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Intelligent control of scheduling and variable frequency control of pumps in an industry production line

Vogiatzis Georgios

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Summary

The soft drink manufacture is one of the non-alcoholic categories of beverage industry. The carbonated drink production line (PL) includes from water treatment to packing. The carbonated drink production line includes pump stations, has water treatment and drink mixers, CO2 steel tanks, balanced pressure machines labeling and packing machines. This Thesis is focused on the automatic control of carbonated soft drinks production line operation based on Distributed Control Systems (DCS), in order to keep the tanks level control, and expand the line's production capabilities with cost-effective resource management that deliver optimal results across the supply chain. One of the basic control aims is the optimal speed control of the automatic carbonated soft drinks production line, in order to be adjusted infinitively and to accord with the standards. This thesis has the following purposes: (1) to examine the available state-of-the-art control methods that can be applied to a production line optimal management(2) to study the structure and operation of action modern soft drink production lines (PLs) which include manufacturing and bottling production line, (3) to design a Distributed Control Systems (DCS) for a standard soft drink PL in order to achieve tank level control, and safety operation (4) to model, simulate and test a soft drink production line including hydraulics which consists of pump stations, tanks, valves, pipelines, speed controllers and the proposed Distributed Control Systems (DCS) system (5) to design scenarios of the incorporation of Model based Predictive Control (MPC) in the proposed DCS system for a standard soft drink PL in order the optimal control management of the PL,(6) to test the performance of the simulated soft drink PL for different operation situations under DCS control, (7) to research upon all available simulation software able to handle large scale hydraulic plants and large scale water distribution networks systems.The data and materials we use are similar to true ones from two modern existing soft drink companies, such as the Czech KOFOLA CeskoSlovensko AS and the Greek ETANAP-Samaria SA. The modeling and simulation of the pump station of a soft drink PL is implemented in Simulink of MATLAB®, using the Simscape Fluids™ (formerly SimHydraulics®) library, based on a time slicing approach. The extracted simulation results of the three different simulated operational scenarios of our virtual PL and the simulated proposed DSC control system, verified that the proposed DSC is effective and appropriate. The first scenario represents the case study that simulates the normal, (nominal) operation of the PL, under the condition of stable flow (nominal manufacturing and the bottling process). The second scenario simulates a situation where one of the three pumps are malfunctioning. The last scenario simulates a situation where two of the three pumps are faulty. The DSC control system manages the first malfunction by scheduling and regulating the remaining pumps and stabilize the optimal flow at the operating range and terminates the system if another (second) malfunction occurred. According to our simulations results, the automatic process control methods as DCS is necessary for soft drink PL.

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