Dynamic Simulation-Based Calibration of Industrial Control Systems for Enhanced Operational Phase Transitions and Stability in Processing Plants

Other conference contribution, 2025

Control system calibration in processing plants is crucial for managing transitions between operational phases, such as start-up, shutdown, and product changes. PID controllers are commonly used and influence both the duration of these transitions and operational stability, which is critical for maintaining product quality. However, in industrial settings, PID parameter selection is often restricted due to the risk of product loss and safety, limiting optimization efforts. The closed milling-screening circuit pilot plant at TU Bergakademie Freiberg is equipped with a PID-controlled mass flow system. A dynamic simulation of the control loop and data from the processing plant is used to optimize the PID parameters with a target to reduce transient time and increase process stability, allowing for safe testing and transfer of these methods to industrial plants. The output of the simulated optimized parameter is tested in a full-scale environment. This method enables testing and configuring control parameters with dynamic simulation.