to the Special Issue Challenges and Advances of Process Control Systems)
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17 pages, 1692 KiB  
Article
Security Assessment of Industrial Control System Applying Reinforcement Learning
by Mariam Ibrahim and Ruba Elhafiz
Processes 2024, 12(4), 801; https://doi.org/10.3390/pr12040801 - 16 Apr 2024
Viewed by 1440
Abstract
Industrial control systems are often used to assist and manage an industrial operation. These systems’ weaknesses in the various hierarchical structures of the system components and communication backbones make them vulnerable to cyberattacks that jeopardize their security. In this paper, the security of [...] Read more.
Industrial control systems are often used to assist and manage an industrial operation. These systems’ weaknesses in the various hierarchical structures of the system components and communication backbones make them vulnerable to cyberattacks that jeopardize their security. In this paper, the security of these systems is studied by employing a reinforcement learning extended attack graph to efficiently reveal the subsystems’ flaws. Specifically, an attack graph that mimics the environment is constructed for the system using the state–action–reward–state–action technique, in which the agent is regarded as the attacker. Attackers may cause the greatest amount of system damage with the fewest possible actions if they have the highest cumulative reward. The worst-case assault scheme with a total reward of 42.9 was successfully shown in the results, and the most badly affected subsystems were recognized. Full article
(This article belongs to the Special Issue Challenges and Advances of Process Control Systems)
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21 pages, 8300 KiB  
Article
CFD Modeling and Experimental Validation of the Flow Processes of an External Gear Pump
by Alexander Mitov, Nikolay Nikolov, Krasimir Nedelchev and Ivan Kralov
Processes 2024, 12(2), 261; https://doi.org/10.3390/pr12020261 - 25 Jan 2024
Cited by 6 | Viewed by 1771
Abstract
This article presents computational fluid dynamics (CFD) modeling of the flow processes at a certain specimen of an external gear pump. The purpose of the developed two-dimensional (2D) CFD model is to carry out a numerical study to obtain the main characteristics of [...] Read more.
This article presents computational fluid dynamics (CFD) modeling of the flow processes at a certain specimen of an external gear pump. The purpose of the developed two-dimensional (2D) CFD model is to carry out a numerical study to obtain the main characteristics of the pump flow rate, especially the flow rate as a function of the pressure and the flow rate as a function of the time. A numerical study was carried out at forty-two different operating modes that were expressed as a variation of two parameters: rotational frequency (950–1450 min−1) and pressure (5–150 bar). The validation of the numerical results was carried out through an experimental study. For this purpose, a laboratory experimental setup equipped with a modern data acquisition (DAQ) system was designed and implemented. It allows the gear pump to be tested at the same operating modes as the numerical study. A validation analysis was performed by comparing the numerical and experimental results using the average relative error index (FIT). A detailed description of the 2D CFD model development (CAD model, mesh, general settings, boundary conditions, etc.) is provided. Based on the 2D CFD model, an original methodology was proposed to take into account the influence of the discharge channels on the displacement volume of the pump by adjusting the face width of the gears. Despite the limitations of the simple 2D CFD model, which are discussed in this article, a very good match between numerical and experimental results is analyzed by calculating the FIT level, which is in the range of 93–97%. Full article
(This article belongs to the Special Issue Challenges and Advances of Process Control Systems)
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19 pages, 8863 KiB  
Article
Experimental Study of Sound Pressure Level in Hydraulic Power Unit with External Gear Pump
by Alexander Mitov, Krasimir Nedelchev and Ivan Kralov
Processes 2023, 11(8), 2399; https://doi.org/10.3390/pr11082399 - 9 Aug 2023
Cited by 2 | Viewed by 1458
Abstract
The article presents the results of an experimental study of the sound pressure level (SPL) caused by a hydraulic power unit with an external gear pump. The study was carried out with a specially developed laboratory experimental setup based on a [...] Read more.
The article presents the results of an experimental study of the sound pressure level (SPL) caused by a hydraulic power unit with an external gear pump. The study was carried out with a specially developed laboratory experimental setup based on a common architecture used in hydraulic power units. Both the hydraulic system and the measuring equipment used are described in detail. The design of the experimental studies performed, including two main configurations with specific parameters regarding the operating modes of the system, is presented. The experimental results obtained are presented in the form of magnitude frequency responses which are compared in accordance with the experiment design. An analysis of the results obtained is performed using various quantitative indicators. For specific operating modes, parametric models were derived by approximation of the experimental data. The resulting models can serve in future work to reduce the SPL by passive or active means (e.g., frequency control of the electric motor). The quantitative analysis can serve as a basis of comparison with results obtained after adding passive (damping ring, etc.) or active means to reduce the SPL. Full article
(This article belongs to the Special Issue Challenges and Advances of Process Control Systems)
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