Advanced Controllers for Level and Temperature Process Applied to Virtual Festo MPS® PA Workstation

Abstract

In this research work, three advanced control algorithms are designed, implemented, and compared to control level and temperature processes in a virtualized Festo Modular Production System of Automatic Processes (MPS ® PA) workstation, with an educational focus. A traditional PID control strategy is designed using the lambda tuning technique for each variable, the second controller designed is a fuzzy PD controller with integral action at the output and finally, a Model Predictive Control (MPC) algorithm is designed. These three controllers have as objectives, to minimize the error in steady-state and reduce the sudden actions of control, the three control strategies are compared and the maximum overshoot, error in steady-state and settling time are evaluated as performance indicators, moreover, the actuator performance is analyzed. The design of the Festo MPS ® PA virtual workstation is also part of this research work. The gamification of the station allows teaching and learning control techniques under a controlled industrial environment. The designed virtual station has physical and operational characteristics identical to the real station with all its instruments virtualized in 3D using Computer-Aided Design (CAD). The controllers designed for the two variables were implemented in Matlab. The mathematical model of processes is linked to the Unity software through shared memory. The results indicate that the advanced controllers (diffuse and MPC) obtained the best performance, which allows increasing the actuators' lifetime.

Metaverse-based Water Level Simulator for the Festo MPS PA Workstation

“…After creating the objects, they are imported into the Roblox Studio, which is further adjusted by adding a human-machine interface from the controller. It continues implementing the mathematical model of the Festo MPS PA workstation, discovered in several previous studies [23,24,26]. The mathematical model of the level control system of Festo MPS PA workstation is as follows:…”

“…Ti is the integral time, and Td is the derivative time. The values of K, Ti, and Td are obtained from [23,24] with K = 6.58, Ti = 0.77, and Td = 3.84. The implemented functions in the Lua programming language are then tested with an open loop system, a system with a parallel PID controller, and a system with a series PID controller, using voltages variable (V) ranging from 1 to 24 volts In this study, the maximum input voltage of the pump at the physical workstation station specified for the pump ranges around 24 volts.…”

“…One of the virtual reality-based technologies previously developed is the simulation of level and temperature control systems found in the Festo modular production system (MPS) process automation (PA) workstation [20]. The research uses the Unity platform to create an immersive simulation application that can be accessed with augmented reality [21,22] or virtual reality [23,24] head-mounted devices. Utilizing the metaverse is expected to advance this research, enabling it to have more open communication access among users and in data communication with physical workstations.…”