Joint-Stock Company 
Research and Design Institute for Atomic and Power Pumpbuilding



Innovations

 

Remote Access Control Systems

 


For more than half a century, the JSC VNIIAEN employees have been developing pumping equipment which is operated at many large nuclear and thermal power facilities, oil, chemical, iron and steel, and food industries as well as is used for oil pipeline transportation and building undergrounds, in municipal and public utilities and in many other fields etc.

Besides the development of pumping equipment, the Institute also develops the control and automation systems for such equipment. Change is all around us, and now the traditional means of automation are increasingly being replaced by microprocessor devices. Many pump units, developed by
JSC VNIAIAEN, are provided with a microprocessor-based control system, which ensures the operation of the process equipment in all operating modes without a constant presence of the attending personnel. At the same time, the control systems allow you to collect and process data on the status of operating mechanisms and automation objects, to monitor process parameters, activate warning signaling and protective shutdown of pump units, if required. Such systems are based on the microprocessor equipment developed by world leaders in this field, namely - Siemens (Germany), Schneider Electric (France), General Electric (USA), Mitsubishi Electric (Japan), etc. The use of the most modern hardware components in combination with our own-developed software makes the control systems truly multi-purpose and real competitive equipment that can be used in a wide range of industries and power economy.

At this stage of development of automated control systems, the systems for remote access and control of process equipment are in great demand. These systems collect and process data in real time. The remote access, if necessary, allows you not only to monitor and control systems, but also make the necessary changes in the algorithms of equipment operation, add new features, evaluate critical parameter values and respond to emergency situations in a timely manner, avoiding costly field visit of specialist.

In order to implement such functions in control systems developing by JSC VNIIAEN, our specialists have mastered the operation of an integration controller that does not have foreign analogues, which is produced by Ukrainian engineering company WebHMI (Dnipro). The use of this device in conjunction with the microprocessor-based control system allows you to monitor and control the process equipment almost anywhere in the world where the Internet or mobile communication is available. At the same time, data received from the controlled object can be stored both locally on a computer and in the Cloud.


The object of the dispatch system can be any object located separately or being a functional part of the production or household infrastructure. To create a remote monitoring and control system, you need only to install a WebHMI controller with a USB 3G modem in a cabinet containing a microprocessor-based hardware. If an automation object has the wireless internet connection or can be connected to the Internet via a cable, the modem is not required. In order to avoid the shielding of signals due to metal cabinet, the modem can be installed outside the cabinet or an external antenna can be connected.

 

You can access to the object dispatch system via a standard web browser from any stationary or mobile device; no specialized software is required for this. Smartphones, tablets, computers can be used to access the system.

 

The WebHMI module installed on a single local object provides users with access to information only of this object. Access to the system is password-protected; therefore, the user of one local object cannot log in the system of another object without authorization. In addition, the WebHMI module maintains a protocol of operator actions in which all actions of the user are recorded, indicating user’s Login and the time of each event.

Also, the WebHMI module can store important data for each object that can be viewed as charts for a selected period of time with the ability to scale, as well as transfer to other applications (Excel, Word, 1C, etc.) using the API or send to shared server for storage and backup.

 

In order to control and monitor a set of distributed objects, you can add multiple WebHMI modules into the Level2 cloud dispatch system. Level2 is a cloud service that allows you to combine any number of objects equipped with WebHMI modules into a shared dispatch system. You can work with the system via a standard web browser, while the user can see a map of the area and objects connected to Level2. The map can display not only the designation of objects but also their state (Norm / Problem / Accident). If necessary, the operator can click on the pointer and go to each individual object to obtain complete information on the object of interest.

 

In addition to combination of a group of distributed objects into the shared dispatch system, Level2 allows you to solve the following problems:

1. Collect combined data of all objects, and use it in the reports and charts, analyze the resource consumption and perform energy audit.

2. Data exchange between the objects, if this is necessary for solving process problems.

3. A simultaneous transfer of data to several objects (or to all objects at once), that can be used for calculations within a local object.

4. Notification of accidents at the facilities by sending SMS messages.

5. User of Level2 creates a personal account to manage the selected services, where you can quickly enable or disable the service to save money on the account.

 

VNIIAEN’s Capabilities in the Field of Software Module Development for Parametric 3D Modeling  

  

 

When developing design documentation within a project, it is important to take into account the relative position of parts for assembling. 3D-model allows a designer to review the project more effective and within a very short time. The use of parametric 3D modeling speeds up the process of developing models due to semi-automatic building of the part, as well as due to the presence of a reference correct set of data (dimensions, associative links). Parameterization allows you to check various designs and avoid fundamental errors.

Computer-aided simulation is one of the CAD methods.

The computer-aided design system is an automated system that provides design automation. It consists of personnel and a set of technical, software and other means to automate its activities.

As part of the life cycle of industrial products , CAD solves the automation tasks at the design and preproduction stages.

The main goal of CAD is to increase the efficiency of engineers’ work, including: 

- the reduction of complexity of designing and planning;

- the reduction of design time;

- the reduction of  cost of designing and manufacturing as well as operating  costs;

- the improvement of quality and technical and economic level of design outputs;

- the reduction of modeling and testing costs. 

These goals are achieved by: 

- automation of paperwork;

- information support and automation of the decision-making process;

- use of concurrent design technologies;

- unification of design solutions and processes;

- reuse of design solutions, data and work results;

- strategic design;

- replacement of field tests and prototyping with mathematical modeling;

- improvement of quality of design management;

- application of alternative design and optimization methods. 

Parametric modeling (parametrization) is a modeling (designing) process involving parameters of the model elements and relations between these parameters.
There are the following types of parameterization: 

1.1.1 Table parameterization

The table parameterization creates a table of parameters for typical parts. A new part is created by selecting sizes from the table of standard sizes. The possibilities of table parameterization are very limited, since the setting of arbitrary new parameters and geometric relations is usually impossible.

However, the table parametrization is widely used in all parametric CAD systems, since it allows you to significantly simplify and speed up the creation of libraries of standard parts, as well as their use in the designing process.

 1.2 Hierarchical parameterization

The hierarchical parametrization (parametrization based on the history of building) is that during the model building, the entire sequence of the actions is displayed in a separate window in the form of “tree”. It lists all auxiliary components that exist in the model, rough sketches, and the operations performed in the order in which they were created.

In addition to the “tree” of the model, the system storages not only the order of its formation, but also the hierarchy of its elements (relations between the elements). Example: assembly → subassembly → parts.

Parameterization based on the history of building is present in all CAD systems, using three-dimensional solid parametric modeling. Typically, this type of parametric modeling is combined with variational and/or geometric parametrization.

 1.3 Variational (dimensional) parameterization

The variational or dimensional parametrization is based on the building of sketches (with the imposing various parametric relations on the objects of the sketch) and the imposition by the user of constraints in the form of a system of equations determining the dependencies between the parameters.

The process of creating a parametric model using variational parameterization is as follows: 

-At the first stage, a sketch (profile) is created for a three-dimensional operation. Next, the necessary parametric relations are imposed on the sketch..

- Then the sketch is “sized”, the individual sizes of the profile are refined. At this stage, individual sizes can be specified as variables (for example, the parameter denoting the length of a certain part, is assigned the name "Length") and the dependencies of other dimensions on these variables can be specified as an equation (for example, "Radius = Length/2").

- Then a three-dimensional operation is performed (for example, extrusion), the value of the attributes of the operation also serves as a parameter (for example, value of extrusion).

- The relative position of the components of the diffuser (casing and channels) is specified by setting the interface between them (the perpendicularity of the elements, the arrangement of objects at an angle to each other). 

Variational parametrization allows you to easily change the shape of the sketch or the value of the parameters of operations, which allows you to conveniently modify the three-dimensional model.

 1.4 Geometric parametrization

Geometric parametrization is called parametric modeling, in which the geometry of each parametric object is recalculated depending on the position of the parent objects, its parameters and variables.

The parametric model, in the case of geometric parametrization, consists of building and imagine elements. Building elements (design lines) define parametric relations. The image elements include lines of the image (which are surrounded by design lines), as well as design elements (dimensions, inscriptions, hatching, etc.).

Some building elements may depend on other building elements. Building elements can also contain parameters (for example, the radius of a circle or the angle of inclination of a straight line). When one of the elements of the model changes, all the elements depending on it are rebuilt in accordance with their parameters and the ways in which they are set.

The process of creating a parametric model using the geometric parametrization method is as follows: 

- At the first stage, the designer sets the profile geometry with design lines and marks key points.

- Next, the dimensions are marked between the design lines. At this stage, you can specify the dependence of the sizes from each other.

- Then the design lines are outlined with lines of the image thus a profile is obtained with which you can perform various three-dimensional operations. 

The subsequent stages are generally similar to the process of modeling by the method of variation parameterization.

Geometric parametrization allows for more flexible editing of models. If it is necessary to introduce an unplanned change, then it is not necessary to delete the original construction lines in the geometry of model (this may lead to the loss of associative relations between the model elements), you can draw a new construction line and transfer the image line on it.

Engineers of the Institute are engaged in the development of 3D-models of parts for pumping equipment. . 3D-models are developed to be used for: 

- creation of a drawing from a 3D model;

- design review of the project;

- strength analysis;

- hydraulic analysis;

- programming CNC machines when milling the finished part;

- programming CNC machines for tooling;

- three-dimensional printing. 

Figure 1 - The Main Window of Program for Building Diffuser

Figure 2 - Sketching Window

 In 2018, the team of the CAD sector developed a software module for the parametric modeling of a 3D-model of diffuser..

he main window of the program (Fig. 1) shows the steps of building a model of the diffuser (according to the method of geometric parameterization).

First, it is necessary to consistently build sketches of diffuser and reverse channels, indicating on the form (Fig. 2) the necessary elements for building.

As a result of the module operation, we will get the generated sketches for further building (Fig. 3).

The next stage is to build a part of the diffuser casing to create on its basis a return channel. It is necessary to specify the dimensions for the body on the form (Fig. 4). After executing the program, we will get the finished part of the casing (Fig. 5).


Figure 3 – Channel Sketch Building
 

Figure 4 - Window for Dimension Selection of Casing для корпуса

Figure 5 - Casing Building

 

Next, using the module, the bodies of the return, diffuser, and cross-over channels are created.

Then, the body of the diffuser is built by removing water from the additional body; cuts are made in accordance with the main section of the diffuser drawing. Next all chamfers and fillets, grooves and holes of diffuser are built. This is followed by machining the diffuser.

As a result, we obtain a ready-made 3D model of the diffuser (Fig. 6 and Fig. 7).

Figure 6 - The ready-made model of the diffuser (view 1)


Figure 7 - The ready-made model of the diffuser (view 2)

 

VNIIAEN develops software for CAD systems, solutions that increase the efficiency of computer-aided design process. We are working on the implementation of new features for 3D modeling by expanding the standard functionality of products for CAD systems.

The parametric 3D models of the following parts were developed and successfully operated:

- coupling;

- cap nut;

- rotor parts;

- nipple;

- distributor;

- flange;

- pipe union;

- diffuser. 

Our team will do for you the following works: 

- development of 3D model (including parts of complex geometry - blades, castings, etc., using surface modeling methods);

- parametrization of part model (using program methods and user interfaces in the VBA, C#, C++ programming languages);

- parametrization of assembly model (using program methods and user interfaces in the VBA, C#, C++ programming languages). 

Our team of highly qualified specialists always strives to fulfill the individual requirements of their customers in the most effective way.