„Wise
Machinery“
Concept: We
proposed the concept of „Wise Machinery“ which
besides their standard functions determine without
assistance from Human being who, what, when and
how should act for availability, functional
efficiency and safety maintaining of the machines.
Every “Wise machine” includes: complex equipment
of the machine; Data Acquisition System, which
measures and reflects the parameters
characterizing functioning process of the machine,
and “Optimal Parametrical Control System (OPCS)”
intended for operative and optimal solution of all
possible management tasks arising in vital
activities process of the machine’s equipment in
the limits of its life cycle.
The
real OPCS receives the information on the measured
parameters characterizing the machine’s
functioning process, processes the above
information and generates optimal recommendations
(instructions) for every specialist engaged in
diagnostics, maintenance and operating of above
machine. The real OPCS is the computer-aided
system, which composes based applied program
packages and integrated modules to provide optimal
solution of all possible management tasks arising
in Operating & Maintenance process of the
machine.
The
problem for OPCS consists in
significant reduction the accidents rate of
machinery and decreasing enormous financial losses
arising in civil and military organizations
because of belated, incorrect or non-optimal
actions in diagnostics, maintenance and operating
of complex equipment in various branches of modern
industry.
Novelty
of OPCS consists in the
fact that they are based on the mathematical
description of unconscious activity process of a
brain in viability maintaining of an organism of
complex biological systems.
Proposed
Optimum
Parametrical Control Systems
function on the basis of new
information processing, decisions making and
control technology needed for reliable
diagnostics, rational maintenance and flexible
operating of complex equipment (“Ergatonics”
technology).
Novelty
of “Ergatonics” technology:
We
discovered a new area in application of artificial
intelligence systems – “viability maintaining of
complex systems”. In this area we have developed
the mathematical description of viability
maintaining process of real physical objects
(power, aviation and others) for their surviving,
self-preservation and steady functioning in
external environment. On the basis of above
mathematical models we developed the information
processing and decisions making technology for
reliable diagnostics, rational maintenance and
flexible operating of industrial equipment.
Novelty of our technology is that it is based on
the cybernetic model of viability maintaining
process of multi-parametrical objects, algebraic
models of equipment as the control object and
analytical models of decisions making processes in
operating and maintenance of the equipment. The
mentioned cybernetic model is multilevel
hierarchical control system. The algebraic model
is the “Relations Matrix” which fixes the actually
existing connections among the parameters
characterizing the functioning process of real
multi-parametrical object. The analytical models
are simple optimizing models, which are developed
on the basis of mathematical description of
unconscious activity of a brain in viability
maintaining of an organism of biological
systems.
Advantages
of OPCS:
Purposefulness – OPCS
make optimal solution of all possible management
tasks arising in Operating & Maintenance
process of complex equipment on the united
criterion of minimum expenses to provide given
technical availability, functional efficiency and
safety indexes of the equipment.
Technical
Uniqueness – OPCS is a new
type management system, which possesses the
advantages of both centralized and decentralized
management systems and deprives the storages of
these management systems.
Practical
Uniqueness – OPCS give
optimal recommendations (instructions) for every
specialist engaged in Operating & Maintenance
of complex equipment and diminish negative
influence of “human factor” in emergency
situations connected with damages of above
equipment.
Economic
Uniqueness - OPCS are
decisions making systems, which for the first time
in the world practice provide significant
increasing the productivity of labor and norm of
profit in various branches of modern
industry.
The
primary users of OPCS:
The
main OPCS’ users are the Shift Personnel;
Engineer-technical Personnel; Operators, which
carry out application of machinery and Technical
managers, which are leadership in operating and
maintenance of complex equipment of their
companies. For example, the typical primary users
of OPCS are the following:
Shift
Personnel of power plants - Unit
Operator; Shift Operator; Shift Engineer.
Engineer
– Technical Personnel of power plants and Aircraft
industries - Operation
Engineer; Efficiency Engineer; Project Engineer;
Operation Technician and Chief Engineer of power
plants or airports.
Operational
Personnel in Aircraft industries -
Pilots, Engineers
and Captains of aircraft. Managers - Manager
of Division and Manager of power plants;
Supervisors by every aircraft type; Director of
Airline carrier.
Note:
The presented
primary users were established in detail
engineering of the project of “Wise Power Steam
Turbine” and in functional engineering of the
project “Optimum Parametrical Control System for
technical availability and safety maintaining of
aircraft”.
Intellectual
profit from OPCS for every user:
OPCS
process operatively the data on the parameters,
characterizing functioning process of complex
equipment and give current data needed for every
user according to his duty in Operating and
Maintenance of above equipment. The above
mentioned data are the following:
Information on
the actual technical state of the equipment;
Recommendations
for optimal actions of every user in Operating
& Maintenance of complex equipment with regard
to actual technical state of the equipment;
Profit
estimation from fulfillment of the recommendations
for every user;
Profit
estimation from fulfillment of recommendations for
Personnel of Controller Office, Engineer-Technical
Personnel, Operators and Technical Managers of the
company;
Testability,
Safety, Functional efficiency, Availability and
Viability indexes, which BCS calculates
operatively for definition the optimal strategy in
ensuring the given above-mentioned indexes of
complex equipment with minimum Operating &
Maintenance cost of above equipment.
Benchmarks
of OPCS’ development:
Benchmarks of
OPCS’ development are determined by the results of
multiple amplification of intellectual
possibilities of Human being in real technical
systems, which were evaluated by the „Ergatonic“
company:
1.
„Optimum functional control system of board
collisions preventing subsytem of airplanes“ which
allowed to increase the testability index of above
subsystem from 0.38 till 0.93;
2.
„Multistepped diagnostics system of power steam
turbines“ which showed the possibility of
recognition so-called “latent” defects before they
become evident failure of the machines. Thanks to
above feature the Multistepped diagnostics system
recognized the damages of steam turbine 2,5 hours
earlier in comparison with the shift personnel of
power plant;
3.
„Optimum parametrical control system for
availability and functional efficiency maintaining
of ground-air missile complexes“ which allowed to
increase the availability index of above complexes
from 0.43 till 0.75 and controllability index -
from 0.25 till 0.72;
4.
„Optimum parametrical control system for technical
availability and safety maintaining of aviation
engines“ which allowed to calculate the increasing
of safety index of aircraft from 0.07 till
0.73;
5.
„Optimum parametrical control system (OPCS) for
availability and safety maintaining of aircraft“
which allowed to show enormous financial profit
from Operating & Maintenance optimization of
complex equipment.
The
mentioned indexes characterize the quality of BCS
and determine the anticipated benefits from
OPCS.
Anticipated
Benefits from OPCS
According to our
calculation OPCS will provide the significant
increasing the viability indexes of complex
equipment (machinery). So OPCS provide increasing
the Testability index of complex equipment in 2 –
2.4 times, the Availability index – in 1.5 – 2
times, the Functional Efficiency index – in 2 –
2.8 times and Safety index – in 4.5 – 5
times.
Expected
Financial Profit from OPCS
The
direct financial profit from OPCS consists in
decreasing the expenses of industrial companies in
operating and maintenance of their equipment.
Thanks to OPCS the operating and maintenance cost
of the equipment according to our calculation will
decrease in 1.5 – 2 times. The expected financial
profit from “Optimum parametrical Control Systems
for Operating & Maintenance optimization of
complex equipment” is enormous. For example,
expected financial profit from OPCS for US
Ministry of Defense, which has budget 109 billions
of dollars for O&M of its military equipment,
will be more than 30 billions of US dollars in a
year.
Note:
Information about budget of US Ministry of Defense
was presented in “Aerospace & Defense”
journal, 2001.
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