PLC-based Control System Research Articles

An Open PLC-Based Robot Control System for 3D Concrete Printing

Three-dimensional concrete printing technology is currently a very topical and developing subject. There is a large number of applications worldwide where this technology can be used. In connection with this technology, the development of custom industrial robotic systems and their control is essential. Conventional closed-loop control system platforms do not provide sufficiently flexible solutions. This paper presents a control system for a unique printing robot that, thanks to its openness and unified platform, will enable simple and fast analysis and testing of key aspects in terms of control and guidance of the printing robot for additive manufacturing applications in the construction industry. The aim of this paper is to introduce the concept of an open PLC-based control system and to demonstrate its usefulness in the task of designing and implementing model-based control. All steps, from the analysis of the printing robot itself and identification of inertial parameters to the actual design and implementation of the control, can be executed in a unified Matlab/Simulink environment using various add-ons and toolboxes thanks to the open control system platform. This solution brings significant savings in terms of programming and prototyping time. The open control system was used to control an experimental model of a printing robot, serving as a test bed for the final version of the printing robot, and the results obtained were evaluated.

Design and implementation of a novel dust collector controller for powder production industry

Industries those work with powder either in production or processing always left a portion of industrial dust in the air. By releasing this air directly in the surrounding environment of the industry pollution occurs. Therefore air filtration system is mandatory in these industries and usually bag filter dust collector controller is used. To control and maintain the proper functionality of the bag filtration system PLC based control system or a modular control board is used. In this paper, a novel dust collector controller is designed which can be installed by any user without having any programming knowledge. The main control keys of the control board are the pulse duration and pulse interval which drive the solenoid valves to release air pressure on the filter bags sequentially. Pulse duration can be controlled in the range of 0.01-0.9 seconds and pulse interval can be varied in the range of 1-99 seconds to control 10 rows of pulse jet simultaneously connected with the solenoid valve. The Number of rows can be adjusted and expanded if required. Moreover, noiseless switching provides silent operational functionalities and switching durability as well as the addition of surge controller ensures a complete protection from any sudden high electrical surge. The finally developed prototype was tested in different industries and provides maximum operational efficiency, which can effectively control online bag filter dust collector to separate micro dust particles from the polluted air.

A PLC based control system for load frequency control in an isolated small hydro power plant

A PLC based control system for load frequency control in an isolated small hydro power plant

A novel gas turbine simulator for testing hybrid solar-Brayton energy systems

A novel gas turbine simulator is developed to establish controllable boundaries for investigating the characteristics of key components in gas turbine based hybrid energy systems under different operating conditions. The gas turbine simulator consists of a compressed air system, an electrical heater, a mass flow controller, a proportional solenoid valve, a dual-flow choked nozzle, and a PLC-based control system. With the proposed control strategy, the fluid parameters, such as temperature, mass flow rate, and pressure, can be automatically regulated to simulate the boundary conditions of a gas turbine under various workloads. Experimental results for both cold and hot states have validated the capabilities of the gas turbine simulator to deliver convergent control results with fast response. The gas turbine simulator has demonstrated considerable performance in stabilizing system boundaries with the precision in terms of pressure control reaching ±0.004 bar for steady states, and ±0.018 bar to ±0.076 bar for transient states with mass flow and temperature perturbations. The gas turbine simulator can also accurately track linear and nonlinear trajectories during operating point migrations, and effectively limit deviations within ±0.037 bar.

Control system software design of tunnel automatic car washing Machine

This paper focuses on the control system of tunnel automatic car washing machine and puts forward a control scheme of automatic car washing system based on PLC control. This design uses domestic Hexin PLC as the core for control and man-machine interaction through touch screen, so as to control and monitor the work of the system. Each switch button, infrared sensor, ultrasonic sensor and limit switch are input to PLC as output signal, and then PLC controls the operation of each working part. This PLC based control system is more reliable, and easy to implement, in the actual use of simple operation, and easy to maintain, and have a good market prospects.

Design and development of the PLC based sensor and instrumentation system for self-propelled pruning residue mulcher prototype

The main idea of this paper is to present a programmable logic controller (PLC) based data acquisition, telemetry, and control system for self-propelled pruning residue mulcher prototype. The main power source of the mulcher prototype is the diesel engine. Hydraulic systems were used to transmit the motion received from the motor to the wheels, pick up and mulching unit, and steering systems. The operation and control of all systems were carried out using a PLC-based electromechanical system. The objective of this paper is to develop a PLC-based measuring and controlling system in order to control, collect, and monitor the sensor-based data such as: number of cycles of the fingers in the pick-up unit, the speed of the mulcher blades, machine forward speed, fuel consumption, and pump pressures. In the system, an embedded industrial computer and differential global positioning system (DGPS) were used to assist in real-time measuring, recording, controlling, and displaying all the sensor data during the field operation. The control of the machine is built using industry-standard off-the-shelf PLCs. The data acquisition software was written using VB.NET programming language. The PLC-based sensor and instrumentation system was tested and validated on different orchards. Test results show that the developed control and data acquisition system is well qualified with high control precision and high reaction speed. The developed machine is the first self-propelled agricultural mulcher machine developed in Turkey. And there is no other example in the world in terms of using PLC-based control and data acquisition system in self-propelled pruning residue mulchers.

Rancang-Bangun Prototipe Sistem Kontrol Berbasis Programmable Logic Controller untuk Pengoperasian Miniatur Penyortiran Material

A miniature sorting of material quality has been made, aided by a prototype of the controller system based on the Mitsubishi FX1N-24MR Programmable Logic Controller (PLC). A number of stages include the manufacture of the conveyor system unit, the electrical system, PLC programming, and performance measurement. The conveyor unit assembling was processed by installing the conveyor belt, dc motor, pneumatic cylinder, solenoid valve, and sensors. The electrical system is an integration of the Mitsubishi FX1N-24MR PLC, switched-mode power supply, miniature circuit breaker (MCB), dc voltage regulator circuit, relays, digital counters, pushbuttons, and selector switches arranged in a 20 x 30 x 15 cm panel box. Mitsubishi PLC system programming is based on algorithmic determination and ladder diagram arrangement assisted by GX Developer (GX Work). Performance measurement in the form of pulse readings is carried out by setting and manufacturing ladder counters and shift registers to count the number of pulses for each material and the accuracy of sorting when the material is detected simultaneously. The system performance is indicated by pulse reading accuracy and sorting timing accuracy. The reading of the pulse from the proximity switch affects the counter calculation to activate the pneumatic cylinder unit in sorting. Sorting for material-A takes 11 pulses, while for material-B, it takes 19 pulses. The synchronization measurement functions when an error occurs in the system in order to maintain the input received is the same as the output in the PLC-based control system.

The Design of the Control System of Fire Control and Smoke Extraction Robot Based on PLC

The purpose of this paper is to design a plc-based control system of fire control and smoke extraction robot, which can realize the purpose of water cannon, vehicle body movement and non-line-of-sight operation. This control system is mainly composed of PLC control system, video system, remote control system, motor drive system. PLC Through CANopen message transmission protocol, the function of distributed control system is realized. The main task is to receive the CAN command of remote control, so as to realize the command control of vehicle body action (multi-way valve), yuntai action and water cannon action. The design meets the design requirements, has good operability and reliability, in the industry has a certain promotion significance.

Design of PLC-based Control System for 18650 Lithium-ion Battery Dismantling Machine

The dismantling process of 18650 lithium-ion battery aims to separate the shell from its contents that contain lithium. The dismantling process is carried out using pneumatic components that automated by using a programmable logic controller (PLC). This research was conducted through 5 stages of the process, namely: machine designing and manufacturing, pneumatic system designing, PLC control designing, assembly, and testing. The design of pneumatic systems and their control is carried out to get the easiest and most effective working system.

Design and Development of Wireless Control System Architecture for ITER-India Gyrotron Test Facility

Background & Objective: Wireless networks are making its way for use in industrial control system applications. The installation of Wireless networks naturally provides a reduction in cable and its maintenance related costs, provides increased flexibility and mobility to enhance the performance of industrial control system. Method: This paper attempts to show the suitability of a wireless network in control system application of ECRH system at IIGTF. IEEE 802.11n network is implemented to interface field instruments with PLC based control system in an industry like environment. The two case studies with different control architecture are implemented with satisfactory test results. The first case demonstrates the use of a wireless network for monitoring and data acquisition of cooling water process parameters. The second case implements the control and monitoring of the DC power supply over the wireless network through a serial ASCII protocol. The performance of wireless communication alone in is evaluated using theoretical analysis, simulation and actual field measurement. Then overall performance of the case studies including field signals and PLC system is evaluated. Conclusion: The PLC application logic is developed for the implementation of logic functions to interface various field instruments and power supply. The DC power supply is simulated using Labview ™ for serial ASCII communication. The above said concept is proposed for the Local Control Unit being developed for ITER-India Test Gyrotron Facility.

Design of PLC Based Control System for Rotary Flexible Fixture with PID Compensator

Machining process consist of machine tool, cutting tool and work piece that must securely held by jig and fixture. A rotary flexible fixture prototype then developed, to locate work piece at desired angular position using rotary and tilt angular positioning components to complement machining processes such as CNC mill, EDM, machining center, etc. This research focused on designing PLC based control system with PID compensator for the prototype, this paper however deal with rotary component in particular. Preliminarily, all components assembled into closed-loop transfer function and calculated its frequency domain overall transfer function. Analysis of control system stability then followed, using such methods as Routh-Hurwitz, Nyquist and Root Locus. Next, the system’s time responses need to be evaluated, design targets are rise time less than 0.2 second, settling time not exceeding 0.4 second and zero steady state error with ±2% allowable error. If target are not satisfied, then use of PID compensator. Stability analysis results shows the system are stable according to Routh-Hurwitz, Root Locus, and Nyquist criteria. Time responses analysis results in rise time 0.267 second and settling time 0,476 second. While, the system yield zero steady state error. To meet design targets, PID compensator were employed, after tuning at proportional gain value 1.5, rotary component reached rise time 0,178 second, settling time 0,317 second, well within design target. These results are essential for PLC programming, assembly process and general consideration or recommendation for selecting components to gain a simple yet better perform control system .

Study on the Short-term Treatment Technology of Landfill Leachate

Domestic garbage is mainly treated by sanitary landfill.The main characteristics of landfill leachate produced in the sanitary landfill process are high concentration of COD and BOD, high ammonia nitrogen content, high levels of refractory organics, heavy metal ions, poor biodegradability, unstable water quality, difficult handling and so on. If the treatment is not carried out, the environment will be severely damaged. According to the needs of the project, this paper proposes a set of short-term landfill leachate treatment process, which involves ozone oxidation, internal electrolytic oxidation technology, coagulation precipitation, deep oxidation of the chain reaction, microwave field catalytic oxidation, adsorption and other treatment processes. Eliminating the biochemical process, the entire process flow is relatively short, and the processing efficiency is high. And the use of PLC-based control system to achieve automatic control of landfill leachate treatment. Since the leachate water quality has a wide range of variation, the PID control method based on BP neural network adaptive control strategy is adopted to achieve on-line adjustment of PID control parameters. The final effluent water quality can meet the emission standards.

Universal Signal Conditioning Technique for Fiber Bragg Grating Sensors in PLC and SCADA Applications

Optical fibre sensors, such as Fibre Bragg Gratings (FBGs), are growing in their utilisation, although very niche in their applications. To enable a more diverse range of end users, expensive application-specific optical fibre interrogation hardware needs to be made compatible with and, ideally, easily incorporated into existing instrumentation and measurement hardware. The Programmable Logic Controller (PLC) is an ideal example of hardware used for data acquisition in many industries. As such, a module that can be connected into an existing PLC slot to collect data from electrically-neutral, EMI-immune and versatile FBG sensors is of significant advantage to the growing optical fibre sensing market. In this work, we show that both digital and analogue signals can be collected from FBG sensors and integrated seamlessly into the PLC-based control system using a transmit-reflect detection system. This technique enables fibre optic sensors to be compatible with standard industrial automation controllers in a relatively low cost and plug and play manner.

The PLC-based Industrial Temperature Control System: Design and Implementation

Targeting at the problem of slow response and low accuracy of the automatic temperature control system for material processing and boiler heating, a new design method is proposed to work with the PLC-based temperature control system, where the box temperature control may be achieved through the fan and the heating plate. The hardware design and software design of the system are analyzed in detail. In this paper, a combination of the traditional PID control and the more popular fuzzy control is taken as the control program to achieve the overall design of the control algorithm. Followed by the simulation in the MATLAB software, the designed system is highlighted by its the characteristics of impressive stability, precision and robustness.

Simulation and validation of diagram ladder—petri nets

Automated systems based on programmable logic controllers (PLC) are still applied in discrete event systems (DES) for controlling and monitoring of industrial processes signals. PLC-based control systems are characterized for having physical input and output signals coming from and going to sensors and actuators, respectively, which they are in direct contact with the production or manufacturing process. The input subsystem to PLC consists of sensor-wiring-physical inputs module, and it can present two kinds of faults: short circuit or open circuit, in one or more signals of the process physical inputs, which it causes faults in the control and/or in the control algorithms behavior. Ladder diagram (LD) is one of the five programming languages supported by the International Electrotechnical Commission (IEC) through the IEC-61131-3 standard, and it remains being used at industry for control algorithm design of PLC-based systems. This paper proposes the simulation and validation of control algorithms developed in LD by using Petri Nets (PN) in order to deal with the possible fault options (short circuit and/or open circuit) in the physical inputs subsystem of a PLC-based control system. One control algorithms in LD have been analyzed in order to show the advantages of the proposed approach.

The Research of Wire Grinding Machine and Wire Stripping Machine Control System Based On PLC

This paper introduces PLC control technology and discusses its characteristics with relay control circuit, computer, SCM control technology then it talks about the PLC control system design methods. To use the method in reality, the paper introduces wire grinding machine and wire stripping machine. In the wire grinding machine, the module is single and easier, with principle of how it works, PLC obtains the status of sensors, data such as the diameter value to control the operation of the corresponding parts to form a closed loop between PLC control system, the motor and wire diameter grinding detectors to grind the wire into segments with different diameters. Finally, the paper completes the PLC-based control system design of stripping machine. The system requires nine different ways to meet the processing requirements, the papers designs multifunctional modules to realize the requirements. Both of the two PLC systems operates very well in reality.

Analysis and Design of PLC-based Control System for Automatic Beverage Filling Machine

Automatic filling system is the main equipment in the food machinery industry. With the development of beverage industry and increasing demand of the filling system. The relay control method in traditional Filling machine has low automation and integration level and cannot satisfy the rapid development of automatic production. PLC control method has advantages of simple programming, strong anti-interference and high working reliability, has gradually replace the relay control method. In this study, hardware and software for the automatic filling system based on PLC control is designed, especially the injection section servo control system which adopts the servo motor driver metering pump is carefully analyzed and the filling precision is highly improved.

PLC-Based Constant Pressure Water Supply Control System Design and Implementation

PLC-based constant pressure water supply control system may well improve the automation level of constant pressure water supply, ensure the water supply system pipe network pressure balance, has the advantages of fully automated control and good energy saving effect, plays an important role and has great significance in ensuring the residents and industrial water demand, improving water quality, and maximizing economic and social benefits .

스마트 LED 가로등을 위한 고속 전력선 통신 기반 자동제어 시스템

스마트 LED 가로등을 위한 고속 전력선 통신 기반 자동제어 시스템

Plc Based Control System Applied To Industrial Automated Fixture with Category 4 Safety

A fixture is a mechanical setup that holds a job so that it will aid the industrial processes carried out on it with ease, in terms of accessibility and reach. The processes may include manipulation of a job like rotation, clamping, declamping and positioning. Fixtures can be handled manually to hold a job. But such a manual process becomes tedious in complex processes. Hence PLC (Programmable Logic controller) can be used to automate the industrial fixture, to reduce the complexity of the process. In the following research we have developed a hardware simulator for a PLC based control system to simulate the automation of an industrial fixture and analyzed it for Category 4 safety.