Fraunhofer Institute for Industrial Mathematics ITWM
Fraunhofer Institute for Industrial Mathematics ITWM

Plant and Production Control

»The Future of Your Machine and Production Control Starts With Us«

We aim to deliver a tailored service, understanding each client's unique requirements and providing solutions that perfectly fit their operational needs and business goals.

  • We analyze your existing systems, identify any inefficiencies and potential improvements to enhance operational effectiveness.
  • We aim to optimize your existing control loops, design new ones, and employ multivariable strategies.
  • Our goal is to implement advanced control systems based on Model Predictive Control and Artificial Intelligence (AI).
  • We are committed to the smooth and efficient delivery of our solutions, which includes careful hardware integration and the implementation of intuitive visualization systems.

System and Controller Analysis

»How stable and optimal your machine/process is running?«
 

Our Goal: Increase the Performance of Your System

Our cutting-edge Dynamic System Analysis service takes your industrial operations to the next level, ensuring resilience, adaptability, and long-term stability. Harnessing the power of modern technology and innovative methodologies, we aim to maximize your system's performance, ensuring optimal results under any operational conditions.
 

Our Services

Performance Analysis: The first step in enhancing your system's performance is a comprehensive analysis of your existing control loops. Our team performs in-depth performance analysis to ensure your systems are functioning at optimal levels. By monitoring key performance indicators and conducting data-driven evaluations, we provide valuable insights into your system's overall efficiency and productivity, guiding strategies for performance enhancement.

Sensor and Actuator Selection and Placement: Selection of best suited minimal number of sensors and actuators and their strategic placement is paramount for accurate data collection, effective process control, and optimal system response. Our team guides you in selection and strategically positioning these elements to maximize their effectiveness, enhance your system’s responsiveness and accuracy, boosting overall operational efficiency.

Actuator Monitoring: Actuators are critical components in any dynamic system. Our real-time actuator monitoring service ensures they operate at peak efficiency, identifying any signs of wear, malfunction, or potential failure. This proactive approach enables prompt interventions, minimizing downtime and maximizing productivity.

Digital Twin:
Our Digital Twin service is a game-changer in system analysis. We create a virtual replica of your system, allowing us to simulate, predict, and optimize your operations in a risk-free environment. This not only accelerates decision-making but also aids in the exploration of alternative strategies, identifying potential improvements, and testing them before implementation.

Stability and Robustness Analysis:
Ensuring system stability under changing conditions is critical in the dynamic world of industry. Our team leverages advanced analytical tools to scrutinize your system's robustness and resilience, providing insights into system response and behavior under a variety of operating scenarios. We identify potential risks that could destabilize your operations, providing actionable strategies to reinforce system stability and future-proof your business.

Plant Control

»What are you waiting for to benefit from game-changer technology?«
 

Our Goal: Optimize Your Industrial Processes

Our Control Systems Service is crafted with precision to revolutionize your industrial operations. We leverage advanced technology and a wealth of expertise to optimize your control loops, introduce new ones, and pave the way for modern control systems using Model Predictive Control (MPC) and Artificial Intelligence (AI). Our aim is to ensure your systems operate at the highest efficiency, with optimal stability and reliability.
 

Our Services 

Retuning of Existing Control Loops Using Digital Twins: Utilizing the power of digital twins, we create a virtual twin of your process to safely and efficiently test and retune your existing control loops. This approach ensures optimal performance with minimal risk and disruption to your actual operations.

Design of New Control Loops Including Multivariable Strategies: Leveraging our deep understanding of control system dynamics, we design new control loops tailored to your unique operational requirements. We also consider the complexity of multivariable systems, ensuring these loops work synergistically to optimize overall system performance. Depending on the process characteristics and complexity, we implement well stablished strategies like multivariable PID, dead-time compensators, state-space feedback (H2, H∞), and nonlinear strategies (backstepping, feedback linearization).

Design of Advanced Control Systems Based on Model Predictive Control: By incorporating the industrial well-established Model Predictive Controller into your system, we enable more precise and reliable control, improving process stability and performance. MPC uses a model of the system consider non-measured states as performance objectives and to predict future behavior, allowing for proactive adjustments and optimized control strategies to handle actuator and states operational constraints as well as linear and nonlinear dynamics.

Artificial Intelligence-Based Control Systems: We bring the future to your doorstep with AI-based control systems. AI allows your system to learn and adapt to changing conditions in real time, improving system responsiveness, caring about the health status of your plant, and enhancing overall performance.

Resource Optimized Control

»Is your process using all resources (energy, material, machines, personnel) as optimal as possible?«
 

Our Goal: Efficient and Sustainable Use of Resources

Our Resource-Optimized Control service offers a comprehensive solution to enhance your industrial operations, focusing on the efficient and sustainable use of resources. From optimizing your production and energy usage to managing your stock effectively and integrating predictive maintenance systems, we aim to deliver a service that increases your productivity and profitability while minimizing waste.
 

Our Services

Production Optimization: We begin by assessing your current production processes and identifying areas for improvement. Our team then develops customized control strategies, maximizing the efficiency of your operations and enhancing productivity. We ensure your production processes are streamlined, robust, and primed for peak performance.

Energy Optimization: Energy costs can be a significant burden for industries. Our service utilizes advanced control techniques and technologies to optimize your energy use, without compromising productivity. We strive to enhance your energy usage, thereby reducing costs and promoting more sustainable operations.

Process Optimization including Predictive Maintenance Systems: By integrating predictive maintenance systems in optimization strategies, we enable a proactive approach to managing your resources and equipment. This integration facilitates timely maintenance, prevents unexpected downtime, and ultimately enhances system reliability and longevity.

Deployment of Our Solutions

»How do game-changer technologies come true?«
 

Our Goal

The deployment of our solutions is performed aiming to ensure a smooth and efficient integration into your existing operations. With our expertise in hardware integration, visualization systems, and IoT/Industrial protocols, we support an effective step forward to improve your operational efficiency.
 

Our Services

  1. Hardware integration: We provide comprehensive hardware integration services, ensuring the systems we design and optimize are correctly implemented within your existing infrastructure. Our team of experts ensures compatibility, optimizes connectivity, and manages the full hardware integration process with utmost precision, minimizing disruption to your operations and ensuring optimal system performance.
  2. Visualization systems: As part of our service, we implement advanced visualization systems (i.e., Grafana dashboards), providing your team with a clear and intuitive interface to monitor and manage your operations. This high level of transparency improves decision-making processes and enhances operational control.
  3. IoT Protocols: With the proliferation of IoT devices in the industrial sector, understanding and effectively implementing IoT protocols is critical.  This ensures seamless communication between devices, promotes data integrity, and enhances the overall functionality of your industrial operations. We integrate controller into the hardware control loop using the most popular protocols including (OPC UA, MQTT, CAN bus, Ethernet TCP).

Why Choose Our Service?

»What else is there to wait for? Benefit from our groundbreaking technology!«

Choosing our services brings a wealth of advantages to your industrial operations, providing you with an edge over competitors and paving the way towards unrivalled operational efficiency. Here are some compelling reasons to choose our services:

  1. Comprehensive Solutions: Our services offer a holistic approach to system control and optimization. From in-depth system analysis to advanced control design and from resource optimization to predictive maintenance, our solutions encompass all facets of your operation. This means you receive an all-inclusive service that caters to all your industrial needs.
  2. Expertise and Experience: Our team comprises seasoned professionals with a wealth of experience and deep knowledge in control systems, dynamic systems analysis, resource optimization and predictive maintenance. Their expertise ensures accurate diagnostics, efficient solutions, and reliable ongoing support.
  3. Cutting-Edge Technology: We employ the latest technologies in all our services, including digital twins, Model Predictive Control, and Artificial Intelligence. This means your business benefits from innovative solutions that align with the industry's leading edge.
  4. Tailored Services: We understand that every business has unique needs and challenges. Our services are tailored to fit your specific operational context and goals, ensuring our solutions are perfectly aligned with your business requirements.
  5. Sustainable and Efficient Operations: We prioritize energy and resource efficiency, driving your operations towards more sustainable and cost-effective practices. With our services, you will witness a significant reduction in waste, optimal use of resources and a considerable improvement in overall system efficiency.
  6. Proactive Approach: Our use of predictive analytics and maintenance techniques ensures a proactive approach to problem-solving. We anticipate potential issues before they escalate, thereby minimizing disruptions and enhancing your system's reliability and longevity.
  7. Continuous Support: We stand by your side, offering comprehensive support throughout the process, from the initial analysis stage to the implementation of our recommendations. Our commitment to your success extends beyond service delivery, ensuring seamless transition and sustained improvements.