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In the summer of 1999, we had used the bottom two layers of 3T to provide autonomous control for a single subsystem--a second-generation biological water processor--during a 450-day, 24-hour-a-day, 7-day-a week test. Then in January 2000, the Advanced Water Research Group received ALS funding for the year-long IWRS test, involving four advanced water-recovery subsystems (Bonasso 2001) (see Advanced Water Recovery System sidebar).BuildupUsing 3T allowed us to develop the control for the IWRS in a modular fashion in two ways. First, moving from bottom to top (figure 4), each layer has its own data structures, timing constraints, and development tools that allow for parallel development of the software. Thus, we were able to develop skills sets based on the evolving hardware specifications and simultaneously develop the sequencer procedures. Early on, as the water research team developed the design for each subsystem, one part of the 3T team wrote the sequencer procedures for each subsystem in the RAPS language (which, in turn, is written in Lisp) (1) using virtual skills, that is, Lisp skills connected to a Lisp simulation of the expected hardware. A virtual simulation of, say, the reverse-osmosis subsystem could then be shown on a laptop to the WRS engineers and the control design refined in an iterative process even before the actual hardware was available. The primary result of this process was a set of skill specifications for each subsystem (figure 5). But the inner workings and components can be a thing of beauty. Industry is demanding pumps and valves that are more reliable, robust, efficient and low-maintenance. A premium also is placed on sanitary design, and the makers of pumps and valves are being nudged to meet and often exceed standards such as 3A.Sanitary clean-in-place (CIP) components help further the goals of process automation, long a priority in food processing. Regulatory hurdles such as the Pasteurized Milk Ordinance (PMO) sometimes work against adoption of the technology that make CIP and automation possible, but sheer doggedness eventually prevails. Such is the case with mix-proof valves, which are starting to be applied in the transfer of large-particulate dairy products.
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