Systems Engineering for Intelligent Industrial Processes Jan van Deventer Thursday, January 28, 2016
Outline •
Definitions,
•
Systems Engineering standards & documentation,
•
System lifecycle management,
•
Model Based Systems Engineering,
•
SOA Framework to promote “Intelligence”.
my Background Why System Engineering?
IIP
•
Processes,
•
Industrial Processes,
•
Intelligent Industrial Processes.
Ultrasonic measurements and modelling of attenuation and phase velocity in pulp suspensions
Paper Production Process Jan Niemi∗ , Yvonne Aitom¨aki and Torbj¨orn L¨ofqvist Department of Computer Science and Electrical Engineering Lulea University of Technology, Sweden ∗ Email:
[email protected]
When determining the phase velocity from pulse-echo measurements, one encounters the problem of performing a correct phase unwrapping. The problem is well known and has been addressed in earlier investigations, for instance [2]. The problem arises when the phase velocity is calculated from the phase spectra of a the Fourier transform of each of the two echoes. In this study, we propose a method, termed Minimum Phase Angle (MPA), that determines an optimal number of circular shifts to the windowed signal which results in a continuous phase spectrum and minimizes the likelihood of discontinuities within the bandwidth. Therefore the ambiguity in the phase unwrapping is avoided. To experimentally test the method experiments were performed in pulp fibre suspensions, which are weakly dispersive. The experiments were carried out using the pulse-echo technique in a custom designed test cell. A schematical view of the measurement cell used in this study is shown in Fig. 1.
p1
p2 Time
Transducer
In the manufacturing process of paper the mass fraction and material properties of the fibres in the pulp suspension are important for the quality of the finished product. When using recycled paper, fibres with unknown and varying material properties enter the process. Therefore, there is an increasing demand for methods of on-line characterisation of the pulp suspension as well as the fibres in suspension. This study presents two different methods of pulp characterisation. The first is based on phase velocity, which we use to investigate the composition of the pulp. The second is based on attenuation and is used to characterise the wood fibres. In the first method, we investigate how the phase velocity changes with different mass fractions of fibres and fines. To determine the phase velocity, a method is proposed based on a method by [1], where the an echo is circularly shifted an optimal number of samples.
A. Theory and experiments
Sample Bufferspace rod
I. I NTRODUCTION
II. P HASE V ELOCITY
Steel reflector
Abstract— In the manufacturing process of paper the mass fraction and material properties of the fibres in the pulp suspension are important for the quality of the finished product. This study presents two different methods of pulp characterisation. The first is based on phase velocity, which we use to investigate the composition of the pulp. Here a method is presented where the optimal number of circular shifts within the sampling window of the signal is determined which gives, in a weakly dispersive medium, a continuous phase spectrum and minimizes the likelihood of discontinuities within the bandwidth. Hence, the ambiguity in phase unwrapping is avoided. The results from phase velocity measurements show that the phase velocity weakly increases with increasing amount of fines in the suspension. The dispersion is caused by the fibres and it correlates with fibre mass fraction. The second method is based on attenuation and is used to characterise the wood fibres. The results of the attenuation experiments show that it is possible to inversely calculate wood fibre properties by fitting the model to the experimental data, if the fibre diameter distribution is known. However, the accuracy of these calculation is difficult to determined and more work in this area is required.
Fig. 1. study
d1
1
2 d2 3
Lattice diagram of the pulse-echo measurement system used this
Steel Pellet Production Processes
Zooming in: Flotation Process
District Heating Process
Increasing the complexity to improve “things”
What “Intelligence” are we seeking? •
When things go wrong (or could be improved) and •
•
there is potential information pointing to the symptoms. •
Information that is available
•
Information that could be available
have an intelligent system that saves or improves the situation.
The fundamental question is: “How do we make Intelligence happen?” •
How do we connect sensors, controllers, actuators together?
•
How do we develop “intelligent” controllers?
•
How do we describe the processes and their improvements?
•
How much will it cost? How long will it take? How do we introduce the new solutions in an existing infrastructure? How do we maintain the systems? How do we retire the systems?
A System •
A combination of interacting elements organized to achieve one or more stated purposes, an integrated set of elements, subsystems, or assemblies that accomplish a defined objective.
•
These elements include products (hardware, software, firmware), processes, people, information, techniques, facilities, services, and other support elements
International Council on Systems Engineering. Systems Engineering Handbook v.3.2.2 , 2011.
Systems Engineering •
Systems Engineering (SE) is an interdisciplinary approach and means to enable the realization of successful systems.
•
It focuses on defining customer needs and required functionality early in the development cycle, documenting requirements, and then proceeding with design synthesis and system validation while considering the complete problem: operations, cost and schedule, performance, training and support, test, manufacturing, and disposal.
•
SE considers both the business and the technical needs of all customers with the goal of providing a quality product that meets the user needs International Council on Systems Engineering. Systems Engineering Handbook v.3.2.2 , 2011.
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אין כל חדש תחת השמש •
There is nothing new under the sun.
•
System Engineering is not new •
•
Common example is the Apollo missions although the term can be found in the 1940’s at Bell Labs.
LTU has no education or research in Systems Engineering.
ion
Introduction
Systems Engineering Fundamentals
TABLE OF DOD’s SE Fundamentals CONTENTS Systems Engineering Fundamentals
PREFACE ............................................................................................................................................. iv PART 1. INTRODUCTION
SYSTEMS ENGINEERING FUNDAMENTALS
Chapter 1.
Introduction to Systems Engineering Management ............................................. 3
Chapter 2.
Systems Engineering Management in DoD Acquisition .................................... 11
PART 2. THE SYSTEMS ENGINEERING PROCESS Chapter 3.
Systems Engineering Process Overview ............................................................ 31
Chapter 4.
Requirements Analysis ....................................................................................... 35
Chapter 5.
Functional Analysis and Allocation .................................................................... 45
Chapter 6.
Design Synthesis ................................................................................................ 57
Chapter 7.
Verification ......................................................................................................... 65
Chapter 8.
Systems Engineering Process Outputs ............................................................... 73
PART 3. SYSTEM ANALYSIS AND CONTROL Chapter 9.
Work Breakdown Structure ................................................................................ 85
Chapter 10. Configuration Management ................................................................................ 91 Chapter 11. Technical Reviews and Audits ............................................................................ 99 Chapter 12. Trade Studies .................................................................................................... 111 Chapter 13. Modeling and Simulation ................................................................................. 117 Chapter 14. Metrics .............................................................................................................. 125 Chapter 15. Risk Management ............................................................................................. 133 PART 4. PLANNING, ORGANIZING, AND MANAGING Chapter 16. Systems Engineering Planning ......................................................................... 147 Chapter 17. Product Improvement Strategies ...................................................................... 157
January 2001
Chapter 18. Organizing and Integrating System Development ............................................ 171 Chapter 19. Contractual Considerations .............................................................................. 185 Chapter 20. Management Considerations and Summary ..................................................... 201
SUPPLEMENTARY TEXT PREPARED BY THE DEFENSE ACQUISITION UNIVERSITY PRESS
GLOSSARY ..................................................................................................................................... 209
Chapter 6
Design Synthesis
A Successful System SUPPLEMENT 6-A
CONCEPT DESCRIPTION SHEET
The Concept Description Sheet describes (in textual or graphical form) the technical approach or the design concept, and shows how the system will
be integrated to meet the performance and functional requirements. It is generally used in early concept design to show system concepts.
Target Missile
Missile Tracking Radar
Steering Commands
Target Tracking Radar
Radio
Computer
External Command Guidance System
Figure 6-3. Concept Description Sheet Example
61
from DOD’s SYSTEMS ENGINEERING FUNDAMENTALS
SYSTEMS ENGINEERING PROCESS OVERVIEW
System Engineering Process 3.1 THE PROCESS
definition with each level of development. As shown by Figure 3-1, the process includes: inputs and outputs; requirements analysis; functional analysis and allocation; requirements loop; synthesis; design loop; verification; and system analysis and control.
The Systems Engineering Process (SEP) is a comprehensive, iterative and recursive problem solving process, applied sequentially top-down by integrated teams. It transforms needs and requirements into a set of system product and process descriptions, generate information for decision makers, and provides input for the next level of development. The process is applied sequentially, one level at a time, adding additional detail and
Systems Engineering Process Inputs Inputs consist primarily of the customer’s needs, objectives, requirements and project constraints.
Process Input • Customer Needs/Objectives/ Requirements – Missions – Measures of Effectiveness – Environments – Constraints • Technology Base • Output Requirements from Prior Development Effort • Program Decision Requirements • Requirements Applied Through Specifications and Standards
System Analysis and Control (Balance)
Requirements Analysis • Analyze Missions and Environments • Identify Functional Requirements • Define/Refine Performance and Design Constraint Requirements
Requirements Loop
Functional Analysis/Allocation • Decompose to Lower-Level Functions • Allocate Performance and Other Limiting Requirements to All Functional Levels • Define/Refine Functional Interfaces (Internal/External) • Define/Refine/Integrate Functional Architecture
• • • • • • •
Trade-Off Studies Effectiveness Analyses Risk Management Configuration Management Interface Management Data Management Perfromance Measurement – SEMS – TPM – Technical Reviews
Design Loop
Synthesis
Verification
• Transform Architectures (Functional to Physical) • Define Alternative System Concepts, Configuration Items and System Elements • Select Preferred Product and Process Solutions • Define/Refine Physical Interfaces (Internal/External)
Related Terms:
Process Output
Customer = Organizations responsible for Primary Functions Primary Functions = Development, Production/Construction, Verification, Deployment, Operations, Support, Training, Disposal Systems Elements = Hardware, Software, Personnel, Facilities, Data, Material, Services, Techniques
• Development Level Dependent – Decision Database – System/Configuration Item Architecture – Specifications and Baselines
Figure 3-1. The Systems Engineering Process
31
from DOD’s SYSTEMS ENGINEERING FUNDAMENTALS
Lots of stakeholders Systems Engineering Fundamentals
Disposal
Chapter 1
Training
Verification
Operation
Support
8 Primary Life Cycle Functions
Development Deployment
Manufacturing/Production/ Construction
Figure 1-4. Primary Life Cycle Functions Operation is the user function and includes activities necessary to satisfy defined operational objectives and tasks in peacetime and wartime environments. Support includes the activities necessary to provide operations support, maintenance, logistics, and material management. Disposal includes the activities necessary to ensure that the disposal of decommissioned, destroyed,
Systems Engineering Considerations Systems engineering is a standardized, disciplined management process for development of system solutions that provides a constant approach to system development in an environment of change and uncertainty. It also provides for simultaneous product and process development, as well as a common basis for communication.
DOD’s SYSTEMS ENGINEERING FUNDAMENTALS Systems engineering ensures that thefrom correct
Systems Lifecycle Management •
ISO/IEC 15288 Systems and software engineering — System life cycle processes (IEEE Std 15288-2008)
•
This International Standard establishes a common process framework for describing the life cycle of man-made systems. It defines a set of processes and associated terminology for the full life cycle, including conception, development, production, utilization, support and retirement. This standard also supports the definition, control, assessment, and improvement of these processes. These processes can be applied concurrently, iteratively, and recursively to a system and its elements throughout the life cycle of a system.
Costs Planning & Follow up Systems Engineering Fundamentals
Chapter 14
Total Allocated Budget
Over Budget
EAC
Management Reserve P R O J E C T E D
PMB
$
Schedule Variancec
Cost Variance c
BCWSc ACWPc BCWPc
Time Now
S L I P P A G E
Completion Date
Figure 14-1. Earned Value Concept from DOD’s SYSTEMS ENGINEERING FUNDAMENTALS
Model Based System Engineering
•
Model-based systems engineering (MBSE) is a systems engineering methodology that focuses on creating and exploiting domain models as the primary means of information exchange between engineers, rather than on document-based information exchange.
A Modeling Tool 2.3 SysML Diagram Overview
15
Figure 2.1 SysML diagram taxonomy
with the hollow, triangular arrowheads mean. They’re called generalizaSysML of Distilled: Brief Guide to the Systems Modeling Language tions. You read them as “is a type of” in the direction theAarrowhead.
Self Awareness •
For the sake of the discussion afterwards, please be aware of your current understanding of the list below (before the rest of the talk) •
District Heating
•
The Arrowhead Framework
•
Model Based System Engineering
District Heating Structure bdd [Package] Structure [ System Context ]
«block» District Heating
management
consumption
«block» Management
system Coordination
data management
simulation
«block» Academic Version for Teaching Only Data management Commercial Development is strictly Prohibited «block» System Coordination
«block» Sim ulation
«block» Consumption
commercial buildings
production
apartment buildings family houses hing Only for Teac demic Version single Aca «block» «block»ibited tly Proh lopment is stricSingle cialentDeve Commer Apartm buildings fam ily houses
«block» Com mercial buildings
«block» Production
parts
parts
district Heating Substation : District Heating Substation [0..1] electricity : Electricity radiators : Radiators [0..*]
fuel : Fuel burnner : Burnner heat exchanger : Heat exchanger pumps : Pumps distribution «block» Distribution parts
insulated pipes : Insulated pipes communication : Communication pressure sensor : Pressure sensor flow meter : Flow meter temperature : Temperature: C valve : Valve pumps : Pumps
Distribution System bdd [Package] Structure [ Distribution ]
«block» Distribution
insulated pipes «block» Insulated pipes
ching Only Academic Version for Tea «block» «block» d «block» ProhibiteLeakage is strictly Commercial Development Pipes Insulation detection pipes
insulation
leakage detection
pressure sensor
flow meter
«block» Pressure sensor
temperature
«block» Flow meter
g Only for Teachin ic Versionpumps Academ valve communication tly Prohibited ent is stric ial Developm Commerc«block» «block» «block» «block» Tem perature: C values
temperature : C Sampling frequency : Hz
Valve
Pum ps
Com m unication
Single Family house bdd [Package] Structure [ House ] «block» Single fam ily houses
district Heating Substation 0..1 «block» District Heating Substation electricity
values
radiators 0..*
«block» Electricity
Loc : Location
«block» Radiators
Academic Version for Teaching Only al Development is strictly Prohibited domestic hot w ater merci Com heatmeter
Academic Version for Teaching Only hydronic heating Commercial Development is strictly Prohibited «block»
«block» Dom estic hot w ater
Hydronic heating
Outdoor temperature «block» Tem perature: C
controller
values
«block» Controller
temperature : C Sampling frequency : Hz Radiator supply temperature
pump
valve «block» Pum p
valve
mechanical controller
«block» Valve
«block» Mechanical controller
heat exchanger
«block» Tem perature: C values
temperature : C Sampling frequency : Hz
«block» Heat exchanger
Domestic hot w ater pressure «block» Pressure sensor
«block» Valve
«block» Heatm eter heat exchanger
Primary return
Primary flow
«block» Tem perature: C
«block» Heat exchanger
values
Primary supply «block» Tem perature: C values
temperature : C Sampling frequency : Hz
temperature : C Sampling frequency : Hz
«block» Flow m eter
communication «block» Comm unication
Component Interactions ibd [Block] District heating substation [ District heating substation ]
Primary supply temperature
pst
Primary return temperature
prt
Primary flow meter
: Heatm eter energy
Commnucation
Primary flow meter
Academic Commerc
Academic Version for Teaching Only Commercial Development is strictly Prohibited : Controller Outdoor temperature Radiator supply temperature
Outdoor temperature Radiator supply temperature
Valve position
Valve position
Arrowhead Framework to the Rescue
Service Oriented District Heating Components Outdoor temperature service provider
Valve service provider
Flow service provider
Heat meter service provider
SOA in District Heating sd [Interaction] vfsd [ vfsd ]
«block» Outdoor tem perature : Tem perature: C
«block» Radiator supply tem perature : Tem perature: C
«block» valve : Valve
Service Registry
Authorization system
Orchestration System
«block» controller : Controller
1: Register outdoors temperature
2: Register radiator supply temperature
Academic Version for Teaching Only Commercial Development is strictly Prohibited
Academic Version for Teaching Only Commercial Development is strictly Prohibited 3: Register Valve
4: Ask for outdoor temp 5: Ask for outdoor temp 6: Propose outdoor temp 7: Authorize outdoors temp? 8: Yes 9: Outdoors temp address
10: Ask for radiator supply temp 11: Ask for radiator supply temp 12: Propose radiator supply temp 13: Authorize radiator supply temp?
Academic Version for Teaching Only Yes opment is strictly Prohibited Devel Commercial 14:
Academic Version for Teaching Only Commercial Development is strictly Prohibited
15: Radiator supply temp address
17: ask for control valve
16: Ask for control valve
18: Propose control valve 19: Authorize control valve? 20: Yes 21: Control valve address loop []
22: Request outdoors temperature 23: Provide temperature 24: Request radiator supply temperature 25: Provide radiator supply temperature
Academic Version for Teaching Only Commercial Development is strictly Prohibited
Academic Version for Teaching Only 26: Request valve position Commercial Development is strictly Prohibited 27: Confirm valve position
Indoors tem perature
Gatekeeper
Orchestration out of problems (or Intelligence) •
The outdoor sensor is offline (e.g., out of battery),
•
You could use the neighbor’s outside sensor via the Gate Keeper, •
•
but the Internet is dead!
You could use an indoor temperature sensor to control the indoor temperature….
Orchestration System Conversations
More can be done in this configuration… •
Estimation of thermal insulation and thermal capacitance of the building in real time,
•
Better control control of heating control strategy in Demand Response applications,
•
System Prognostic and and Diagnostics, e.g., damaged pipe insulation,
•
Tamper proof, information to stakeholders,
•
System phase in and out, Scalability.
System Engineering in IIP •
Increase stakeholder communication to understand their paradigms or views on the same issue,
•
Manage the lifecycle of the systems and subsystems,
•
With MBSE, zoom in and out within the systems,
•
Develop “Intelligence” through Use Cases.
Do we know what we really want?
•
•
The technology is here.
•
The Arrowhead Framework is here.
How does one make an Industrial Process Intelligent?
Which is the right problem?
•
Successful problem solving requires finding the right solution to the right problem. We fail more often because we solve the wrong problem than because we get the wrong solution to the right problem. Russell L. Ackoff, Redesigning the future, 1974, p. 8.
