Técnicas de automatización avanzadas en procesos industriales

Abstract

This work presents a methodology for the improvement of productive processes in automated industrial plants. It mainly focuses on industrial processes, advanced graphic modeling tools, discrete events dynamic systems, programmable logic controllers, simulation, supervision and graphic engineering. Initially certain automation elements are presented: PLCs, SCADAs and formalisms for modeling, analysis, and implementation of discrete systems: GRAFCET and PNs. These issues are shown from basic levels, with many definitions, classifications, and references (articles, PhD thesis, internet addresses, etc.), in order to constitute a starting point for non experts readers. Next chapter analyzes the methodology and architecture of simulation and automatic control of complex processes, and the performance improvement derived from the coordinated use of programmable logic controlers and SCADAs. An adaptive redundant control is proposed, which is able to detect automatism failures and system behavior deviations. Starting from models developed with high-level formalisms, a methodology to implement automations in programmable logic controllers and industrial devices of automatic control is presented. The interrelated implementation of automation and system models, leads to the semi-physical simulation concept, which permits to verify the correct working of the automation before applying it to the real system, or to simulate, in real time, complicated maneuvers and operations. On the subsequent chapter a similar methodological analysis based on computer is presented. This permits to use the models of the automation and the system to simulate the global process what implies the possibility of implementing additional performances. Then, adaptive automation techniques in flexible systems with restrictions and priorities are presented, as well as their adaptation to control devices and simulation and performance analysis programs. Applications developed with diverse programming languages are presented, and the integration of complex controllers in the global automation of the process is shown. All that, together with 3D and virtual reality applications, drives to the concept of Virtual Factory. Finally all the above-mentioned developments are applied, as a practical example, to a real plant of ceramic elements production of last generation. The process type and its peculiarities are methodologically analyzed, from their diverse subsystems. Obviously the techniques can equally be applied in other industrial sectors.