Programmable Logic Controller Technology Research Articles

Fruit Sorting by Pizzo-electric Sensor and PLC Controlling

Abstract: The fruit sorting process traditionally relies on visual inspection, primarily considering size as a key quality parameter. However, industries engaged in large-scale fruit trading have turned to image processing technology for sorting, despite its high cost and impracticality for small traders. This paper proposes an alternative sorting system that offers an economical solution suitable for automated fruit sorting at various scales. Aim: The aim of this study is to develop an economical automated fruit sorting system capable of classifying fruits based on their weight, thereby eliminating the need for manual labor and improving sorting accuracy and efficiency. Place and Duration of Study: Department of Electrical Engineering Finolex Academy of Management and Technology, Ratnagiri, Maharashtra, between July 2023 to April 2024. Study Design: This study employs a practical approach to design an automated fruit sorting system that utilizes Programmable Logic Controller (PLC) technology in conjunction with load cells. The system is designed to classify fruits based on their weight as they move along a conveyor belt, thereby automating the sorting process. Methodology: The proposed sorting system integrates PLC technology and load cells to accurately measure and classify fruits based on their weight. By eliminating the need for manual intervention, the system enhances sorting efficiency and accuracy. The system is designed to be cost-effective and suitable for implementation by small traders and farmers. Results: The developed sorting system demonstrates precise, reliable, and consistent sorting outcomes based on fruit weight. By automating the sorting process, the system achieves improved efficiency and productivity compared to traditional manual sorting methods. Moreover, the cost-effectiveness of the system makes it accessible to small traders and farmers seeking to enhance their sorting practices. Conclusion: The proposed sorting system offers an economical and efficient solution for automated fruit sorting, particularly for small traders and farmers. By leveraging PLC technology and load cells, the system provides reliable alternative to costly image processing-based methods. The automation of the sorting process eliminates the risk of errors and inconsistencies associated with manual sorting, while ensuring accurate and quantitative classification based on fruit weight. This sorting system presents a practical approach to improving fruit trading operations, enhancing efficiency, and productivity.

Goosewolf: An Embedded Intrusion Detection System for Advanced Programmable Logic Controllers

Critical infrastructures are making increasing use of digital technology for process control. While there are benefits, such as increased efficiency and new functionality, digitalization also introduces the risk of cyber-attacks to systems that support critical functions. A valuable target in these Industrial Control Systems (ICSs) are the Programmable Logic Controllers (PLCs) controlling the machinery that manages a physical process. PLCs have proven to be vulnerable to a range of cyber-attacks in the past; however, newer technologies such as embedded servers and virtualization have the potential to improve this situation and be used to monitor a PLC’s function. In this article, the implementation of a Host-based Intrusion Detection System (HIDS) for a modern PLC is described. This method uniquely makes use of native technologies on the PLC to monitor a dynamic simulated process in real time. Both the PLC’s integrity (checksum, file size, etc.) and the process control are monitored to determine whether the PLC has been compromised in a cyber-attack. The proposed solution detects a range of attacks, even when the PLC’s control logic is compromised and—unlike previous PLC HIDS methods—requires no modification of the underlying PLC technology.

Realization of optimization design of electromechanical integration PLC program system based on 3D model

Abstract A three-dimensional simulation model of the electromechanical control system was built using the fuzzy control proportional–integral–derivative (PID) adjustment algorithm after an automatic electromechanical control system based on programmable logic controller (PLC) technology was optimized to achieve the practical use of electromechanical program control. First, the hardware of the electromechanical control system is discussed and designed. The findings demonstrate the viability of the mechanical and electrical integration PLC program optimization solution based on three-dimensional (3D) model. The system has a higher control and management efficiency, which is 30% greater than that of the conventional system. The mechatronic manufacturing system’s continuous operation efficiency enhancement can significantly lower the investment costs and boost the financial gains of industrial organizations. Traditional systems have a control and management efficiency of around 30%, but automatic electromechanical control systems based on PLC technology and created using 3D models have a control and management efficiency between 60 and 70%.

Design of New Test System for Proton Exchange Membrane Fuel Cell

A comprehensive test system for proton exchange membrane fuel cells (PEMFCs) is designed and developed for monitoring and controlling the inlet and outlet parameters and safety issues of fuel cells. The data acquisition and output instruction rely on the connection between PLC (programmable logic controller) and OPC (object linking and embedding for process control). Based on Siemens S7-200 series PLC and PID (proportion integration differentiation) technology, the margin of error in relative humidity of inlet air is controlled at less than 0.7%. Furthermore, a hydrogen recycling system and an alarm module are introduced, considering the hydrogen or nitrogen solenoid valve power failure, cooling fan power failure, temperature anomaly, and hydrogen leakage. This developed test system is evaluated by the experimental investigation of PEMFC performance. The results show that the test system has very good test and control performances. At a cell temperature of 40 °C, enhanced performance in the polarization tests is depicted at a high humidification temperature of 60 °C.

-种新型旋耕机调控参数的PLC系统设计研究

The purpose of this paper is to design a rotary tiller control system based on programmable controller technology, and verify the application of this control system. In this paper, the traction and depth control of rotary tiller are transformed into the control of piston rod displacement of hydraulic cylinder, and the intelligent fuzzy control of axial extension displacement of rotary tiller and output torque of piston rod is realized. According to the characteristics of the mathematical model, the objective function is determined and the motion parameters are optimized by the steepest descent method, which provides a reliable calculation model for the optimization design of the overall parameters of the rotary tiller. The rotary tiller control system based on PLC (Programmable Logic Controller) can realize the effective control of rotary tillage depth and speed, and the error of rotary tillage depth can be guaranteed within 4.5%. When the soil resistance of the rotary tiller suddenly increases, the fuzzy control of the comprehensive tillage depth value of the stressed position can effectively improve the rotational speed stability of the hydraulic motor for tillage depth control. PLC technology puts the digital control of rotary tiller on a higher technical platform, thus reducing the labour required for agricultural planting, providing a good growth environment for crops and realizing the intelligence of rotary tiller.

Heating Analysis and Temperature Control of Spiral Sand Core Box for Water-Cooled Housing

Based on the shape characteristics of spiral sand cores used in low-pressure casting processes of aluminum alloy housings for electric vehicles, and instead of using two half-circle sand cores and then re-assembling the cores into a full-circle one, we designed and developed a spiral core box structure for forming an integral core. This improved the production efficiency and dimensional accuracy of the sand core. According to the characteristics of the forming process based on coated sand, we performed thermal analysis on the heating process of the core box. We used programmable logic controller technology to accurately control the process parameters, such as the core temperature, to ensure that the sand core was balanced, heated, and cured in a suitable temperature range and for an adequate amount of time to improve the strength and quality of the formed sand core.

AUTOMATION OF A STEEL WALL FRAMING ASSEMBLY

Modular construction has become increasingly popular in North America in recent years. In this emerging paradigm of building construction, building components are manufactured off site and then transported to the construction site for assembly. In Canada, automated modular steel structure fabrication is in high demand. Offsite manufacturing of steel wall frames for residential and commercial buildings provides timesaving and improvement of working conditions and morale that translates to improved productivity and safety performance. This paper demonstrates the feasibility of efficiently fabricating steel wall frames for offsite modular construction using automated assembly controlled by a Programmable Logic Controller (PLC) and connected in a cost-effective and efficient electrical installation and centralized communication by Fieldbus technology. In particular, this paper describes the control strategy used to automate a steel wall framing assembly that incorporates a PLC and Fieldbus technology.

PLC Trainer Kit Simulator: An Improvement for Automation Study in Polimas

Programmable logic controller (PLC) is a basic and essential element in the engineering of industrial automation. Therefore, basic knowledge of the early stages of PLC plays an important role, especially for mechatronics and manufacturing engineering students. However, due to limited equipment available, high cost equipment, high trainer student ratios, and low reliability of existing equipment, many educational institutions do cannot provide the sufficient resources necessary to help students to become proficient with PLC technology. To alleviate these main problems, the PLC Trainer Kit Simulator is to be developed and used in the Automation Lab at Polytechnic of Sultan Abdul Halim Mu’adzam Shah (POLIMAS). The PLC Trainer Kit Simulator will be used to help student on PLC applications for basic course in JF506 Manufacturing Engineering Laboratory. This study is a descriptive study with a quantitative approach. Evaluation will be determined based on pre-test and post-test. This paper reviews the necessity of the simulation kit prior to its implementation. It is expected that, the teaching and learning processes could become more effective thus contribute to positive impacts on students’ interest in learning PLC.

A Remote Irrigation Monitoring and Control System for continuous move systems. Part A: description and development

Continuous move irrigation systems have been modified since the 1990s to support variable rate irrigation. Most of these systems used PLC (Programmable Logic Controllers) technology that performed well for on-site control but were very expensive to add remote, real-time monitoring and control aspects that have been made possible by wireless sensor networks and the Internet. A new approach to the monitoring and control of continuous move irrigation systems is described. This system uses a Single Board Computer (SBC) using the Linux operating system to control solenoids connected to individual or groups of nozzles based on prescribed application maps. The main control box houses the SBC connected to a sensor network radio, a GPS (Global Positioning System) unit, and an Ethernet radio creating a wireless connection to a remote server. A C-software control program resides on the SBC to control the on/off time for each nozzle group using a “time on” application map developed remotely. The SBC also interfaces with the sensor network radio to record measurements from sensors on the irrigation system and in the field that monitor performance and soil and crop conditions. The SBC automatically populates a remote database on the server in real time and provides software applications to monitor and control the irrigation system through the Internet.

Automated synthesis of Ladder automation circuits based on state-diagrams

One area where discrete event systems are currently used is the design of control systems based on programmable logic controllers (PLCs). As the PLC technology is evolving into a family of control functions of many types at many different levels of complexity, there is an increasing need for software tools providing the systematic development of real industrial applications including modeling and control of discrete event systems. This paper describes the use of a state-diagram method in the computer aided logical synthesis and design of automation circuits. It also presents the corresponding software package developed for control logic creation. The developed software generates control logic in the form of Ladder electric circuits since they present descriptive simplicity and are widely known in the PLCs' world. The developed software package is also suitable for both industrial practice and teaching purposes.

An adaptive pattern based nonlinear PID controller

This paper presents a nonlinear proportional-integral-derivative (PID) controller, combining a pattern based adaptive algorithm to cope with the problem of tuning the controller, and an associative memory to store the parameters, according to different operating conditions. The simplicity of the algorithm enables its implementation in current programmable logic controller technology. Several real-time experiments, carried out in a pressurized tank, illustrate the performance of the proposed controller.