<p>The fourth industrial revolution is currently accelerating the transition from conventional manufacturing facilities to “smart factories.” This paper demonstrates the practical application of a Real-Time Digital Simulator (RTDS) for modeling the brine filtration stage within a chemical plant. This model, applicable to smart factory environments, simulates the real-time process controls for both level and concentration. Furthermore, the system establishes a connection with an ABB 800xA SCADA platform. This linkage is achieved using the IEC 60870-5-104 (IEC 104) protocol, facilitated by OPC and the Triangle MicroWorks SCADA Data Gateway (SDG triangle). To enhance the system’s overall quality and stability in caustic soda systems, an advanced control strategy is implemented. This strategy integrates a Fuzzy Logic Decoupling Control scheme with optimization performed by a Genetic Algorithm (GA). The paper concludes that RTDS serves as a potent tool for smart factories. It enables the optimization of supervisory functions, leading to reduced operational costs, greater efficiency, and comprehensive real-time visibility across all control layers of the facility.</p>

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A fuzzy logic decoupling control approach for quality improvement in caustic soda systems using RTDS and 800xA SCADA with IEC 104 integration

  • Duc Duong Nguyen,
  • Ngoc Thanh Pham,
  • Manh Hung Do,
  • Phong Tuan Dang,
  • Viet Phuong Pham,
  • Thanh Tung Phan

摘要

The fourth industrial revolution is currently accelerating the transition from conventional manufacturing facilities to “smart factories.” This paper demonstrates the practical application of a Real-Time Digital Simulator (RTDS) for modeling the brine filtration stage within a chemical plant. This model, applicable to smart factory environments, simulates the real-time process controls for both level and concentration. Furthermore, the system establishes a connection with an ABB 800xA SCADA platform. This linkage is achieved using the IEC 60870-5-104 (IEC 104) protocol, facilitated by OPC and the Triangle MicroWorks SCADA Data Gateway (SDG triangle). To enhance the system’s overall quality and stability in caustic soda systems, an advanced control strategy is implemented. This strategy integrates a Fuzzy Logic Decoupling Control scheme with optimization performed by a Genetic Algorithm (GA). The paper concludes that RTDS serves as a potent tool for smart factories. It enables the optimization of supervisory functions, leading to reduced operational costs, greater efficiency, and comprehensive real-time visibility across all control layers of the facility.