🏭 ПРОМЫШЛЕННАЯ СИСТЕМА АВТОМАТИЗАЦИИ

 1🏭 INDUSTRIAL CONTROL SYSTEMS = МОЗГ ЗАВОДА
 2
 3АРХИТЕКТУРА АВТОМАТИЗАЦИИ:
 4
 5УРОВЕНЬ 1 - FIELD LEVEL (Полевой уровень):
 6🔧 Sensors & Actuators
 7   • Температура, давление, положение, скорость
 8   • Моторы, клапаны, реле, приводы
 9   • Smart devices с встроенной диагностикой
10
11УРОВЕНЬ 2 - CONTROL LEVEL (Управляющий уровень):  
12🤖 PLC (Programmable Logic Controllers)
13   • Real-time управление процессами
14   • Logic solving в микросекундах
15   • Модульная архитектура
16   • Fault-tolerant design
17
18УРОВЕНЬ 3 - SUPERVISION LEVEL (Диспетчерский уровень):
19🖥️ SCADA (Supervisory Control And Data Acquisition)
20   • HMI (Human Machine Interface)
21   • Real-time мониторинг
22   • Alarm management
23   • Historical data logging
24
25УРОВЕНЬ 4 - MANAGEMENT LEVEL (Управленческий уровень):
26📊 MES (Manufacturing Execution System)
27   • Production planning
28   • Quality management  
29   • Resource optimization
30   • Performance analytics
31
32УРОВЕНЬ 5 - ENTERPRISE LEVEL (Корпоративный уровень):
33💼 ERP (Enterprise Resource Planning)
34   • Business management
35   • Supply chain
36   • Financial integration
37   • Strategic planning
38
39ПРОМЫШЛЕННЫЕ ПРОТОКОЛЫ:
40🔌 MODBUS RTU/TCP:
41   • Простой, надежный
42   • Master-slave архитектура
43   • Широко поддерживается
44
45🔌 PROFIBUS/PROFINET:
46   • Siemens стандарт
47   • High-speed communication
48   • Deterministic timing
49
50🔌 EtherNet/IP:
51   • Rockwell Automation
52   • TCP/IP based
53   • Common Industrial Protocol
54
55🔌 OPC UA:
56   • Platform independent
57   • Security built-in
58   • Semantic data modeling
59
60🆕 INDUSTRY 4.0 CONCEPTS:
61
62DIGITAL TWIN:
63• Виртуальная копия физического процесса
64• Real-time синхронизация
65• Predictive simulation
66• Optimization testing
67
68CYBER-PHYSICAL SYSTEMS:
69• Integration физического и цифрового
70• Autonomous decision making
71• Self-organizing production
72• Adaptive manufacturing
73
74IIoT (Industrial Internet of Things):
75• Massive sensor networks
76• Edge computing
77• Cloud analytics
78• Machine learning integration

 1🔄 MANUFACTURING EXECUTION SYSTEMS
 2
 3ПРОИЗВОДСТВЕННЫЙ ПРОЦЕСС:
 4
 5МАТЕРИАЛЬНЫЙ ПОТОК:
 6Raw Materials → Processing → Assembly → Testing → Packaging → Shipping
 7
 8ИНФОРМАЦИОННЫЙ ПОТОК:
 9Orders → Scheduling → Execution → Quality → Reporting → Analytics
10
11ОСНОВНЫЕ ФУНКЦИИ MES:
12
13📋 PRODUCTION SCHEDULING:
14• Resource allocation
15• Sequence optimization  
16• Capacity planning
17• Bottleneck management
18
19🔍 QUALITY MANAGEMENT:
20• In-process monitoring
21• Statistical process control (SPC)
22• Defect tracking
23• Root cause analysis
24
25📊 PERFORMANCE TRACKING:
26• OEE (Overall Equipment Effectiveness)
27• Throughput monitoring
28• Downtime analysis
29• Energy consumption
30
31🛠️ MAINTENANCE MANAGEMENT:
32• Preventive maintenance scheduling
33• Condition-based monitoring
34• Spare parts management
35• Work order tracking
36
37KEY PERFORMANCE INDICATORS (KPIs):
38
39⚡ OEE = Availability × Performance × Quality
40   • Availability = Actual Production Time / Planned Production Time
41   • Performance = Actual Output / Theoretical Output  
42   • Quality = Good Parts / Total Parts Produced
43
44📈 THROUGHPUT:
45   • Parts per hour/day/week
46   • Cycle time optimization
47   • Takt time alignment
48
49💰 COST METRICS:
50   • Cost per unit
51   • Energy consumption per unit
52   • Labor efficiency
53   • Material utilization
54
55🆕 ADVANCED MANUFACTURING CONCEPTS:
56
57LEAN MANUFACTURING:
58• Just-in-time production
59• Waste elimination (7 wastes)
60• Continuous improvement (Kaizen)
61• Value stream mapping
62
63FLEXIBLE MANUFACTURING:
64• Rapid changeover capability
65• Multi-product lines
66• Adaptive scheduling
67• Mass customization
68
69SMART MANUFACTURING:
70• Self-optimizing processes
71• Predictive quality control
72• Autonomous material handling
73• Real-time supply chain integration
74
75PRODUCTION LINE TYPES:
76
77🔄 CONTINUOUS FLOW:
78   • Chemical processing
79   • Food production
80   • Paper manufacturing
81   • 24/7 operation
82
83⚙️ DISCRETE MANUFACTURING:
84   • Automotive assembly
85   • Electronics production
86   • Machinery manufacturing
87   • Batch processing
88
89🔀 HYBRID SYSTEMS:
90   • Pharmaceutical production
91   • Semiconductor fabrication
92   • Food processing
93   • Complex assemblies

 1🛡️ INDUSTRIAL SAFETY SYSTEMS
 2
 3ФУНКЦИОНАЛЬНАЯ БЕЗОПАСНОСТЬ:
 4
 5IEC 61508 - FUNCTIONAL SAFETY STANDARD:
 6🎯 SIL (Safety Integrity Levels):
 7   • SIL 1: 10⁻¹ to 10⁻² (basic safety)
 8   • SIL 2: 10⁻² to 10⁻³ (enhanced safety)  
 9   • SIL 3: 10⁻³ to 10⁻⁴ (high safety)
10   • SIL 4: 10⁻⁴ to 10⁻⁵ (ultra-high safety)
11
12SAFETY LIFECYCLE:
131. Hazard Analysis & Risk Assessment
142. Safety Requirements Specification  
153. Safety System Design
164. Implementation & Integration
175. Validation & Verification
186. Operation & Maintenance
197. Modification & Decommissioning
20
21EMERGENCY STOP SYSTEMS:
22
23КАТЕГОРИИ STOP:
24🔴 Category 0: Immediate power removal (uncontrolled stop)
25🟡 Category 1: Controlled stop, then power removal
26🟢 Category 2: Controlled stop, power maintained
27
28SAFETY FUNCTIONS:
29🚨 Emergency Stop (E-Stop)
30🚪 Safety Door Monitoring
31⚡ Light Curtain Protection
32🤖 Safe Torque Off (STO)
33🔒 Lockout/Tagout (LOTO)
34
35RISK ASSESSMENT:
36
37RISK = SEVERITY × PROBABILITY × EXPOSURE
38
39SEVERITY LEVELS:
40• S1: Light injury (scratches, bruises)
41• S2: Serious injury (fractures, amputations)
42• S3: Death or permanent disability
43
44PROBABILITY:
45• P1: Very low (once per century)
46• P2: Low (once per decade)  
47• P3: High (once per year)
48
49EXPOSURE:
50• E1: Rare (few times per year)
51• E2: Frequent (daily)
52• E3: Continuous (hourly)
53
54🆕 CYBERSECURITY FOR INDUSTRIAL SYSTEMS:
55
56IEC 62443 - INDUSTRIAL CYBERSECURITY:
57🔒 Security Levels (SL):
58   • SL 1: Protection against casual or accidental violation
59   • SL 2: Protection against intentional violation using simple means
60   • SL 3: Protection against intentional violation using sophisticated means
61   • SL 4: Protection against state-of-the-art attacks
62
63SECURITY MEASURES:
64🛡️ Network Segmentation
65🔐 Authentication & Authorization
66🔒 Encryption
67📊 Security Monitoring
68🚨 Incident Response
69
70COMMON VULNERABILITIES:
71❌ Default passwords
72❌ Unpatched systems
73❌ Unsecured remote access
74❌ Insufficient network monitoring
75❌ Lack of security awareness
76
77INDUSTRIAL STANDARDS:
78
79📋 ISO 9001: Quality Management
80📋 ISO 14001: Environmental Management
81📋 OHSAS 18001: Occupational Health & Safety
82📋 ISO 27001: Information Security
83📋 IEC 61511: Process Industry Safety
84📋 NFPA 70E: Electrical Safety
85
86🆕 DIGITAL SAFETY:
87• Secure boot processes
88• Cryptographic key management
89• Over-the-air update security
90• Blockchain for supply chain integrity
91• AI-powered threat detection

  1🚗 ПРОИЗВОДСТВЕННАЯ СИСТЕМА:
  2• Сборка автомобильных компонентов
  3• Multi-stage assembly процесс
  4• Quality control stations
  5• Automated guided vehicles (AGV)
  6• Paint booth automation
  7
  8🔧 HARDWARE ECOSYSTEM:
  9STAGE 1 - PART FEEDING:
 10├── Conveyor system (stepper motor controlled)
 11├── Part detection (vision system)
 12├── Sorting mechanism (servo-driven)
 13└── Inventory tracking (RFID readers)
 14
 15STAGE 2 - ASSEMBLY STATION:
 16├── 6-DOF robotic arm (servo coordination)
 17├── Pneumatic grippers (solenoid controlled)
 18├── Torque monitoring (current sensors)
 19└── Assembly verification (force sensors)
 20
 21STAGE 3 - QUALITY CONTROL:
 22├── Vision inspection (camera + AI)
 23├── Dimensional measurement (laser sensors)
 24├── Electrical testing (automated test equipment)
 25└── Reject mechanism (pneumatic ejector)
 26
 27STAGE 4 - FINISHING:
 28├── Paint application (electrostatic spray)
 29├── Curing oven (PID temperature control)
 30├── Surface inspection (lighting + cameras)
 31└── Final packaging (robotic palletizer)
 32
 33CONTROL ARCHITECTURE:
 34┌─────────────────┐
 35│   ERP SYSTEM    │ ← Production orders, materials
 36├─────────────────┤
 37│   MES SYSTEM    │ ← Scheduling, tracking, quality
 38├─────────────────┤
 39│   SCADA/HMI     │ ← Operator interface, alarms
 40├─────────────────┤
 41│ PLC CONTROLLERS │ ← Real-time control logic
 42├─────────────────┤
 43│ FIELD DEVICES   │ ← Sensors, actuators, drives
 44└─────────────────┘
 45
 46#include <WiFi.h>
 47#include <PubSubClient.h>
 48#include <ArduinoJson.h>
 49#include <ModbusRTU.h>
 50
 51// Manufacturing Execution System
 52class AutomotiveMES {
 53private:
 54  struct ProductionOrder {
 55    String orderId;
 56    String partNumber;
 57    int quantity;
 58    int completed;
 59    int rejected;
 60    unsigned long startTime;
 61    unsigned long estimatedCompletion;
 62    String status; // "PENDING", "ACTIVE", "COMPLETED", "PAUSED"
 63  };
 64  
 65  std::vector<ProductionOrder> activeOrders;
 66  
 67  struct StationStatus {
 68    String stationId;
 69    String currentOperation;
 70    bool operational;
 71    int cycleCount;
 72    float cycleTime;
 73    float oeeAvailability;
 74    float oeePerformance;
 75    float oeeQuality;
 76  };
 77  
 78  StationStatus stations[4]; // 4 assembly stations
 79  
 80public:
 81  void initializeProductionLine() {
 82    // Initialize all stations
 83    stations[0] = {"FEED_001", "Part Feeding", true, 0, 0, 0, 0, 0};
 84    stations[1] = {"ASSY_001", "Assembly", true, 0, 0, 0, 0, 0};
 85    stations[2] = {"QC_001", "Quality Control", true, 0, 0, 0, 0, 0};
 86    stations[3] = {"PACK_001", "Packaging", true, 0, 0, 0, 0, 0};
 87    
 88    Serial.println("Automotive Production Line INITIALIZED");
 89    
 90    // Start production monitoring
 91    startProductionMonitoring();
 92  }
 93  
 94  void processProductionOrder(String orderId, String partNumber, int quantity) {
 95    ProductionOrder order;
 96    order.orderId = orderId;
 97    order.partNumber = partNumber;
 98    order.quantity = quantity;
 99    order.completed = 0;
100    order.rejected = 0;
101    order.startTime = millis();
102    order.estimatedCompletion = millis() + (quantity * 30000); // 30 sec per part
103    order.status = "ACTIVE";
104    
105    activeOrders.push_back(order);
106    
107    Serial.printf("Production Order %s STARTED: %d units of %s\n", 
108                  orderId.c_str(), quantity, partNumber.c_str());
109    
110    // Trigger production sequence
111    startProductionSequence(order);
112  }
113  
114  void updateStationPerformance(int stationIndex, float cycleTime, bool qualityPass) {
115    stations[stationIndex].cycleCount++;
116    stations[stationIndex].cycleTime = cycleTime;
117    
118    // Calculate OEE components
119    float plannedCycleTime = 25.0; // 25 seconds target
120    stations[stationIndex].oeePerformance = min(1.0f, plannedCycleTime / cycleTime);
121    
122    if (qualityPass) {
123      stations[stationIndex].oeeQuality = 
124        (stations[stationIndex].oeeQuality * 0.95f) + (1.0f * 0.05f);
125    } else {
126      stations[stationIndex].oeeQuality = 
127        (stations[stationIndex].oeeQuality * 0.95f) + (0.0f * 0.05f);
128    }
129    
130    // Overall OEE calculation
131    float oee = stations[stationIndex].oeeAvailability * 
132                stations[stationIndex].oeePerformance * 
133                stations[stationIndex].oeeQuality;
134    
135    Serial.printf("Station %s OEE: %.1f%% (A:%.1f%% P:%.1f%% Q:%.1f%%)\n",
136                  stations[stationIndex].stationId.c_str(), oee * 100,
137                  stations[stationIndex].oeeAvailability * 100,
138                  stations[stationIndex].oeePerformance * 100,
139                  stations[stationIndex].oeeQuality * 100);
140    
141    // Publish to MES dashboard
142    publishOEEData(stationIndex, oee);
143  }
144  
145  // 🆕 Predictive maintenance algorithm
146  void predictiveMaintenance() {
147    for (int i = 0; i < 4; i++) {
148      // Analyze performance trends
149      if (stations[i].oeePerformance < 0.85f) {
150        Serial.printf("MAINTENANCE ALERT: Station %s performance degrading\n",
151                      stations[i].stationId.c_str());
152        
153        // Predictive actions
154        scheduleMaintenanceWindow(stations[i].stationId);
155        orderReplacementParts(stations[i].stationId);
156      }
157      
158      // Vibration analysis (simulated)
159      float vibrationLevel = readVibrationSensor(i);
160      if (vibrationLevel > VIBRATION_THRESHOLD) {
161        Serial.printf("VIBRATION ALERT: Station %s - %.2f g\n",
162                      stations[i].stationId.c_str(), vibrationLevel);
163      }
164      
165      // Temperature monitoring
166      float operatingTemp = readTemperatureSensor(i);
167      if (operatingTemp > TEMP_THRESHOLD) {
168        Serial.printf("TEMPERATURE ALERT: Station %s - %.1f°C\n",
169                      stations[i].stationId.c_str(), operatingTemp);
170      }
171    }
172  }
173  
174  // 🆕 Digital Twin integration
175  void updateDigitalTwin() {
176    StaticJsonDocument<1000> twinData;
177    
178    for (int i = 0; i < 4; i++) {
179      JsonObject station = twinData.createNestedObject("station_" + String(i));
180      station["id"] = stations[i].stationId;
181      station["status"] = stations[i].operational ? "RUNNING" : "STOPPED";
182      station["cycle_count"] = stations[i].cycleCount;
183      station["cycle_time"] = stations[i].cycleTime;
184      station["oee"] = stations[i].oeeAvailability * 
185                       stations[i].oeePerformance * 
186                       stations[i].oeeQuality;
187      
188      // Real-time sensor data
189      station["temperature"] = readTemperatureSensor(i);
190      station["vibration"] = readVibrationSensor(i);
191      station["power_consumption"] = readPowerMeter(i);
192    }
193    
194    // Current production status
195    twinData["active_orders"] = activeOrders.size();
196    twinData["total_production_today"] = getTodayProduction();
197    twinData["overall_oee"] = calculateOverallOEE();
198    
199    String twinJson;
200    serializeJson(twinData, twinJson);
201    
202    // Send to digital twin platform
203    client.publish("factory/digital_twin/automotive_line", twinJson.c_str());
204  }
205};
206
207AutomotiveMES productionSystem;
208
209void setup() {
210  Serial.begin(115200);
211  
212  // Initialize production line
213  productionSystem.initializeProductionLine();
214  
215  // Setup communications
216  setupMQTT();
217  setupModbus();
218  
219  // Safety systems initialization
220  initializeSafetySystems();
221  
222  Serial.println("Automotive Assembly Line READY FOR PRODUCTION");
223}
224
225void loop() {
226  // SAFETY FIRST - Monitor emergency stops
227  if (digitalRead(EMERGENCY_STOP_PIN) == LOW) {
228    emergencyShutdown();
229    return;
230  }
231  
232  // Production line control
233  productionSystem.updateStationPerformance(0, measureCycleTime(0), checkQuality(0));
234  productionSystem.updateStationPerformance(1, measureCycleTime(1), checkQuality(1));
235  productionSystem.updateStationPerformance(2, measureCycleTime(2), checkQuality(2));
236  productionSystem.updateStationPerformance(3, measureCycleTime(3), checkQuality(3));
237  
238  // Predictive maintenance
239  productionSystem.predictiveMaintenance();
240  
241  // Digital twin updates
242  productionSystem.updateDigitalTwin();
243  
244  // MQTT communication
245  if (mqttClient.connected()) {
246    mqttClient.loop();
247  }
248  
249  delay(100); // 10 Hz production control
250}
251
252// MQTT Production Commands
253void onMqttMessage(char* topic, byte* payload, unsigned int length) {
254  String message = String((char*)payload, length);
255  StaticJsonDocument<300> doc;
256  deserializeJson(doc, message);
257  
258  if (String(topic) == "production/orders/new") {
259    String orderId = doc["order_id"];
260    String partNumber = doc["part_number"];
261    int quantity = doc["quantity"];
262    
263    productionSystem.processProductionOrder(orderId, partNumber, quantity);
264  }
265  
266  else if (String(topic) == "production/control/pause") {
267    pauseProduction();
268  }
269  
270  else if (String(topic) == "production/control/resume") {
271    resumeProduction();
272  }
273  
274  else if (String(topic) == "maintenance/schedule") {
275    String stationId = doc["station_id"];
276    unsigned long scheduledTime = doc["scheduled_time"];
277    scheduleMaintenanceWindow(stationId, scheduledTime);
278  }
279}
280
281ПЕРВАЯ ПРОМЫШЛЕННАЯ ЗАДАЧА:
282✓ Полный цикл automotive assembly
283✓ Real-time OEE monitoring
284✓ Predictive maintenance alerts
285✓ Digital twin synchronization
286✓ MQTT production control
287✓ Safety system integration
288✓ Quality control automation

  1🍞 ПРОИЗВОДСТВЕННАЯ СИСТЕМА:
  2• Automated food processing line
  3• Temperature/humidity critical control
  4• HACCP compliance monitoring
  5• Packaging and labeling
  6• Inventory management
  7
  8🥖 HARDWARE ECOSYSTEM:
  9STAGE 1 - RAW MATERIAL HANDLING:
 10├── Ingredient dosing systems (load cells)
 11├── Mixing equipment (variable speed drives)
 12├── Temperature control (PID heating/cooling)
 13└── Humidity monitoring (environmental sensors)
 14
 15STAGE 2 - PROCESSING:
 16├── Continuous mixing (torque monitoring)
 17├── Forming equipment (pneumatic presses)
 18├── Baking/cooking (multi-zone ovens)
 19└── Cooling tunnels (airflow control)
 20
 21STAGE 3 - QUALITY ASSURANCE:
 22├── Metal detection (electromagnetic sensors)
 23├── Weight checking (precision scales)
 24├── Visual inspection (AI vision systems)
 25└── Moisture analysis (NIR spectroscopy)
 26
 27STAGE 4 - PACKAGING:
 28├── Primary packaging (flow wrappers)
 29├── Secondary packaging (case packers)
 30├── Date/lot coding (inkjet printers)
 31└── Palletizing (robotic systems)
 32
 33#include <OneWire.h>
 34#include <DallasTemperature.h>
 35#include <HX711.h>
 36
 37class FoodProcessingMES {
 38private:
 39  struct Recipe {
 40    String recipeId;
 41    String productName;
 42    std::map<String, float> ingredients; // ingredient -> amount
 43    float mixingTime;
 44    float bakingTemp;
 45    float bakingTime;
 46    float targetWeight;
 47    float moistureTarget;
 48  };
 49  
 50  std::vector<Recipe> recipes;
 51  
 52  struct QualityParameters {
 53    float weight;
 54    float moisture;
 55    float temperature;
 56    bool metalDetected;
 57    bool visualDefects;
 58    String lotNumber;
 59    unsigned long timestamp;
 60  };
 61  
 62  struct HACCPRecord {
 63    String controlPoint;
 64    float criticalLimit;
 65    float actualValue;
 66    bool inSpec;
 67    String corrective Action;
 68    unsigned long timestamp;
 69  };
 70  
 71  std::vector<HACCPRecord> haccpLog;
 72  
 73public:
 74  void initializeFoodLine() {
 75    // Load standard recipes
 76    loadRecipes();
 77    
 78    // Initialize HACCP monitoring
 79    setupHACCPMonitoring();
 80    
 81    // Temperature probe calibration
 82    calibrateTemperatureProbes();
 83    
 84    Serial.println("Food Processing Line INITIALIZED");
 85    Serial.println("HACCP monitoring ACTIVE");
 86  }
 87  
 88  void processProductionBatch(String recipeId, int batchSize) {
 89    Recipe recipe = getRecipe(recipeId);
 90    String lotNumber = generateLotNumber();
 91    
 92    Serial.printf("Starting batch %s: %s (%d units)\n",
 93                  lotNumber.c_str(), recipe.productName.c_str(), batchSize);
 94    
 95    // Stage 1: Ingredient dosing
 96    if (!doseIngredients(recipe, batchSize)) {
 97      recordHACCPDeviation("INGREDIENT_DOSING", "Dosing accuracy out of spec");
 98      return;
 99    }
100    
101    // Stage 2: Mixing
102    if (!mixIngredients(recipe.mixingTime)) {
103      recordHACCPDeviation("MIXING", "Mixing time/torque deviation");
104      return;
105    }
106    
107    // Stage 3: Forming and baking
108    if (!bakingProcess(recipe.bakingTemp, recipe.bakingTime)) {
109      recordHACCPDeviation("BAKING", "Temperature/time out of critical limits");
110      return;
111    }
112    
113    // Stage 4: Quality control
114    QualityParameters quality = performQualityCheck();
115    
116    if (evaluateQuality(quality, recipe)) {
117      Serial.printf("Batch %s PASSED quality control\n", lotNumber.c_str());
118      proceedToPackaging(lotNumber);
119    } else {
120      Serial.printf("Batch %s FAILED quality control - REJECTED\n", lotNumber.c_str());
121      rejectBatch(lotNumber);
122    }
123  }
124  
125  bool doseIngredients(Recipe recipe, int batchSize) {
126    Serial.println("=== INGREDIENT DOSING ===");
127    
128    for (auto& ingredient : recipe.ingredients) {
129      float targetAmount = ingredient.second * batchSize;
130      float actualAmount = doseIngredient(ingredient.first, targetAmount);
131      
132      float accuracy = abs(actualAmount - targetAmount) / targetAmount * 100;
133      
134      Serial.printf("%s: Target %.2fkg, Actual %.2fkg (±%.1f%%)\n",
135                    ingredient.first.c_str(), targetAmount, actualAmount, accuracy);
136      
137      // HACCP Critical Control Point
138      if (accuracy > 2.0) { // 2% tolerance
139        recordHACCPDeviation("INGREDIENT_DOSING", 
140                           ingredient.first + " dosing accuracy: " + String(accuracy) + "%");
141        return false;
142      }
143    }
144    
145    return true;
146  }
147  
148  bool bakingProcess(float targetTemp, float bakingTime) {
149    Serial.println("=== BAKING PROCESS ===");
150    
151    unsigned long startTime = millis();
152    unsigned long endTime = startTime + (bakingTime * 60000); // minutes to ms
153    
154    // Multi-zone oven control
155    setOvenTemperature(1, targetTemp);      // Zone 1: Heating
156    setOvenTemperature(2, targetTemp + 10); // Zone 2: Peak
157    setOvenTemperature(3, targetTemp - 5);  // Zone 3: Finishing
158    
159    while (millis() < endTime) {
160      // Monitor all zones
161      for (int zone = 1; zone <= 3; zone++) {
162        float actualTemp = readOvenTemperature(zone);
163        float setpoint = getOvenSetpoint(zone);
164        
165        // HACCP Critical Control Point - Temperature
166        if (abs(actualTemp - setpoint) > 5.0) { // ±5°C tolerance
167          recordHACCPDeviation("BAKING_TEMPERATURE", 
168                             "Zone " + String(zone) + " temp deviation: " + 
169                             String(actualTemp) + "°C");
170          
171          // Corrective action
172          adjustOvenTemperature(zone, setpoint);
173        }
174        
175        Serial.printf("Oven Zone %d: %.1f°C (SP: %.1f°C)\n", 
176                      zone, actualTemp, setpoint);
177      }
178      
179      delay(5000); // Check every 5 seconds
180    }
181    
182    Serial.println("Baking process COMPLETED");
183    return true;
184  }
185  
186  QualityParameters performQualityCheck() {
187    Serial.println("=== QUALITY CONTROL ===");
188    
189    QualityParameters quality;
190    quality.timestamp = millis();
191    quality.lotNumber = getCurrentLotNumber();
192    
193    // Weight check
194    quality.weight = readProductWeight();
195    Serial.printf("Product weight: %.2fg\n", quality.weight);
196    
197    // Moisture analysis
198    quality.moisture = readMoistureContent();
199    Serial.printf("Moisture content: %.1f%%\n", quality.moisture);
200    
201    // Metal detection
202    quality.metalDetected = performMetalDetection();
203    Serial.printf("Metal detection: %s\n", quality.metalDetected ? "FAIL" : "PASS");
204    
205    // Visual inspection (AI)
206    quality.visualDefects = performVisualInspection();
207    Serial.printf("Visual inspection: %s\n", quality.visualDefects ? "DEFECTS" : "PASS");
208    
209    // Core temperature (for baked goods)
210    quality.temperature = readCoreTemperature();
211    Serial.printf("Core temperature: %.1f°C\n", quality.temperature);
212    
213    return quality;
214  }
215  
216  // 🆕 HACCP compliance monitoring
217  void recordHACCPDeviation(String controlPoint, String deviation) {
218    HACCPRecord record;
219    record.controlPoint = controlPoint;
220    record.actualValue = getCurrentCriticalValue(controlPoint);
221    record.criticalLimit = getCriticalLimit(controlPoint);
222    record.inSpec = false;
223    record.corrective Action = "AUTOMATIC_CORRECTION_INITIATED";
224    record.timestamp = millis();
225    
226    haccpLog.push_back(record);
227    
228    Serial.printf("HACCP DEVIATION: %s - %s\n", 
229                  controlPoint.c_str(), deviation.c_str());
230    
231    // Automatic corrective actions
232    implementCorrectiveAction(controlPoint);
233    
234    // Alert quality manager
235    sendQualityAlert(controlPoint, deviation);
236  }
237  
238  // 🆕 Traceability system
239  void generateTraceabilityRecord(String lotNumber) {
240    StaticJsonDocument<1000> traceRecord;
241    
242    traceRecord["lot_number"] = lotNumber;
243    traceRecord["production_date"] = getCurrentDate();
244    traceRecord["recipe_id"] = getCurrentRecipeId();
245    traceRecord["line_id"] = "FOOD_LINE_001";
246    
247    // Ingredient traceability
248    JsonArray ingredients = traceRecord.createNestedArray("ingredients");
249    for (auto& ingredient : getCurrentIngredients()) {
250      JsonObject ing = ingredients.createNestedObject();
251      ing["name"] = ingredient.name;
252      ing["supplier_lot"] = ingredient.supplierLot;
253      ing["expiry_date"] = ingredient.expiryDate;
254      ing["amount_used"] = ingredient.amountUsed;
255    }
256    
257    // Quality test results
258    JsonObject quality = traceRecord.createNestedObject("quality_tests");
259    quality["weight"] = getQualityResult("weight");
260    quality["moisture"] = getQualityResult("moisture");
261    quality["metal_detection"] = getQualityResult("metal");
262    quality["visual_inspection"] = getQualityResult("visual");
263    
264    // Environmental conditions
265    JsonObject environment = traceRecord.createNestedObject("environment");
266    environment["temperature"] = getAverageRoomTemp();
267    environment["humidity"] = getAverageRoomHumidity();
268    environment["air_pressure"] = getAirPressure();
269    
270    String traceJson;
271    serializeJson(traceRecord, traceJson);
272    
273    // Store in traceability database
274    client.publish("food_safety/traceability", traceJson.c_str());
275    
276    Serial.printf("Traceability record generated for lot %s\n", lotNumber.c_str());
277  }
278};
279
280ПЕРВАЯ ПИЩЕВАЯ ЗАДАЧА:
281✓ Complete food processing automation
282✓ HACCP compliance monitoring
283✓ Multi-zone oven control с PID
284✓ Quality control с AI vision
285✓ Traceability system
286✓ Automatic corrective actions
287✓ Moisture/weight precision control

  1⚡ КРИТИЧЕСКИ ВАЖНАЯ СИСТЕМА:
  2• Nuclear/thermal power plant simulation
  3• Multi-parameter monitoring
  4• Cascade control systems
  5• Emergency shutdown procedures
  6• Regulatory compliance
  7
  8🔥 CONTROL ROOM SETUP:
  9MAIN CONTROL PANELS:
 10├── Primary HMI (21" touchscreen)
 11├── Alarm management system
 12├── Trend displays (historical data)
 13├── Emergency controls (hardwired)
 14└── Communication systems
 15
 16PROCESS MONITORING:
 17├── Reactor temperature (multiple RTDs)
 18├── Steam pressure (transmitters)
 19├── Turbine speed (tachometers)
 20├── Electrical output (power meters)
 21└── Radiation monitoring (Geiger counters)
 22
 23CONTROL SYSTEMS:
 24├── Reactor control rods (stepper positioning)
 25├── Steam valves (pneumatic actuators)
 26├── Cooling pumps (variable frequency drives)
 27├── Generator excitation (voltage regulation)
 28└── Emergency systems (safety PLCs)
 29
 30#include <TFT_eSPI.h>
 31#include <ArduinoJson.h>
 32#include <PIDController.h>
 33
 34TFT_eSPI tft = TFT_eSPI();
 35
 36class PowerPlantSCADA {
 37private:
 38  struct ReactorParameters {
 39    float coreTemperature;
 40    float coolantFlow;
 41    float steamPressure;
 42    float neutronFlux;
 43    float controlRodPosition;
 44    bool emergencyShutdown;
 45    bool cooling SystemActive;
 46  };
 47  
 48  ReactorParameters reactor;
 49  
 50  struct TurbineGenerator {
 51    float steamFlow;
 52    float turbineSpeed;
 53    float generatorOutput;
 54    float frequency;
 55    float voltage;
 56    bool generatorOnline;
 57  };
 58  
 59  TurbineGenerator generator;
 60  
 61  struct SafetySystem {
 62    bool scrammed;           // Emergency reactor shutdown
 63    bool coolingActive;      // Emergency core cooling
 64    bool containmentSealed;  // Containment isolation
 65    float radiationLevel;    // Background radiation
 66    bool evacuationAlarm;    // Site evacuation
 67  };
 68  
 69  SafetySystem safety;
 70  
 71  // PID Controllers for critical parameters
 72  PIDController reactorTempPID;
 73  PIDController steamPressurePID;
 74  PIDController generatorFreqPID;
 75  
 76public:
 77  void initializePowerPlant() {
 78    Serial.println("=== POWER PLANT INITIALIZATION ===");
 79    
 80    // Initialize display
 81    tft.init();
 82    tft.setRotation(1);
 83    tft.fillScreen(TFT_BLACK);
 84    
 85    // Initialize reactor parameters
 86    reactor.coreTemperature = 280.0;  // °C
 87    reactor.coolantFlow = 1000.0;     // L/min
 88    reactor.steamPressure = 7.0;      // MPa
 89    reactor.neutronFlux = 1e12;       // neutrons/cm²/s
 90    reactor.controlRodPosition = 50.0; // % inserted
 91    reactor.emergencyShutdown = false;
 92    reactor.cooling SystemActive = true;
 93    
 94    // Initialize generator
 95    generator.steamFlow = 500.0;      // kg/s
 96    generator.turbineSpeed = 3000.0;  // RPM
 97    generator.generatorOutput = 1000.0; // MW
 98    generator.frequency = 50.0;       // Hz
 99    generator.voltage = 13800.0;      // V
100    generator.generatorOnline = true;
101    
102    // Initialize safety systems
103    safety.scrammed = false;
104    safety.coolingActive = true;
105    safety.containmentSealed = false;
106    safety.radiationLevel = 0.1;     // mSv/hr (background)
107    safety.evacuationAlarm = false;
108    
109    // Configure PID controllers
110    reactorTempPID.setGains(2.0, 0.5, 0.1);
111    steamPressurePID.setGains(1.5, 0.3, 0.05);
112    generatorFreqPID.setGains(3.0, 1.0, 0.2);
113    
114    Serial.println("Power plant systems INITIALIZED");
115    Serial.println("Reactor critical - normal operation");
116    
117    drawMainDisplay();
118  }
119  
120  void runPowerPlantControl() {
121    // Read all sensors
122    updateSensorReadings();
123    
124    // Safety system monitoring (HIGHEST PRIORITY)
125    monitorSafetySystems();
126    
127    if (safety.scrammed) {
128      handleEmergencyShutdown();
129      return;
130    }
131    
132    // Normal operation control
133    controlReactorTemperature();
134    controlSteamPressure();
135    controlGeneratorFrequency();
136    
137    // Update displays
138    updateMainDisplay();
139    updateTrendDisplays();
140    updateAlarmStatus();
141    
142    // Data logging
143    logPlantData();
144  }
145  
146  void controlReactorTemperature() {
147    float targetTemp = 285.0; // °C setpoint
148    float currentTemp = reactor.coreTemperature;
149    
150    // PID control of control rods
151    float rodAdjustment = reactorTempPID.compute(targetTemp, currentTemp);
152    reactor.controlRodPosition += rodAdjustment;
153    
154    // Safety limits
155    reactor.controlRodPosition = constrain(reactor.controlRodPosition, 0.0, 100.0);
156    
157    // Simulate reactor physics
158    if (reactor.controlRodPosition > 80.0) {
159      // Rods mostly inserted - reducing power
160      reactor.neutronFlux *= 0.99;
161      reactor.coreTemperature -= 0.5;
162    } else if (reactor.controlRodPosition < 20.0) {
163      // Rods mostly withdrawn - increasing power
164      reactor.neutronFlux *= 1.01;
165      reactor.coreTemperature += 0.5;
166    }
167    
168    Serial.printf("Reactor: %.1f°C, Rods: %.1f%%, Flux: %.2e\n",
169                  reactor.coreTemperature, reactor.controlRodPosition, reactor.neutronFlux);
170  }
171  
172  void monitorSafetySystems() {
173    // Critical parameter monitoring
174    
175    // TEMPERATURE TRIP
176    if (reactor.coreTemperature > 350.0) {
177      Serial.println("EMERGENCY: Core temperature trip!");
178      initiateReactorScram("HIGH_CORE_TEMPERATURE");
179    }
180    
181    // PRESSURE TRIP  
182    if (reactor.steamPressure > 8.5) {
183      Serial.println("EMERGENCY: High steam pressure trip!");
184      initiateReactorScram("HIGH_STEAM_PRESSURE");
185    }
186    
187    // COOLANT FLOW TRIP
188    if (reactor.coolantFlow < 800.0) {
189      Serial.println("EMERGENCY: Low coolant flow trip!");
190      initiateReactorScram("LOW_COOLANT_FLOW");
191    }
192    
193    // RADIATION MONITORING
194    if (safety.radiationLevel > 10.0) { // 10 mSv/hr limit
195      Serial.println("EMERGENCY: High radiation detected!");
196      initiateContainmentIsolation();
197    }
198    
199    // SEISMIC MONITORING (simulated)
200    float seismicActivity = readSeismicSensor();
201    if (seismicActivity > 0.1) { // 0.1g acceleration
202      Serial.println("EMERGENCY: Seismic event detected!");
203      initiateReactorScram("SEISMIC_EVENT");
204    }
205  }
206  
207  void initiateReactorScram(String reason) {
208    Serial.printf("=== REACTOR SCRAM INITIATED: %s ===\n", reason.c_str());
209    
210    safety.scrammed = true;
211    
212    // IMMEDIATE ACTIONS (hardware safety systems)
213    reactor.controlRodPosition = 100.0; // Full insertion
214    reactor.neutronFlux = 1e8;          // Rapid decay
215    reactor.emergencyShutdown = true;
216    
217    // Start emergency cooling
218    reactor.cooling SystemActive = true;
219    reactor.coolantFlow = 1500.0; // Maximum flow
220    
221    // Generator trip
222    generator.generatorOnline = false;
223    generator.generatorOutput = 0.0;
224    
225    // Alarm systems
226    activateAlarms();
227    
228    // Notify operators
229    sendEmergencyNotification(reason);
230    
231    // Update display to emergency status
232    drawEmergencyDisplay();
233    
234    Serial.println("Reactor SCRAMMED - entering safe shutdown mode");
235  }
236  
237  void drawMainDisplay() {
238    tft.fillScreen(TFT_BLACK);
239    
240    // Title bar
241    tft.fillRect(0, 0, 480, 30, TFT_BLUE);
242    tft.setTextColor(TFT_WHITE);
243    tft.setTextSize(2);
244    tft.drawString("POWER PLANT CONTROL ROOM", 10, 5);
245    
246    // Reactor status
247    tft.setTextColor(TFT_GREEN);
248    tft.setTextSize(1);
249    tft.drawString("REACTOR STATUS", 10, 40);
250    
251    tft.setTextColor(TFT_WHITE);
252    tft.drawString("Core Temp:", 10, 60);
253    tft.drawString(String(reactor.coreTemperature, 1) + " C", 120, 60);
254    
255    tft.drawString("Control Rods:", 10, 80);
256    tft.drawString(String(reactor.controlRodPosition, 1) + " %", 120, 80);
257    
258    tft.drawString("Steam Press:", 10, 100);
259    tft.drawString(String(reactor.steamPressure, 1) + " MPa", 120, 100);
260    
261    // Generator status
262    tft.setTextColor(TFT_YELLOW);
263    tft.drawString("GENERATOR STATUS", 250, 40);
264    
265    tft.setTextColor(TFT_WHITE);
266    tft.drawString("Output:", 250, 60);
267    tft.drawString(String(generator.generatorOutput, 0) + " MW", 330, 60);
268    
269    tft.drawString("Frequency:", 250, 80);
270    tft.drawString(String(generator.frequency, 2) + " Hz", 330, 80);
271    
272    tft.drawString("Voltage:", 250, 100);
273    tft.drawString(String(generator.voltage, 0) + " V", 330, 100);
274    
275    // Safety status
276    uint16_t safetyColor = safety.scrammed ? TFT_RED : TFT_GREEN;
277    tft.setTextColor(safetyColor);
278    tft.drawString("SAFETY SYSTEMS", 10, 140);
279    
280    tft.setTextColor(TFT_WHITE);
281    String scramStatus = safety.scrammed ? "SCRAMMED" : "NORMAL";
282    tft.drawString("Status: " + scramStatus, 10, 160);
283    
284    tft.drawString("Radiation:", 10, 180);
285    tft.drawString(String(safety.radiationLevel, 2) + " mSv/h", 120, 180);
286    
287    // Draw reactor diagram
288    drawReactorDiagram();
289  }
290  
291  void drawEmergencyDisplay() {
292    tft.fillScreen(TFT_RED);
293    
294    tft.setTextColor(TFT_WHITE);
295    tft.setTextSize(3);
296    tft.drawString("EMERGENCY", 100, 50);
297    tft.drawString("SHUTDOWN", 100, 100);
298    
299    tft.setTextSize(2);
300    tft.drawString("REACTOR SCRAMMED", 50, 150);
301    tft.drawString("FOLLOW EMERGENCY", 50, 180);
302    tft.drawString("PROCEDURES", 50, 210);
303    
304    // Flash display
305    for (int i = 0; i < 10; i++) {
306      delay(200);
307      tft.invertDisplay(i % 2);
308    }
309  }
310  
311  // 🆕 Digital twin reactor simulation
312  void updateReactorPhysics() {
313    // Simplified reactor kinetics
314    float reactivity = calculateReactivity();
315    
316    // Neutron flux dynamics
317    reactor.neutronFlux *= (1.0 + reactivity * 0.001);
318    
319    // Heat generation from fission
320    float thermalPower = reactor.neutronFlux * CONVERSION_FACTOR;
321    
322    // Core temperature dynamics
323    float heatRemoval = reactor.coolantFlow * COOLANT_HEAT_CAPACITY * 
324                       (reactor.coreTemperature - COOLANT_INLET_TEMP);
325    
326    float tempChange = (thermalPower - heatRemoval) / CORE_THERMAL_MASS;
327    reactor.coreTemperature += tempChange * 0.01; // Time step
328    
329    // Steam generation
330    reactor.steamPressure = calculateSteamPressure(thermalPower);
331    
332    // Generator dynamics
333    generator.turbineSpeed = calculateTurbineSpeed(reactor.steamPressure);
334    generator.generatorOutput = calculateElectricalOutput(generator.turbineSpeed);
335    generator.frequency = generator.turbineSpeed / 60.0; // Convert RPM to Hz
336  }
337};
338
339ПЕРВАЯ ЭНЕРГЕТИЧЕСКАЯ ЗАДАЧА:
340✓ Complete power plant simulation
341✓ Multi-parameter cascade control
342✓ Emergency shutdown systems
343✓ Real-time SCADA displays
344✓ Safety system monitoring
345✓ Digital twin reactor physics
346✓ Regulatory compliance logging