S7-300 PLC Research Articles

Design and Development of a Pipeline Maintenance System for Pipe Surge and Water Hammer Equipment Based on Siemens S7-1200 PLC

Fluids play a crucial role in the lives of living beings, as they are substances that can flow. In a piping system, a common issue is water pressure fluctuation caused by sudden closures of water flow (Idul, 2021). Pipe surge and water hammer equipment are utilized to demonstrate the transient pressure effect resulting from abrupt changes in flow velocity within pipes (David, 1981). Water hammer can lead to pressure surges throughout the piping system, potentially causing failures that result in leaks in pipes, valves, pipe joints, and even pumps if the pressure exceeds the pipe's capacity (Prasetya, 2016). The likelihood of pipe ruptures or leaks at joints increases significantly. Additionally, equipment movement, slope, and precision of pipe installation can also contribute to leaks during water hammer events. This research aims to develop a pipe leakage monitoring system to address the impact of water hammer. The system will be installed in areas deemed susceptible to this phenomenon, along with a periodic maintenance indicator system to minimize the impact of pipe leaks. The research will also investigate the potential risks associated with varying fluid flow rates in the piping system. The monitoring, indicator, and sensor systems will be integrated into a PLC and HMI system for data processing.

Automatic Control of Bottle Contents and Separation of Empty Bottles In The Packaging Process Using Programmable Logic Controller Siemens S7-1200

Filling liquid into bottles with the same volume is an important part of product packaging. All packaged bottles must be filled per a product's provisions. A device is needed to control the contents of the bottles from a certain distance or from outside the bottles by moving on the conveyor track. So that the bottles can be automatically filling the same volume continues to the packaging process. To be able to control the contents of the bottle automatically and properly may need a tool and a control program. This research was carried out to be able to control the contents of transparent bottles, using a Siemens S7-1200 PLC, so that a system for controlling bottle contents quickly and precisely, which helps the production process run smoothly. The main components used in this research were the Siemens S7-1200 Programmable Logic Controller, Omron E3S-DB sensor, and pneumatic cylinder. The result showed the Control Module Program 1 successfully detected empty bottles and rejected them properly. Control module program 2 successfully moves the pneumatic cylinder to move the cylinder continuously until the stop button was pressed. The module 3 programs succeeded in moving the cylinder, which was limited to only 10 repeated movements until it stopped.

Implementation of Siemens S7-1200 PID Control on Festo Labvolt 3531 Plant Level Controller with Topkapi SCADA Using Modbus Communication Protocol

Plant Festo LabVolt 3531 is a DCS, SCADA and process control system trainer based on the Allen Bradley Controllogix 5572 PLC and Factorytalk View SCADA. This research aims to provide another controller solution that can be used on the Festo Labvolt 3531 plant besides the Allen Bradley Controllogix 5572 PLC and FactoryTalk View SCADA. So that students have alternatives and variations of other technologies in learning. In this research, the Siemens S7-1200 PLC was used as a replacement for the Allen Bradley Controllogix 5572 PLC and Topkapi SCADA as a replacement for FactoryTalk View SCADA. As validation of the test, PID control was used to regulate the water level in both tubes at the Festo Labvolt 3531 plant. The test results for several specified height levels showed that the Siemens S7-1200 PLC with PID control integrated into Topkapi SCADA using the mobus communication protocol was successfully implemented , where the resulting control response has an average steady-state error of less than 2% and the delay between the interface and the device on the plant is 0s.

Design of silicon box cleaning control system

Abstract The performance, efficiency, and stability of semiconductor materials are directly influenced by the quality of wafer cleaning, which is a crucial step in the production of integrated circuits and photovoltaic cells. For this reason, the final product’s quality greatly depends on the cleaning effect’s quality. Approximately half of the issues and malfunctions in large-scale integrated circuits are related to inadequate cleanliness of the silicon material, a result of the shortcomings of current wafer cleaning technology. Wafer cleaning process optimization is therefore crucial. The control system is designed based on the structural features and process flow of the chemical liquid spray wafer cassette cleaning machine. Siemens S7-1200 PLC is used as the control core of the control scheme, which is built by examining the control principles of each cleaning machine module and choosing and designing the hardware component of the control system. The wafer cleaning process is fully automated thanks to the design of the upper computer monitoring interface, which also includes a touch screen for online debugging. This significantly raises the production efficiency of the wafer-cleaning machine.

Development of DCS SCADA Module for Factory I/O Pick and Place XYZ Case Based on Siemens S7-1200 PLC and HMI Excel Link

The DCS SCADA course plays a significant role in the latest curriculum introduced at Politeknik ATI Makassar in 2022. However, the utilization of real plant instrumentation in industrial environments often proves costly. To overcome this cost barrier, this research develops a DCS SCADA module employing an industrial simulation application, namely the virtual plant Factory I/O, with a case study involving Pick and Place XYZ. This scenario entails the placement of boxes onto pallets using a three-axis robotic manipulator. The module utilizes the PLC Siemens S7-1200 as the control device and HMI Excel Link as the supervisory device. To detect the boxes and parts, two retroreflective sensors are employed, with three conveyors facilitating transportation and a robotic pick and place arm moving in three XYZ axes. Through integrated procedural testing, the system's performance evaluation demonstrates a 100% success rate (OK status).

Development of an experimental prototype of a manufacturing cell for process automation teaching

For the industrial sector, the filling, sealing and labeling system represents one of the most used processes with several applications, that involves the food and beverage industry until the chemical plants, among many others applications. The propouse of this work is to develop an academic prototype of a manufacturing cell for teaching the automation of industrial processes, in order to emulate the filling, sealing and labeling system. The goal is to design a learning methodology such that the acquired academic knowledge can be transported to a real industrial environment. To achieve this, the PLC S7-300, industrial proximity sensors, pneumatic cylinders of the Festo brand, as well as their respective solenoid valves, are used. The programming methodology is based on a functional graph controlled by stages and transitions (GRAFCET). In contrart with other project based on Arduino, this project employs standard signals and variable scaling.

Implementation of Forward Reverse Control and Monitoring on Three Phase Motor with Siemens S7-1200 PLC Based on LabView HMI and OPC

Implementasi kontrol motor tiga fasa dengan PLC Siemens S7-1200 dapat meningkatkan automasi pada industri. Pada lembaga pendidikan implementasi kontrol motor tiga fasa dengan PLC Siemens dalam modul forward reverse berbasis HMI LabView dan OPC sangat bermanfaat untuk meningkatkan pengetahuan dalam hal pengontrolan motor tiga fasa dengan PLC Siemens, serta mengintegrasikan antara PLC dan HMI LabView menggunakan protokol OPC. Tujuan penelitian ini adalah untuk membuat implementasi kontrol dan monitoring forward reverse pada motor tiga fasa dengan PLC Siemens S7-1200 berbasis HMI LabView dan OPC. Metode yang digunakan yaitu dengan melakukan desain melalui perancangan hardware dan sofware program untuk menjalankan sistem. Bila kedua proses selesai selanjutnya adalah melakukan pengujian dan pengukuran performance untuk mengetahui bahwa sistem telah berkerja dengan baik. Hasil pengujian koneksi kabel ethernet LAN antar modul PLC dengan PC tidak terdapat gagal koneksi antara PLC dan PC. PLC S7-1200 dengan IP Address 192.168.0.1 terkoneksi dengan PC dengan IP Address 192.168.0.10 dengan baik. Pengujian koneksi OPC server terhadap OPC client menunjukan kualitas data untuk tiap tag I/O dengan nilai good yang artinya komunikasi antara OPC server terhadap OPC client berhasil dengan baik. Pengujian pengendalian forward reverse motor induksi tiga fasa menunjukan bahwa putaran motor dapat dikendalikan sesuai dengan durasi waktu yang relah ditentukan tanpa kegagalan adanya kegagalan kendali. Sesuai dengan hasil seluruh pengujian maka disimpulkan sistem telah bekerja dengan baik.

PLC Controlled Substation Standby Power Form the Input System

This paper introduces the application of Siemens S7-200 PLC in standby power supply. PLC collects the normal running state signal of the primary equipment, which is used as the starting condition and locking condition of the standby power supply automatically input. It realizes different functions through programming to adapt to different running modes. Through PLC and king view in the laboratory, I verified the operation mode. It is also increases the obstacles, enriches the content of the standby self-casting system, and realizes the simulation of the joint adjustment with PLC. It is more obvious to watch the practical application of the stand auto-casting and the diversification of its functions.

Design of Parts Flexible Palletizing System

Part palletizing packaging is an important part of the logistics industry. Traditional manual palletizing can no longer meet today’s order volume. In order to improve the production efficiency of the palletizing process, a part flexible palletizing system was designed. The S7-1200 PLC was used as the controller, and the high-precision altimeter and length measurement photoelectric sensors were used to check the parts in real time, and the manipulator and the end actuator were used for grasping and stacking. The end actuator with multi-axis synchronous control technology is adopted to realize simultaneous grasping of multiple boxes of different specifications, which greatly improves the production efficiency and automation level of part palletizing. This flexible palletizing system and robotic gripping technology greatly improves the efficiency of gripping small objects and also allows for extended applications in the field of FAST disassembly and handling robots.

Research and design of capacitance plug-in assembly manipulator

In order to improve the efficiency of PCB (Printed Circuit Board) capacitor plug-in, reduce labor input and improve the accuracy of plug-in, a capacitor plug-in assembly manipulator was designed. The manipulator was mainly composed of X-axis module, Y-axis module and Z-axis module. The mechanical gripper of Z-axis module could adjust the distance between two mechanical grippers to meet the needs of different capacitance sizes. By adopting double z-axis design, the work efficiency of rectangular coordinate manipulator was improved. The addition of the X-ray axis improved the synchronization of the movement at both ends of the X and enhanced the rigidity of the structure. Siemens PLC S7-200 motion library function controlled manipulator grasp, positioning and plug-in. The efficiency of the plug-in unit was 2.5 s/board, and the manipulator could complete capacitor plug-in efficiently and accurately. The whole system has the advantages of high control accuracy, simple operation, stable operation and low noise, and has important practical significance for enterprises.

Automation of a drilling process via a wireless connection using the EMQX protocol

This paper proposes an alternative solution to automate a system called “Drill Station." Our automation proposal focuses on wireless communication between a GUI and a PLC S7-200 CPU 226 from the manufacturer Siemens to achieve remote control and monitoring of the process. In our proposal, the enriched production Grafcets diagrams and the security Grafcet diagrams are used with the transfer-type process forcing order. The process consists of three work areas: loading, drilling, testing, and evacuation of the part. We showed that with the use of Grafcets, it is possible to fully automate the process, considering the various running, operating, and safety modes, to improve the operation, achieve a better understanding of the drive, and facilitate the training of the operators.

Application of S7-300 PLC and Single Axis Motion Controller in Manipulator Control System

A set of flexible manufacturing production line training equipment in the college carries materials through a manipulator, which is controlled by S7-300 PLC. The FM353 module in the control system is damaged, and the device cannot be used. In order to repair the control system, this paper proposes a low cost solution. By choosing a single axis motion controller to replace the FM353 module function and S7-300 PLC with the control system/PLC control single axis motion controller can send high speed pulse output to the stepper driver, achieve the position and speed control of the stepper motor, and realize the control of a four degrees of freedom manipulator. Based on the design scheme, the control system of the manipulator is reformed. After modification, the system can run normally, which verifies the rationality and effectiveness of the design.

Industry Communication Based on TCP/IP Protocol

Abstract The design of control systems needs to ensure communication between multiple PLCs or external IoT devices. Furthermore, there are several ways of communication between them. This article dealt with the PLC communication based on TCP/IP protocol, and compared several communication options between two PLCs of the S7-300 and S7-1200 series connected using Profinet with a solution built in C# connected to the PLC via an OPC server. We used MODBUS TCP, TCON, and PUT/GET program blocks for comparison. We transmitted a digital Boolean data type and an analogue value of the integer data type via Profinet to read data from the S7-300 PLC and send data to the S7-1200. We compared the programming instructions standardly used as a client/server PLC programming with a Windows Forms application, and evaluated the advantages and disadvantages of this solution even when using external IoT devices. The solution was applied and successfully tested for communication between PLC S7-1200 and Nvidia Jetson Nano. We wrote program instructions for PLC in Siemens Tia Portal V15.

Design of laser welding workstation control system based on industrial robot

In order to realize the automation of laser welding industry, a control system of laser welding workstation based on PLC and industrial robot is designed. The control system takes ABB industrial robot and S7-300 PLC as the control core, adopts PROFIBUS bus communication, carries out the hardware selection, construction and program design of workstation control system. Production practice shows that the system workstation can automatically complete laser welding and other production tasks, the overall operation is good, the working speed is stable, the working speed is fast, and it has broad application prospects.

Design and Implementation of an Emergency Traffic Light Pre-emption System Using PLC Automation

As traffic on the urban Ghanaian road network increases, congestion and delays are becoming more severe. Traffic signals are the most common method by which right of way is dynamically allocated to conflicting movements. Ghanaian traffic light control system is mainly designed by using devices such as timers, relays etc. The critical timing operation is required to be carried out under the existence of heavy traffic situations. This does not give this conventional traffic light control system the flexibility to control throughput to favor emergency vehicles. This conventional practice leads to many problems and subsequent delay for a long time. With the help of a PLC, the requirement of fast automation and effective optimization of traffic light control even in times of emergency can be achieved.At intersections, capacity bottlenecks are formed in urban road networks because at these locations, capacity must be shared by competing traffic movements. For this reason, this thesis introduces an execution and implementation of T-junction emergency traffic control system using SEIMENS S7-200 PLC. Programming in PLC is written in ladder logic with the help of STEP7 MICROWIN software.

Design of Intelligent Feeding Control System Based on S7-1200 PLC

In order to satisfy the needs of pig breeding, an intelligent feeding control system based on S7 1200PLC is designed in this paper. The design scheme selects Siemens S7-1200 PLC as the main controller and MCGS TPC7062TI touch screen as the man-machine interface. The article has carried on the electrical design, including I/O address allocation, the main circuit design, the control circuit design and so on, and has written the PLC control program in the debugging mode and the operation mode, finally has designed the man-machine interface to realize the configuration of the system using MCGS. After the actual operation, the system runs stably, safely and reliably, has achieved the expected goal, and has a certain prospect of popularization and application.

A Dual Detection Method for Siemens Inverter Motor Modbus RTU Attack

Since the Modbus RTU wired communication protocol of Siemens variable frequency motors is unstable and lacks a protection mechanism, there is a risk of user information leakage. Aiming at the problems of insufficient flexibility of traditional defense methods and poor defense effects, The present work proposed a new dual detection method based on MODBUS RTU, which combines the dual monitoring mechanism of “Address Resolution Protocol (ARP) request detection” and “ARP response detection”. In order to improve detection efficiency, two real-time updated linear tables are introduced, which can effectively deal with the three ARP spoofing methods of updating the ARP buffer. Based on the analysis of the hidden dangers of the Modbus RTU wired communication protocol, a wired connection between the S7-1200 PLC and the variable frequency motor was established, and a real experimental platform was constructed to demonstrate the attack. The intensity of ARP attacks has gradually increased over time. Through comparative experiments with traditional defense methods, it is proved that the algorithm enhances the protocol mechanism in principle, and is more flexible and reliable than traditional methods.

Application of PLC-Based Stroke Control in Industrial Production

According to the requirements of large-stroke and high-precision positioning control in industrial production, the paper proposes a position closed-loop control system based on belt-type magnetic scale and PLC. The Siemens S7-200 PLC is used to capture the high-speed pulses of the magnetic scale in real time, realize the closed- loop automatic positioning control of the large-stroke position, and apply it to the plastic steel profile sawing centre control system, which solves the traditional stepper motor open loop at a lower cost The accuracy problems caused by the control greatly reduce the threshold of precise positioning control, which has strong practical application value.

Smart and sustainable technologies for recycling photovoltaic panels

“Every dark side has its bright side” like adopting Solar energy as an alternative to non-conventional Energy sources. Similarly, “Every bright side has its dark side” like improper PV end-of-life management might create million tons of waste by 2050, which is a burden to the environment. Creating sustainable goals is easier than implementation the same for an Individual to the industrial level. We are responsible for that we create, with proper implementation of end of life management, we can clear out the dark shades. We are the achievers when the technologies what we created make these Sustainable options so smart and viable. With this motivation, the study presents the policies under PV recycling and implemented the Smart control and Supervisory Control and Data Acquisition (SCADA) Screens of the Thin-film cd Te thermal treatment process. The PV recycling process consists of the mechanical, thermal, chemical treatment process. Irrespective of the process, each treatment requires an engineered system (hopper, conveyor, pumps, mixers, crushers) with proper control and communication set up. This study considered each stage as an individual unit consisting of a programmable logic controller (S7300 PLC) and a closed-loop controlled vector drive (G120). Software simulations performed in the TIA Portal for PLC- Drive communication and WINCC RT professional Software to implement SCADA screens by considering Virtual Inputs from the controller.

Development of a three-bladed horizontal axis wind turbine with active control by using a programmable logic controller

For the increasing the physical efficiency, useful life and avoid accidents in wind turbines, it is very useful to implement a pitch control on the blades that help as an aerodynamic brake and orientation in the base to follow the wind direction. The main goal of this paper was to develop a digital controller on the wind turbine blades that allows to keep the constant angular velocity and monitor the orientation of the wind. A computer-aided design software was developed for allowing the aerodynamic analysis by using Solid Works® software based on a flow simulation tool. On the other hand, a MATLAB model was created employing Simulink tool and the Simscape toolbox with typical data from a 2MW wind turbine whereas the electrical and mechanical dynamics and control feedback were calculated having as input parameters the wind direction and speed. Consequently, a prototype was designed in 3D which was implemented to make the different tests. For lab experimentation, a fuzzy control algorithm was developed in structured control language and then implemented using the S7-1200 PLC. The trials with programmable logic controller and the fuzzy algorithm were satisfactory, which could be a basis for the optimization of the performance of a three-bladed horizontal axis wind turbine.