PLC Programming Research Articles

Design Method for Building Automation Control Programs to Enable the Energetic Optimization of Industrial Supply Systems

Standard PLC programming language does not allow to use complex algorithms in building automation for the energetic optimization of industrial supply systems. This paper discusses how future building automation systems should be designed for this purpose. An adapted building automation control program is implemented on an industrial PC and evaluated in the real scale ETA Research Factory. The program ensures scalability and functional safety through object-oriented programming and implementation of a safety fallback system. The industrial PC is enabled to communicate via OPC UA. Finally we present a communication interface to connect the building automation to optimization programs using Python.

Reinforcement learning for energy reduction of conveying and handling systems

One important reason for wasting energy in manufacturing processes is that individual plant components often consume too much energy despite not being needed for production or nothing being produced at that moment. The implementation of standby-strategies in the PLC to switch each component into an optimal energetic state is applied seldom due to the great programming effort. This is because there are many functional dependencies between the plant components and therefor the PLC program must be adapted manually to the respective manufacturing process. The presented solution shows an intelligent system, which can adapt to plant-specific process requirements and derive decisions about the optimal energetic state of each component autonomously. In this paper, we provide an approach that uses reinforcement learning algorithms, which train on virtual plant models. The results are verified on a conveying and handling system in our learning factory.

Manufacturing Tasks Synchronization by Algebraic Synthesis

The development of control programs for PLCs is mainly carried out by direct implementation. We propose to switch to formal methods to obtain these control laws. For this we use a task-based structural analysis approach assisted by algebraic synthesis. We obtain a control law in ST language allowing to ensure the functional behaviour defined in the specifications. This makes the generation of PLC programs more reliable and efficient.

Virtual commissioning of automated manufacturing systems — Quality-handling station case study

The aim of the contribution is to create an event-controlled simulation of an automated production system using selected simulation software according to analyses and creation PLC control program compatible with human-machine control interface (HMI) visualization. The programmer can test the control program without the need for additional hardware on a virtual model of the machine. This method is called as a Virtual Commissioning method. The question is whether these new digital technologies are beneficial in the development process of new machines. The theoretical part of the contribution deals with the evaluation of the current state of knowledge in the field of virtual commissioning systems from the perspective of the Industry 4.0 concept and the use of principles taken from the technology of digital twins for analysing the possibilities of productive support of simulation, programming and visualization of control. For the Virtual Commissioning of the Quality-handling station from a flexible production system. It was chosen Tecnomatix Process simulating software for the developing of the Digital Twin of the station that is suitable for the connection of the logical behaviour inputs and outputs of the Digital Twin to the PLCSIM emulator. The main goal is to create a functional PLC program, so that in the second phase the process of virtual commissioning can be tested by the Software-the-Loop method. The preparation of the simulation model consists in a sample of the control station model of the production system, the process of creating kinematic bonds, behaviour model, creating control signals in the Tecnomatix Process Simulate program. Programming procedure and acquaintance with control means in the Simatic Manager program, selection of communication interface and creation of control visualization. In the final work, validation is performed and evaluation supports the objectives and the results confirmed the benefits of the Virtual Commissioning tool.

A GEMMA-GRAFCET Methodology to enable Digital Twin based on Real-Time Coupling

Abstract Digital Twin (DT) represents the next wave in modelling, simulation and optimization technology. A key enabling technology of the DT is the real-time coupling of the digital models with the controllers of the physical plant. To implement the DT through real-time coupling, common approaches and vocabularies are desirable for the automation software to facilitate the exchange of information between the PLCs and the digital models. However, the scarce adoption of guidelines and standards within the industrial practice of PLC programming complicates this context. To face this challenge, this paper proposes a methodology for PLC code to standardize the vocabulary and the management of the operational modes of industrial automation systems. The methodology consists of a GEMMA-GRAFCET representation and a Hierarchical Design Pattern. By implementing the approach to a case study, it is demonstrated that the methodology generates a standard interface for the communication between PLCs and digital models within a DT architecture.

Development of Interactive PLC Learning Media Based on Virtual Learning

This research aims to develop interactive PLC learning media based on virtual learning. The interactive PLC learning media uses a 3D simulator design to simulate the application of PLC in the industry, so it looks like real and makes students more interested in learning PLC This study uses experimental methods. The 3D simulation software is Factory I/O developed by Real Games. It enables us to build a conveyor virtual plant and to bring it into the classroom. The automatic controller used to control the virtual plant is the PLC Siemens S7-1200 with Tia Portal software. The PLC is connected to the computer server through an ethernet network via TCP/IP protocol. With the rapid development of current internet technology, PLC learning can be done in virtual learning. This PLC learning media can be run remotely through the internet with team viewer program so that PLC learning is not only done on campus but can be done anywhere. From the results of research that has been done, the user can create PLC programs remotely to control conveyor virtual plant on a computer server through an internet network without having to install the program on their computers.
 Keywords: PLC, interactive learning media, virtual learning, remote desktop

Speed Optimization Design of Stacker in Automatic Stereoscopic Warehouse Based on PLC

The S-type speed control is applied to the motion control of the stacker, and the S-type speed curve control is simulated by MATLAB to verify the feasibility of the optimal design. In practice, Siemens S7-300 is used for PLC programming to realize S-type speed curve control technology of stacker. The high efficiency, real-time and accuracy of the design realized the effective optimization of the speed of the stacker in the automatic stereoscopic warehouse.

PID control realization of drying system of the finishing line based on MCGS and PLC

In order to achieve the temperature control accuracy of the finishing line drying system, a PID control system based on MCGS and PLC is proposed. Using MCGS configuration software to edit the touch screen picture, Siemens PLC hardware configuration and programming, PID control algorithm to realize the conversion of analog and digital quantity, as well as the communication design between the upper computer (PC) and PLC and touch screen. Through the practical verification of assembly and debuggin, the control of the given value ± 5 °C of the drying system temperature of the finish line is realized.

Data-driven digital twin model for predicting grinding force

Digital twin gives a new approach for predictive and monitoring of manufacturing machines which can consider the influence of working condition on grinding wheel and application of prediction. In this article, we a develop methodology for grinding force prediction using digital twin approach, with the vertical double side grinding machine performing the required work while connecting the PLC program. The proposed approach integrates the information obtained from sensor data, physic models, and operational of system to establish the grinding machine model. Data driven modelling and quantification of the model form uncertainties associated with the resulting reduced order models. Simulation results show the proper connection between models and communication. The digital model was programmed to exactly match the operation of the physical system.

Design of AGV Automatic Navigation System Based on Baidu Static Map

In order to solve the problem of “the last kilometer” of heavy load logistics, an AGV automatic navigation system based on Baidu static map for path planning was developed. The upper computer program was designed to collect Baidu static map images as the base map of the electronic map. Path planning was conducted on the base map to generate trajectory data in byte form, which was sent to the data register area of PLC through Modbus RTU protocol. According to the data transmitted by the upper computer and sensor fusion technology, the PLC program realizes AGV positioning and automatic cruise. Replacing hardware with software to expand AGV functions is a low-cost and highly reliable alternative to current unmanned driving technology, which has certain innovation and practicability.

PLC programming to optimize water flow in secondary cooling zone

In the paper was made PLC programming, with which an adaptive system was implemented, was used the Simatic Manager Step 7 software, which is specific to the chosen PLC Simatic S7-300. Input data, computation relationships and correlations between the different sizes were retrieved and processed from the database of the two human operators, commanding the opening of the valve automatically. With this software, it was possible to eliminate the human factor in controlling parameters specific to the continuous casting secondary cooling zone.

The construction and implementation of the positive-negative pressure pulse control system for oil well plug removal

In oilfields in the high water cut stage and with multi-set well patterns, parallel exploiting, exploitation and underground conditions have become much more complex and problems like oil well mineralisation blockage and scaling are obvious, seriously impacting the oilfield water flooding efficiency. This paper designs a positive-negative pressure pulse control system for oil well plug removal based on the principle of positive-negative pulse, implements the main equipment selection, PLC and software programming, constructs a set of plug removal control system and successfully conducts the experiment of the positive-negative pressure pulse control system for oil well plug removal.

Design of control instrumentation system for setting the stripper position on DECY-13 Cyclotron

This research aims to design a stripper positioning system with input in the form of angle values and outputs are the x, y coordinates of each stripper. This system consists of hardware and software. The hardware consists of Fx2424 Super PLC, micro-step driver, stepper motor and dc power supply. The software includes Super PLC programming for stepper motor motion using features of the i-TRILOGI program and LabView program for the user interface. The test results show that stripper A with a length of 85 mm, an input angle of 60 degrees, obtained x; y coordinates are 435; 193mm. For stripper B with a length of 85 mm, an input angle of 240 degrees, obtained x; y coordinates are 400; 118 mm. For stripper C with a length of 85 mm, an input angle of 90 degrees, obtained x; y coordinates are 415; 75 mm. Overall test results show that the stripper position control system can be used to rotate and monitor the position of the stripper on the DEC-13 cyclotron.

Leveraging Horn clause solving for compositional verification of PLC software

Real-world PLC software is modular and composed of many different function blocks. Nevertheless, common approaches to PLC software verification do not leverage this but resort to inlining, or analyse instances of the same function block type independently. With the advent of constrained Horn clauses as the basis for automated program verification, many state-of-the-art verification procedures build upon them. We illustrate how this formalism allows for a uniform characterisation of PLC program semantics and safety goals, derived from reactive systems safety foundations. Furthermore, we give a natural extension of the resulting encoding which enables compositional reasoning about modular software. Due to the cyclic execution of PLCs, an engineer’s mental model of a single function block often exhibits state machine semantics – partitioning a block’s behaviour into different modes of operation. We illustrate how such a mode space, and similar high-level knowledge, can be integrated with our compositional characterisation. We investigate the impact of each technique on the model checking performance by characterising PLC software verification problems, both in a non-compositional and a compositional way that may incorporate mode transitions, and solving them with an SMT solver. Evaluation of our prototypical implementation on examples from the PLCopen Safety library shows the effectiveness of both the chosen formalism and using high-level summaries.

Research on AGV Transportation Vehicle Based on PLC

To improve the workshop production efficiency and degree of automation, a PLC based magnetic guided AGV (automated guided vehicle) transport trolley was designed. Taking PLC as the control core and the inductance as the path detection sensor, hardware and software are developed. The inductance signal is amplified by the operational amplifier LM358, and the design of the AGV transport vehicle is completed according to the control and process requirements of the AGV system. Use Solidworks modeling the AGV, and simulate the actual path of motion simulation. Use CodeSys of the PLC programming and Realization of motion control, and on the scene of the input and output panel monitoring and simulation test. The test results show that the system has characteristics of simple operation, stable operation, reliable operation, etc., and can meet the design requirements.

SYNTHESIS AND SIMULATION OF COMBINATION CIRCUITS THROUGH THE BASIC FUNCTIONS OF A PROGRAMMABLE LOGIC CONTROLER

The purpose of this article is to assist and enrich the laboratory and teaching practice in technical and vocational education with preliminary information, examples and solved tasks. The advantages of electronic modeling, which is designed to facilitate the ever-expanding electronization of the learning process, are explained. The synthesis of combinatoric summers is a task related to the methodology of practical study of digital and logic circuits through a programmable logic controller. The schematic examples are intended for students, students, teachers - specialists and lecturers in all technical specialties of vocational high schools, colleges and universities. Examples are presented illustrating the advantages of electronic modeling in research and design, the possible application of software products for electronics in the automation of engineering work and in non-electrical subjects such as electrical engineering, electrical equipment, mechatronics and others. The programmable logic controller"LOGO" from Siemens is easily portable, simplified enough to study the programming with it and, moreover, the virtual simulation of the circuits can be monitored at every stage of their operation. The teaching practice shows that the combination of LOGO's PLC programming environment and the study of the synthesis of combinational aggregators in this environment gives the fastest and highest results in the learning process, especially in non-electronic specialties. The method can also be successfully applied in design practice. The Siemens LOGO module is highly functional and easy to operate. It runs and runs on Windows, Linux, MacOSX. Programs can be tested, recorded, printed and archived independently of the controller. LOGO on a modular principle is easily portable, needs fewer accessories and can be expanded as needed. Other advantages include simple installation and easy programming. The LOGO controller remembers the program permanently, it is not erased when the power is turned off. The program remains stored until it is deleted with the corresponding command. The program part can be used for computer simulations of synthesized circuits and without the physical presence of the controller.The best result compared to other simulators is obtained with the CEEMS controller due to its main advantages of visualizing the work environment. The simplicity of installation and uninstall, the poor computer requirements, the ability to monitor and record all the simulation variants and the individual windows are discussed in this material.

Design and Implementation of SCADA System for Sugar Production Line

SCADA is the technology that allows the operator to gather data from one or more various facilities and to send control instructions to those facilities. This paper represents an adaptable and low cost SCADA system for a particular sugar manufacturing process, by using Programmable Logic Controls (Siemens s7-1200, 1214Dc/ Dc/ Rly). The system will control and monitor the laboratory production line chose from sugar industry. The project comprises of two sections the first one is the hardware section that has been designed, and built using components suitable for making it for laboratory purposes, and the second section was the software as the PLC programming, designing the HMI, creating alarms and trending system. The system will have two HMI screens according to the two operating states of system (Automatic and Manual), the operator can choose between them by a selector switch, this method helps the operators when fixing a failure and wanting to check it without operating all the process. The result has accomplished the goals of controlling, the parameters (temperature, flow, humidity) were monitored, failure was detected by an alarm.

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 .

Development of critical and creative thinking skills to increase competence of PLC programming for electrical engineering education students

PLC learning emphasizes on teaching and learning activities as well as developing the concepts and skills of the students process with various teaching methods that are in accordance with the study materials being taught. PLC learning demands an active role for students, because PLC is a scientific process based on logical thinking based on supporting facts. The low ability of students thinking is caused by PLC learning so far only tends to hone aspects of remembering and understanding. Basically students have critical thinking skills in learning such as questioning skills, hypothesis, classification, observation and interpretation. Problem-based learning model (PBL) is a learning model designed on problem solving process that faced scientifically so that students get important knowledge. Thus expected students are adept at solving problems, have their own learning models and have the skills to participate in the team. Teacher’s role as a trainer in problem-based learning is asking about thinking, monitoring learning, probbing (challenging students to think), keeping students engaged, organizing group dynamics, keeping the process going. This critical and creative thinking design aims to make students able to think critically and able to consider everything and be able to act on the decisions that have been considered and creative thinking that aims to learners are able to create ideas, or ideas and able to express the idea to solve a problem.

ANALISIS PENGARUH PENGEMBANGAN EKSTRAKULIKULER PRAMUKA TERHADAP KEDISIPLINAN SISWA DI SMP JAYA BAKTI JAKARTA

Efforts to develop national character through various learning activities and living habits, like religious, honest, disciplined, tolerant, hard work, peaceful and peaceful, and responsible, are undertaken in schools. The common practice is to teach the proper and wrong knowledge and feel if the value is good or not. This study is a quantitative description of qualitative research. This research kind is a correspondence. All the kids who participated in Jaya Bakti Junior High School Jakarta's Scouting Extrascientific activities comprised 24 pupils. Total sampling methods were used to collect a sample of 24 students. The research sample the methodology for collecting data is a survey. Pearson's product-moment correlation with the help of the PLC program was employed in data analysis methodology. The association between SMP Jaya Bakti Jakarta Scouting and Student Discipline with a significance (0.000 < 0.05) is positive and significant, this study demonstrates. Student discipline must be taken into account, as discipline is an initial key for the formation of students. Scouting discipline has a major influence on kids' molding.