过程控制与优化
概述
过程控制和优化 (PCO) 是在不违反过程约束的情况下调整过程以维持或优化一组指定参数的学科。 PCO 市场受到对节能生产流程、安全和安保问题的需求不断增长以及能够可靠预测流程偏差的物联网系统开发的推动。从根本上说,可以调整三个参数以影响最佳性能。 - 设备优化:第一步是通过检查运行数据以识别设备瓶颈来验证现有设备是否被充分利用。 - 操作程序:操作程序可能因人而异或因班次而异。工厂的自动化可以提供很大帮助。但是,如果操作员控制并手动运行工厂,自动化将无济于事。 - 控制优化:在典型的加工厂,例如化工厂或炼油厂,有数百甚至数千个控制回路。每个控制回路负责控制过程的一部分,例如保持温度、液位或流量。如果控制回路没有正确设计和调整,则过程会低于其最佳值。该过程的操作成本将更高,并且设备会过早磨损。为了使每个控制回路以最佳方式运行,识别传感器、阀门和调整问题很重要。已充分证明超过 35% 的控制回路通常存在问题。持续监控和优化整个工厂的过程有时称为绩效监督。
适用行业
- 运输
- 设备与机械
- 化学品
适用功能
- 离散制造
- 质量保证
市场规模
案例研究.
Case Study
Hitachi Data Systems (Hitachi) - Global Manufacturers Improve Yield by 90 Percent
The company’s polymer mixing process was producing output of inconsistent quality, with yields sometimes dipping as low as 50% or 60%. The scrapping of poor batches created huge costs and was crippling production capacity. The root cause was traced to ever-changing product specifications, in addition to variations in a range of production parameters. Production engineers were unable to stabilize the process using traditional approaches as mixing polymer was stubbornly unstable and each new product formulation only exacerbated the problem. To solve this issue, this global manufacturer needed a solution that provided the following capabilities: • Ingest and integrate Internet of Things (IoT) data from machinery, sensors, the environment and other sources • Discover the critical factors and optimal process parameters through correlation, visual analysis, and optimization algorithms • Provide deep process insight, enabling daily decision support and continuous improvement • Dynamically and continuously optimize the process through machine learning
Case Study
Greater Peace of Mind with Pentair
When severe weather hits, the potential damage to a home could be disastrous. Insurance claims for flooding damage exceed $3 billion per year in the United States, and most homeowners are not even covered for even basic water damage to carpet, drywall, electrical, furniture and personal items. Sump pumps are one of the best defenses against flood damage, but when storms knock out electricity, traditional sump pumps are rendered useless. As a seller of water management and equipment protection, Pentair sought a communication platform that will support a wide range of Pentair Internet-connected products.