Control of Mechatronic Systems. Patrick O. J. Kaltjob

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      1 time-based objectives, such as improving service or productivity through an enhancement of mechatronic system functions;

      2 cost-based objectives, such as reducing the cost of system operation (e.g. energy reduction) or service by improving the performance of the controlled mechatronic systems;

      3 quality-based objectives, such as improving system operations efficiency or service reliability through the enhancement of control functions for mechatronic systems;

      4 a combination of control system design objectives, such as delivering new services or products, replacing or extending them; or

      5 monitoring and analysis objectives to be integrated into the mechanism system design.

      1 Preliminary studies based on mechatronic system and process schematics.

      2 Performance technical audit:performance assessment;performance objectives and controller specifications.

      3 Functional analysis and modeling:FAST decomposition method;operating conditions and discrete time modeling;startup and shutdown sequence relationship diagram;operating description and discrete event formal modeling.

      4 Hybrid controller and digital system design:continuous controller algorithm;logic controller software design;storage requirement assessment (memory size etc.), control system throughput, user interface requirements;controller hardware design (control panel design and layout, instrumentation system design and layout);logic controller circuitry design (distribution and control architecture).

      5 Controller solution execution and commissioning:control feedback variable tuning;operation monitoring under failure modes;operation validation based on control system test protocol;personnel training;deployment.

      1 Mechatronic system and process diagrams, especially:process flow (PF) and piping and instrumentation (P&I) drawings based on the mechatronic system description, if possible;cabling and wiring diagrams (power distribution schemes, data cable routing and cable diagrams, instrument hook-up drawings);electrical schematics and connection diagrams connecting operator user interface actuators and sensors through a detailed panel layout;power supply, interconnection, and distribution diagrams, and electrical device placements, such as the number of repeaters between nodes;field control instrument lists with data sheet formulation for various instruments such as: flow, level, pressure, differential pressure, temperature, transmitters, converters, isolators; multipliers; control valves and so on; anddiagrams for safety compliance (interlock schematics).

      2 Documents for mechatronic device sizing and selection, especially on:actuating elements such as motor drives, control valves, orifices with estimates (calculations) of their operating conditions;sensing elements such as piezoelectric flow sensors;data processing and computing elements (memory size, scan cycle etc.); andpower storage and utilities equipment, such as uninterruptible power source (UPS) batteries (capacity etc.).

      3 Documents on sizing and selection of data network components (type, media etc.) and replacements especially related to:selection of I/O modules (integrated/distributed);I/O addressing;data logging and process data archiving; anddatabase structure formulation.

      4 Documents on hybrid controller structure, configuration, and operation:continuous control and logic control design algorithm and digital system circuitry; andcontrol system configuration and instrument calibration.

      5 Control system maintenance/support procedures and documents including:I/O process interface for discrete and analog fields devices as well as memory organization;detection and diagnosis of external field control device failure, I/O module replacement procedure; I/O process wiring check, operational testing (factory acceptance testing), definition of emergency stops, and safety control relays;power supply, controller memory card replacement procedures; andtroubleshooting procedure and listing of hybrid control software errors.