산업용 도금공장 자동화를 위한 제어로직과 저비용 고성능 자동밸브 상업화 연구 = A Study on Control Logic for Industrial Plating Process Automation and the Commercialization of a Low-Cost, High-Performance Automatic Valve

다국어 초록 (Multilingual Abstract)

This study presents (i) a cost-effective retrofit valve automation platform and (ii) an industrially validated, data-driven control strategy for galvanizing processes.
In aging industrial plants, automation upgrades are often constrained by high capital costs and long procurement lead times, especially when manual valves must be replaced with dedicated control valves. To address this barrier, this study develops a retrofit-oriented automatic valve platform that integrates an encoder-based actuator with commercial manual valve bodies and provides digital connectivity via Modbus RTU and long-range wireless communication, enabling installation without re-piping or extended production downtime. The proposed actuator demonstrates practical responsiveness, achieving a full-stroke motion of a 1/2-inch ball valve from 0°to 90° with a settling time of 6 s.

In a separate but related effort, this research investigates a data-driven control methodology for zinc coating weight regulation in Continuous Galvanizing Lines (CGL), where strong nonlinearity and transport delay can limit conventional feedback control and where predictive model-based approaches can degrade under model mismatch in aging equipment. Operational robustness is improved through a Case-Based Reasoning (CBR)-based operating recipes from historical successful runs, combined with an adaptive feedback mechanism that updates controller gains according to line speed and process sensitivity. An asymmetric feedforward policy is additionally introduced to provide a safety margin and mitigate under-coating risks.
Field trials indicate that the coating-related control deviation remains within 10g/m² of the set value(SV) without falling below SV−10 g/m². supporting stable operation under practical Continuous Galvanizing Line(CGL) disturbances.

목차 (Table of Contents)

• 서론 1
• 1장 저비용 고성능 자동 밸브 시스템 설계 및 구현 5
• 1.1 레트로핏(Retrofit)개념과 밸브 자동화 액추에이터 시스템 구성 5
• 1.2 밸브의 자동화 구현 6
• 1.3 밸브 정밀 제어 7
• 1.4 산업용 IoT – Modbus RTU, LoRa 무선 통신 9
• 1.5 저유량 액추에이터 시스템 케이스 10
• 1.6 3상 교류 전동기를 사용한 대유량 밸브 액추에이터 시스템 구조 15
• 1.7 전원부 설계 및 구현 17
• 1.8 전원부의 안정화 18
• 1.9 공압 솔레노이드 제어 회로 설계 19
• 1.10 밸브의 재현성, 반응속도 테스트 20
• 1.11 액위 제어기 21
• 1.12 증류탑 밸브 컨트롤러 23
• 1.13 대용량 밸브의 자동화 24
• 1.14 게이트 밸브 공압 자동화 25
• 1.15 결론 27
• 2장 도금공정 자동화 로직 29
• 2.1 레시피 기반 초기 도금량 제어 30
• 2.2 초기 도금량 제어 시뮬레이터 34
• 2.3 되먹임 제어 기반 도금량 제어 34
• 2.4 되먹임 제어 파라미터 설정 36
• 2.5 도금량 제어기 적용 결과 38
• 2.6 결론 39
• 참고문헌 40
• 영어 초록 41
• 부록 A. MCU 코드 43
• 부록 B. P-Automation 코드 45
• 부록 C. VB.Net 코드 47