Comparison of MATLAB Simulink application with PLC application of real-time classical PID controllers in laboratory

Abstract

Process control is a common area of study for different engineering disciplines. Controllers working ‎with ‎the ‎proportional–integral–derivative (PID) method are generally used in process control. ‎Parameters like ‎level, ‎flow, position, pressure, and temperature are controlled in-process control. PID ‎algorithm can be ‎formed ‎with different microprocessor-based devices. Process control is ‎implemented by using analog input ‎and ‎outputs terminals of PLCs (Programmable logic controller) ‎which is recently the most commonly used ‎in ‎industries. Also, a real-time PID method can be ‎implemented by using a computer-based ‎MATLAB ‎ ‎program in the laboratory.‎ The liquid level and flow control in the laboratory has been done by using PID algorithms and ‎PLC ‎device ‎and MATLAB real-time interface by using an experimental set. Necessary connections ‎and ‎configurations have ‎been prepared to perform process control. (SIMATIC Manager Step7) is ‎used for ‎programming in PLC. ‎Besides, the MATLAB simulation program is configured to implement ‎real-time ‎control to be ‎compatible with the MF624 data acquisition card. Liquid level and fluid flow ‎control ‎experiments were ‎performed separately for the same PID algorithms formed on two different ‎devices, then ‎liquid level ‎detection and liquid flow control results have been collected and ‎investigated. Based on these ‎results, a total ‎of four experiments were compared with both devices ‎considering the ease and difficulties of ‎using PLC and ‎MATLAB.‎