S7-300 PLC Research Articles

English

English

Modeling and control of processes using the EMSO simulator and SIMATIC PLC as OPC interface

This work shows a procedure for modeling and control of level and flow processes. It uses the EMSO simulator to connect to a process by means of a SIMATIC S7-200 PLC as interface for the communication between the process instrumentation and the controller computing system. In order to supervise the variables, a SIMULINK model was connected to a laboratory process module through OPC communication. The model obtained was used in the design of controllers PID and PBSM, which were tested for step disturbances of the set point and an imposed set point trajectory.

Energy optimization of chillers by automating a Cooling System

This publication presents the work done on energy optimization of a group of chillers by automating the cooling system of blowing dies in an industry that is entrusted with the manufacture of plastic containers. In a first stage, the preliminary study on the energy analysis of the old system, where each chiller was in charge of cooling a specific group of blow moulding machines, without taking into account whether or not the blow moulding machines are working, is detailed; subsequent to this, the implementation of the automated cooling system was carried out, where all chillers were centralized in a machine room, automation was carried out with a Siemens S7-1200 PLC, switching the chillers on and off is based on the total thermal capacity required by the blow moulding machines. Finally, the energy analysis of the new cooling system was carried out, where the results were compared, and conclusions were drawn.

The control system of a 2kW@20K helium refrigerator

The automatic control of a helium refrigerator includes three aspects, that is, one-button start and stop control, safety protection control, and cooling capacity control. The 2kW@20K helium refrigerator’s control system uses the SIEMENS PLC S7-300 and its related programming and configuration software Step7 and the industrial monitoring software WinCC, to realize the dynamic control of its process, the real-time monitoring of its data, the safety interlock control, and the optimal control of its cooling capacity. At first, this paper describes the control architecture of the whole system in detail, including communication configuration and equipment introduction; and then introduces the sequence control strategy of the dynamic processes, including the start and stop control mode of the machine and the safety interlock control strategy of the machine; finally tells the precise control strategy of the machine’s cooling capacity. Eventually, the whole system achieves the target of one-button starting and stopping, automatic fault protection and stable running to the target cooling capacity, and help finished the cold helium pressurization test of aerospace products.

Design of Electronic Control System for Robot Cleaning Machine Based on Profibus-DP

Introduces the composition of industrial cleaning robot and the main control function based on the key signal between ABB robot and SIEMENS PLC S7-300, given the Profibus-DP communication programming of the robot and PLC, finally through the flow chart of industrial washing machine work cycle are described, the main program logic robot and motion control using ABB robot Rapid language. The research and development of the electronic control system can improve the degree of automation and production efficiency.

Miti-Simulation of Rolling Mill Machine Rolling Control System

Contraposing rolling machine’s efficient emulation, simple technological requirements, TIA Portal V13’s adoption SIMATIC WinCC flexible 2008, King View 6.03 and the force control etc. Several well-know configuration control interface design, this design is based on S7-300 PLC monitoring system of rolling mill, and it uses the PLC ladder diagram and configuration software communication to realize effective monitoring of rolling machine. Four configuration ways contain the user management interface, main interface and alarm interface. And the thickness of the steel plate could be controlled by manually roll distance

Experimental Study for a Micro Smart Grid to Meet the Energy Demand of a Household

Abstract In this research, a smart grid using renewable energy and energy storage unit is studied. The system's storage units applies novel supercapacitor technologies to work with traditional batteries. This study aims at satisfying the dynamic demand of a household and evaluate the performance of the smart grid. The system design and the control strategy design is expressed in the paper combined with the discussion of the system's operation theory. The control panel of the system use SIEMENS S7-200 PLC as the core chipset. Digital software is an auxiliary tool for monitoring the system's operation process. The controlling method is divided into two situations, with renewable energy source and without renewable energy source, and both the operation processes are presented in detail in the results discussion part. After analysing the operation details of the system, the controlling strategy is proven to be useful for the operation of the smart grid system. Future work for the system is combining the electrical smart grid with other energy source. This system is potentially to be developed as electrical part of a multi energy system.

PLC Control System Design for Egg Carton Unloader

An egg carton unloader is a device used to feed eggs loaded in cartons to the clean egg production line, and mainly includes three major components: loaded carton conveying mechanism, carton unloading mechanism, and egg feeding platform. In this paper, based on the mechanical and pneumatic systems designed for the device, the Siemens S7-1200 PLC is selected for control system development for the egg carton unloader, distribution design and program control flow chart design for I/O point, realization of automation control of the carton conveying mechanism, carton unloading mechanism and egg feeding platform. It features high reliability and high cost effectiveness.

Development of a measurement and control system for a 10 kW@20 K refrigerator based on Siemens PLC S7-300

A 10 kW@20 K refrigerator has been established by the Technical Institute of Physics and Chemistry, Chinese Academy of Sciences. A measurement and control system based on Siemens PLC S7-300 for this 10 kW@20 K refrigerator is developed. According to the detailed measurement requirements, proper sensors and transmitters are adopted. Siemens S7-300 PLC CPU315-2 PN/DP operates as a master station. Two sets of ET200M DP remote expand I/O, one power meter, two compressors and one vacuum gauge operate as slave stations. Profibus-DP field communication and Modbus communication are used between the master station and the slave stations in this control system. The upper computer HMI (Human Machine Interface) is compiled using Siemens configuration software WinCC V7.0. The upper computer communicates with PLC by means of industrial Ethernet. After commissioning, this refrigerator has been operating with a 10 kW of cooling power at 20 K for more than 72 hours.

Design and Implementation of PLC based Automatic Liquid Distillation System

Objectives: This paper proposes the design and implementation of an automatic liquid distillation system. The prototype is designed for mainly two functions: liquid distillation and tank level. Methods/Statistical Analysis: Prototype presented involves a process of separating the mixture (Methanol & water) and improves the production by managing the whole system automatically. The prototype designed gives a simple controlling & monitoring i.e. data acquisition of fluid level with the help of PLC S7200. Distillation is the main theme behind this research work that plays a vital role in many industries in dealing with boiling of liquids and liquid levels. Findings: At initial stage the implementation of a robust mechanical design is constructed to sustain excessive temperature; besides this a console panel is made to manually control and indicate the state of actuators. At final stage PLC interfacing and programming with electrical components (level detector circuit, thermocouple, pump, heater, solenoid valve etc.) is done for achieving the efficient and fast automatic process. In the last design was experimented with actual solution, it was found that 90% of the methanol was retrieved in condensation chamber; also temperature linearization was observed during the process. Applications: Error free mechanism and fast actuation makes this model significant for many industries which deal with huge boilers where engineers tackle with controlling & monitoring of liquids i.e. sugar mills, milk factories etc.

Implementation of PID autotuning procedure in PLC controller

In this paper, we present the automatic PID tuning procedure based on the Method of Moments and AMIGO tuning rules. The advantage of the Method of Moments is that the time constant and transport delay are estimated at the areas rather than on the individual points. This results in high resistance to the measurement noises. The sensitivity to measurement noises is a serious problem in other autotuning methods. The second advantage of this method is that it approximates plant during identification process to first order model with time delay. We combined the Method of Moments with the AMIGO tuning rules and implemented this combination as a stand-alone autotuning procedure in Siemens S7-1200 PLC controller. Next, we compared this method with two built-in PID autotuning procedures which were available in Siemens S7-1200 PLC controller. The procedure was tested for three types of plant models: with lag-dominated, balanced, and delay-dominated dynamics. We simulated the plants on a PC in Matlab R2013a. The connection between the PC and PLC was maintained through a National Instruments data acquisition board, NI PCI-6229. We conducted tests for step change in the set point, trajectory tracking, and load disturbances. To assess control quality, we used IAE index. We limited our research to PI algorithm. The results prove that proposed method was better than two built-in tuning methods provided by Siemens, oscillating between a few and even a dozen percent in most cases. The proposed method is universal and can be implemented in any PLC controller.

Design of Five Floors Elevator with SCADA System Based on S7200 PLC

Design of Five Floors Elevator with SCADA System Based on S7200 PLC

Implementation of the resonant vibratory feeders control algorithm on Simatic S7-1200 from MATLAB Simulink enviroment

Simulink is an important tool for modeling and simulation of process and control algorithms. It's expansion, PLC Coder, enables direct conversion of model subsystem into SCL, structured text code, which is then used by PLC IDE to create function blocks. This shortens developing time of algorithms for PLC controller. Also, this reduces possibility for a coding error. This paper describes Simulink PLC Coder and workflow for developing PID control algorithm for Siemens Simatic S7-1200 PLC. Control object used here is resonant vibratory feeder having electromagnetic drive.

Research on a Kind of PLC Based Fuzzy-PID Controller with Adjustable Factor

A kind of fuzzy-PID controller with adjustable factor is designed in this paper. Scale factor’s self-adjust will come true. Fuzzy control algorithm is finished in STEP7 software, and then downloaded in S7-300 PLC. WinCC software will be used to control the change-trend in real time. Data communication between S7-300 PLC and WinCC is achieved by MPI. The research shows that this fuzzy-PID controller has better robust capability and stability. It’s an effective method in controlling complex long time-varying delay systems. DOI: http://dx.doi.org/10.11591/telkomnika.v14i2.7661

Development of a Measurement and Control System for a 40l/h Helium Liquefier based on Siemens PLC S7-300

A 40l/h Helium Liquefier has been commissioned by the Technical Institute of Physics and Chemistry, Chinese Academy of Sciences. A measurement and control system based on Siemens PLC S7-300 for this Helium Liquefier is developed. Proper sensors are selected, for example, three types of transmitters are adopted respectively according to detailed temperature measurement requirements. Siemens S7-300 PLC CPU315-2PN/DP operates as a master station and three sets of ET200M DP remote expand I/O operate asslave stations. Profibus-DP field communication is used between the master station and the slave stations. The upper computer HMI(Human Machine Interface) is compiled using Siemens configuration software WinCC V7.0. The upper computer communicates with PLC by means of industrial Ethernet. A specific control logic for this Helium Liquefier is developed. The control of the suction and discharge pressures of the compressor and the control of the turbo-expanders loop are being discussed in this paper. Following the commissioning phase, the outlet temperature of the second stage turbine has reached 8.6K and the temperature before the throttle valve has reached 13.1K.

Application of Control System Based on S7-300 in the Producting of Pu\'er Tea

Aim to the workshop temperature and humidity fluctuation is bigger influence the stability of the pu-erh tea ripe tea fermentation quality and the production efficiency of the enterprise. Control system is developed based on S7-300, it can automatically adjust the workshop environment temperature and humidity. According to the conditions for pu 'er ripe tea production, the S7-300 PLC control system overall scheme is put forward. The system is divided into data acquisition and workshop control two parts. Data acquisition part can automatically collect workshop environment temperature and humidity, tea reactor temperature; Control part can automatically adjust according to the need of production workshop temperature and humidity and ventilation oxygen. The small artificial fermentation environment is created and it can improve the uniform of the pu-erh tea ripe tea fermentation efficiency, shorten the fermentation period. Finally by analyzing the collected data, the results of the analysis verify the control system is feasible. This study provides the technical support for the late pu'er ripe tea production quality control and automation.

Aplicación al control de procesos batch

En este documento se muestra el diseño e implementación de una plataforma de control para proceso Batch, dicha plataforma de control permite la elaboración y aplicación de secuencias programadas (recetas), así como la modificación y operación de los diferentes lazos de control a partir de las variables de proceso. Para esto, se integraron tres plantas en cascada de análisis de pH, térmica y nivel (flujo de la marca Amatrol que se encuentran en los Laboratorios de la Universidad Distrital, Facultad Tecnológica), la sensórica de campo (RTD, pH metro, medidor de caudal, ultrasonido, presión diferencial) empleada mide de manera continua las variables de la receta a través de los PLC S7-300, y procesa la variable medida en cada uno de los lazos de control. En caso de presentarse alguna variación en el proceso dada por la materia prima, cambios ambientales, etc., el controlador PID y sus variantes regulan el sistema de tal manera que se mantengan las cantidades requeridas de la mezcla, todo por medio del software TIA Portal 12 (Step 7 y WINCC). Asimismo, se puede verificar el histórico de las alarmas y un reporte que indica las recetas generadas con el PLC Siemens (SIMATIC CPU 313C) en el tablero de control, en el PC con visualización en 42¨, y en la interfaz hombre – máquina HMI. Esta investigación y su desarrollo fueron co-financiadas con los equipos existentes en los laboratorios de la Universidad Distrital, por un valor aproximado de $170.000.000 de pesos.

Design and Experimental Research of Automatic Control System of Material Transport Car Based on Siemens S7-300 PLC

Aiming to the problem of the traditional relay control system, such as high failure rate, low precision control, complex installation, slow system response, etc ,which caused by the extensive uses of intermediate relay, time relay, counter and other devices in the system, this paper provides a design of an automatic control system which integrates automatic positioning, automatic feeding, automatic cleaning equipment based on siemens S7-300 PLC instead of the traditional relay control system and carry out simulation analysis by PLCSIM software, compared with the material transport car model motion excellent to verify the rationality of the control system design.

The Design of Product Packaging Transmission Line Control System Based on Siemens PLC

This paper mainly introduces a kind of product packaging transmission line control system based on Siemens S7-200 PLC. It elaborated the main function principle of the system and the implementation of the control program; SIMATIC WinCC flexible 2008 of SIEMENS was used to monitor the status of the system, and display the real-time data and alarm report. At the same time the system can also be controlled by the screen.

Research and Design of the Temperature Control System of Crystal Annealing Furnace

Herein, a novel fuzzy PID temperature control system was proposed based on the technological process and control requirement of the crystal annealing furnace. Simultaneously, the electric control system was also designed with SIEMENS S7-300 PLC as the master controller. The results indicated that the system has the merit of rapid response time, low temperature fluctuation and all of the test items could meet the requirement of the actual utilization.