Programmable Logic Controller Research Articles

Thermo-mechanical behaviours investigation of Nano-Sized Al2O3, TiO2, and Graphene Nanoplatelet Reinforced Epoxy Composites

Composite materials find extensive applications in various industries, thanks to their remarkable properties. These sectors include energy, maritime, motor sports, aviation, space and defense. The materials commonly used in these sectors are fiber reinforced plastic (FRP) composite materials. Epoxy materials are commonly used as matrix in the production of FRP materials. This study delves into the enhancement of epoxy-based nanocomposites by using graphene nanoplatelets (GNP-5nm), TiO2 (13nm), and Al2O3 (8nm) nanoparticles. These nanoparticles were added at varying mass ratios into a commercial epoxy to investigate their effects on some chemical, thermal and mechanical properties. Meticulous mixing methodologies were used to reduce clumping effects and ensure even distribution during the process. The curing process was carried out in a PLC (Programmable Logic Controller) controlled hot air oven under isothermal conditions under the influence of 100 °C for 30 minutes. Tensile strength, elongation at break, toughness, resilience modulus, elasticity modulus, hardness, FTIR analysis and thermal conductivity properties were characterized to assess the nanoparticle influence on the epoxy matrix. The results showed that there were remarkable improvements in mechanical properties with nanoparticle reinforcement. Especially, 1.25% Al2O3 inclusion exhibited a substantial increase of 140.32% in tensile strength and a 7% rise in shore D hardness compared to pure epoxy. This enhancement was attributed to enhanced O-H bonding between 'O' atoms in Al2O3 nanoparticles and epoxy polymer chains, enhancing matrix-filler interactions. Additionally, the effect of 1.0% TiO2 led to plasticity, displaying a 32% rise in elongation at break, signifying improved deformation energy absorption compared to neat epoxy. In thermal conductivity measurements, the highest thermal conductivity was observed in the sample with 1.25% GNP added and it increased by 123.5% compared to neat epoxy. In TiO2 and Al2O3 added samples, an increase of 69% and 47%, respectively, was observed at 1.25% additive rates compared to neat epoxy. According to the results, thanks to the nanoparticle reinforcement added into the epoxy matrix, composite structures can be given new and superior properties specific to the applications.

Enhancing Hydraulic System Performance through Intelligent Control and Energy Efficiency

In addressing the operational constraints of conventional hydraulic systems, significant advancements have been achieved through the development of an energy-efficient hydraulic system for press applications. This research identifies key inefficiencies, such as pressure losses and suboptimal flow rates, while proposing a novel architecture that utilizes advanced components, including energy-saving valves and variable displacement pumps. By automating critical processes, the integration of intelligent control algorithms - enabled by a programmable logic controller (PLC) - enhances fluid distribution and timing accuracy. The prototype notably employs gravity to propel fluid, significantly reducing energy consumption by minimizing the need for continuous pumping. Testing results confirm substantial energy savings, demonstrating the system’s potential to improve operational reliability and promote more environmentally sustainable industrial practices. Overall, this project exemplifies a holistic approach to hydraulic system design, addressing both performance enhancement and energy efficiency in a rapidly evolving industrial landscape.

PLC BASED RAILWAY ACCIDENT AVOIDANCE SYSTEM

The paper presents a comprehensive framework for enhancing railroad security by integrating technologies such as signalling arrangements, train closure security systems, automatic railroad gate control, intrusion detection, obstacle detection, tunnel control, and automatic blockade systems. These systems utilize sensors and advanced controls to detect and mitigate potential threats, enhancing security measures and reducing the risk of accidents. Programmable Logic Controllers (PLCs) in railroad systems manage several security protocols, including emergency brake, over-speed control, train door control, and fire detection. They also ensure passenger and train safety by monitoring temperature, pressure, and voltage parameters. In the event of any anomalies, the PLC triggers an alert and takes necessary actions to prevent accidents. Key Words: : Automatic Barricade System, Automatic Railway Gate Controlling, Crack Detection System, Obstacle Detection, PLC, Signalling Deployment System, Tunnel Power Saving System.

Automated Storage and Retrieval System for Warehouse

Manual picking and retrieval of items from storage locations can be time-consuming, leading to delays in order fulfillment. This can negatively impact customer satisfaction and the overall responsiveness of the supply chain. In addition, manual data entry and tracking systems are prone to human errors, resulting in discrepancies between recorded and actual inventory levels. This can lead to stockouts, overstocking, and difficulties in maintaining accurate inventory records. Therefore, a fully automated storage and retrieval system is proposed to tackle this problem. The overall system consists of infrared sensor as presence of item stored, LEDs indicator, warehouse model with compartments and stepper motors act as actuator to pick and place the item. This project aims to automate the storage and retrieval system with the assist of monitoring system for accurate tracking of inventory and space savings. The use of Programmable Logic Controller (PLC) in this project is a good representation of integrated automation technology in automated storage system design. Furthermore, monitoring system connected to a web-based system will be used to remotely monitor and operate the facility. Implementing an Automated Storage and Retrieval System (ASRS) in the warehouse can address these challenges by automating the storage, retrieval, and tracking of inventory.

Application of Photovoltaic Panels as Producers of Electrical Energy With IoT Technology Based on Programmable Logic Controller

The process of converting solar cell electrical energy is a form of utilizing environmentally friendly alternative energy sources (renewable energy). The conversion system is in the form of PV panels that are installed in a location exposed to sunlight and unobstructed. Monitoring is carried out when the sun shines from morning to evening. The location of the panel is in the vehicle parking lot of the engineering faculty, while monitoring is carried out in the Control Laboratory of the Tanjungpura University Engineering Faculty, which is 300 meters away. Factors that determine the quality of PV panels are the system and dimensions. This shows that fluctuations in current (I), voltage (V) and power (P) need to be controlled so that load distribution and reserves can prevent reduced energy generation. Observation and control using Long Range Area (LoRa) radio transmission media connections, Internet of Things (IoT) and Programmable Logical Control (PLC) in real-time. Observation and test results show that energy generation has experienced an increase in temperature which has an impact on reducing power. Meanwhile, the effect of the distance between the installed panels produces an average delay of 7 milliseconds (midday conditions). Meanwhile, the Signal to Noise Ratio (SNR) value for data transmission is 30 dBm at the device frequency of 868.125 MHz. Baud rate 2400-9600 bps with a speed of 0.3 bps – 62.5 Kbps. The application of this system is a research novelty because it can determine and control the generation of electrical energy at minimum, maximum and optimum conditions with a certain distance between the observer and the installed panel.

Synthesis of resilient fallback control system under cyber-attacks via supervisory control

Industrial control systems (ICS) require system design and operation under cyber-attacks. This study aims to design a fallback control system that can switch from normal control to fallback control and verify its superiority. The target system is a factory automation (FA) system consisting of a normal programmable logic controller (PLC) and a fallback PLC. In this system, we design a fallback logic that takes over control in the case of cyber-attacks. The design of this logic requires a system model that manages smooth state transitions between normal control and fallback control in an integrated manner under cyber-attacks. In response, we model a control program in the framework of discrete event systems (DESs) and apply supervisory control to derive a supervisor model that can manage the system in an integrated manner. To ensure the controllability of the FA system during cyber-attacks, we design a control specification that includes a detection function to enable rapid switching of the control state. As a result, we generate the fallback logic from the supervisor model with guaranteed controllability under cyber-attacks and implement it in a fallback PLC to verify the effectiveness of the proposed logic.

METHOD OF PROTOTYPING CONTROL UNITS BASED ON THE OPENPLC APPLICATION

The problem of designing control devices based on programmable logic controllers (PLCs) is their high cost and, as a rule, unavailability at the initial design stage. The purpose of the research is to reduce the time and cost of designing the system by creating prototypes of control units with the software implementation of control algorithms in the languages of the MEK 61131-3 standard and the execution of programs in the Arduino board. The research method consists in the decomposition of project models of operating and control automata of the control device and their implementation in the software environment of the OpenPLC application in the form of program organization components (POU) in Ladder Diagram, Function Block Diagram, Sequential Function Chart and Structured Text languages. The result of the study is a method of creating typical POU operating and control automata of the control system, which are executed in the Arduino board. An example of the application of the proposed methodology for the design of a prototype of the facility's temperature control system is given. The developed prototype was tested using a logical PLC and a physical prototype, which confirmed their functional compliance with the original and a reduction in the cost of the equipment by at least an order of magnitude.

PLC Based Transformer Protection from Over Voltage and Under Voltage

A PLC (Programmable Logic Controller) based transformer protection system is an electronic system designed to protect industrial transformers from various electrical faults and abnormalities. The system utilizes sensors to detect electrical parameters such as voltage, current, and temperature and uses a PLC to process the data and control the transformer's operation. The protection system can be programmed to detect faults such as overload, overvoltage, undervoltage, phase loss, phase reversal, and over-temperature conditions. Once a fault is detected, the PLC will automatically shut down the transformer to prevent further damage. The system provides reliable and accurate protection to the transformer, reducing the risk of costly downtime and repairs. Transformer protection from over and under voltages is a critical aspect of any transformer control system. Overvoltage can damage the transformer's insulation, bearings, and winding, while undervoltage can cause the transformer to stall or overheat. To protect the transformer from these conditions, various protection devices can be employed, including overload relays, circuit breakers, and voltage monitors. To protect against overvoltage, a voltage monitor can be installed, which will detect any voltage spikes or surges and trigger an alarm or shut down the transformer if the voltage exceeds a predetermined threshold. Similarly, an undervoltage relay can be used to protect the transformer from low voltage conditions. The undervoltage relay will monitor the voltage levels and shut down the transformer if the voltage drops below a certain level.. Key Words:-PLC (Programmable Logic Controller), SMPS, Voltage Controlled Relay, LED indicators, Transformer and Dimmer.

Programmable logic controlled lithium-ion battery management system using passive balancing method

Advancements in electric vehicle technologies and the widespread adoption of electric vehicles have brought energy storage systems to the forefront. However, efficient and secure utilization of energy storage systems requires Battery Management Systems (BMS).BMSs are typically designed with power electronics, electronic cards, integrated circuits, and auxiliary hardware components. Nevertheless, BMSs designed with such microcontrollers can only control a limited number of battery cells and constrained current values. Furthermore, employing a separate controller for each battery pack exacerbates these issues.In this study, a Programmable Logic Controller (PLC) - based BMS proposal for lithium-ion batteries has been presented, aiming to address the challenges in existing BMSs. The developed system is a passive balancing BMS comprised of controller PLC modules and auxiliary hardware. The Ladder Diagram (LD) programming language was employed for programming the PLC.In the conducted research, the voltage levels of the cells comprising the battery pack were monitored, and a passive balancing method was employed to equalize the cell voltages. Passive balancing has been applied to cells with voltage values of 2.70 V, 2.40 V, and 2.80 V using the minimum reference voltage cell balancing method to equalize the voltage levels. The output voltage has been balanced according to the maximum reference charge voltage set at 6 V through the maximum reference charge voltage balancing method. Additionally, a cooling circuit was integrated into the system to safeguard the Battery Management System (BMS) against thermal hazards. The developed PLC controller and algorithm can effectively control multiple battery packs with a single controller and operate at higher current values. This advantage allows the PLC-controlled BMS to have a broader control capacity. The presented test results indicate the successful performance of the PLC-based BMS.

Continuous and low-carbon production of biomass flash graphene

Flash Joule heating (FJH) is an emerging and profitable technology for converting inexhaustible biomass into flash graphene (FG). However, it is challenging to produce biomass FG continuously due to the lack of an integrated device. Furthermore, the high-carbon footprint induced by both excessive energy allocation for massive pyrolytic volatiles release and carbon black utilization in alternating current-FJH (AC-FJH) reaction exacerbates this challenge. Here, we create an integrated automatic system with energy requirement-oriented allocation to achieve continuous biomass FG production with a much lower carbon footprint. The programmable logic controller flexibly coordinated the FJH modular components to realize the turnover of biomass FG production. Furthermore, we propose pyrolysis-FJH nexus to achieve biomass FG production. Initially, we utilize pyrolysis to release biomass pyrolytic volatiles, and subsequently carry out the FJH reaction to focus on optimizing the FG structure. Importantly, biochar with appropriate resistance is self-sufficient to initiate the FJH reaction. Accordingly, the medium-temperature biochar-based FG production without carbon black utilization exhibited low carbon emission (1.9 g CO2-eq g−1 graphene), equivalent to a reduction of up to ~86.1% compared to biomass-based FG production. Undoubtedly, this integrated automatic system assisted by pyrolysis-FJH nexus can facilitate biomass FG into a broad spectrum of applications.

Domain‐specific translation tool from structured text to C source code with code readability enhancement in programmable logic controllers

AbstractThe Industrial Internet has emerged as a key technology in the field of industrial automation, revolutionizing traditional manufacturing processes and enabling advanced control systems by integrating machines, sensors, and software systems through network connectivity, allowing for real‐time data exchange, analysis, and decision‐making in industrial environments. Programmable Logic Controllers (PLCs) play a critical role in industrial automation systems, which are specialized digital computers designed to control various manufacturing processes and machinery. As a promising language, Structured Text (ST) is of paramount importance for industrial Internet, and it is essential to translate ST into C, which is widely used in various industries for implementing control systems. However, due to differences in syntax, data types, and programming paradigms between the two languages, the translation process is facing several challenges. In this paper, we present a domain‐specific translation tool that automates the process of converting ST code to C code. This tool incorporates advanced AI techniques, particularly leveraging the capabilities of NL‐PL LLMs, to facilitate accurate and efficient translation while generating comprehensive documentation to assist developers. Finally, the evaluation and case studies conducted validate the effectiveness of the tool, demonstrating its practical applicability and benefits in real‐world industrial settings.

A cloud-based infrastructure to deploy supervisory forecast models for predictive coagulant dosing control

Abstract Advanced optimal dosing control based on multiple online sensor data is operational in several treatment facilities in Norway. The benefits of the dosing control system in maintaining stable phosphate/solids removal and saving coagulant usage are documented in the literature. The dosing algorithm is currently implemented in a programmable logic controller (PLC) connected to the treatment plant's Supervisory Control and Data Acquisition System (SCADA) system. The PLC receives online sensor data from the plant's SCADA, calculates the optimal dosing values, and transmits optimal dosage values back to the SCADA system. The dosing algorithm is frequently updated to keep in sync with the process and equipment upgrades of the treatment plant and advances in control algorithm schemes. The upgrades include new regulatory feedback loops structural changes to the dose equation, and the addition of conditional setpoints. Each maintenance and upgrade routine entails operational downtime where the dosing algorithm is set to a sub-optimal flow-proportional dose. This paper presents a non-intrusive Internet of Things (IoT) infrastructure to implement a predictive/forecast component to an existing dosing control algorithm. The benefits of the new cloud-based system in improving nutrient removal, increasing operational flexibility, and reducing maintenance downtime are presented in this work.

SIHQR model with time delay for worm spread analysis in IIoT-enabled PLC network

Industrial Internet of Things (IIoT) is a product of deep integration between Internet of Things (IoT) and industrial control networks. As an important component of IIoT, Programmable Logic Controller (PLC) has become a springboard for many hackers to disrupt industrial networks by spreading viruses. It is known that worm can cause enormous loss. Therefore, revealing the rules of worm spread in PLC networks and exploring methods to inhibit worm spread are increasingly important. To this end, we propose a new worm spread model named SIHQR with time delay. Additionally, we establish a game model between susceptible and infected nodes in order to express the infection rate by several game parameters. Through analysis, we discuss the conditions for the emergence of three scenarios: disease-free equilibrium, endemic equilibrium and Hopf bifurcation. We study the stability at the equilibrium points and obtain an expression for a threshold value which determines whether the system exhibits endemic equilibrium or Hopf bifurcation. In the experimental section, we analyze the impact of initial values of node states and the magnitude of game parameters on worm spread in the three aforementioned scenarios. Finally, we propose a method to mitigate or even eliminate the Hopf bifurcation. The experimental results show that the proposed model has welldone performance.

Smart compound library based on machine learning, sensing technology, and programmable logic control

Smart compound library based on machine learning, sensing technology, and programmable logic control

BOTTLE FILLING MACHINE USING ALLEN BRADLEY PLC AND PROFACE HMI


 
 
 
 The objective for this scientific paper is to build and design a bottle filling machine by using Allen Bradley PLC with Pro-face HMI. In this research, PLC Programmable Logic Controller with HMI is used to introduce a cup filling machine.
 
 
 
 
 (PLC) based controller in automation industry. The primary concept for the study is to design and fabricate a filling system by utilizing PLC. The cup is moved via a belt conveyor by using DC Stepper Motor. When the cup reaches the sensor, it will stop and the sensor will give instructions to the valve that controls the flow of the water. The position of the bottle is identified through the use of laser sensors so that the pump can operate when it is needed. The PLC used in this framework could be the Micrologic 1400 which makes the framework more adaptable and simpler to operate. When the bottle is beneath the tank, the pump starts, filling it with water. This filling device is inexpensive and can be utilized in bottle filling systems for small businesses like tea shops, milk industries, and any other liquid manufactures.

The effect of Problem-based Learning (PBL) with mockup media in learning programmable logic controller

This research aims to (1) examine the differences in learning outcomes of programmable logic controllers between cadets who use problem-based learning strategies assisted by mockup media and problem-based learning strategies, (2) examine the differences in learning outcomes of programmable logic controllers between cadets who have high and low initial abilities, and (3) examine the interaction effect between learning strategies and initial abilities on learning outcomes of programmable logic controllers. This research uses a 2 x 2 factorial design with the object of research being the 3rd-semester airport electrical engineering study program students at Aviation Polytechnic Surabaya. The sample of this research includes 47 students of the TLB 11 AB class as the experimental group of problem-based learning strategy assisted by mockup media and 46 students of the TLB 12AB class as the control group of problem-based learning strategy. A learning outcomes test collected the data on learning outcomes in the form of multiple choice. Learning outcomes data were analyzed using two-tailed ANOVA (analysis of variance). The results showed that there is a significant difference in learning outcomes of the programmable logic controller between cadets who learn using problem-based learning assisted by mockup media and problem-based learning, there is a significant difference in learning outcomes of the programmable logic controller between cadets who have high and low initial abilities, there is no interaction effect between learning strategies and cadets' initial abilities on learning outcomes of the programmable logic controller. This research can contribute to improving students' understanding and skills in the field of PLC. Through practical experience and relevant projects, students can develop a deeper understanding of PLC concepts and improve their technical skills in designing, implementing, and solving problems related to PLC systems.

Construction of an innovative system for isolating and transporting people with infectious diseases

Objective: To propose the construction of an innovative system to isolate and transport people with infectious and contagious diseases with total safety to the physical integrity of both the health professionals involved in this activity and the patient himself. Material and Methods: The product was designed in TopSolid parametric design software, and its structure was manufactured with metallic plates, metalon, acrylic plates and a control system. Every automation system through pneumatics was made using pressure and flow controllers through the use of a PLC (programmable logic controller), thus allowing the insertion of medical protocols. The system allows air to exit the hermetic chamber (whether atmospheric and/or oxygen) sanitized, thus allowing a continuous flow with pressure and flow control without risk of infecting the external environment. Results: The results showed a great innovation that consisted of creating a proof of concept for use in hospitals, SAMUs, ambulances and aircraft, allowing safe isolation and transport for all involved. Conclusion: The innovative system for isolating and transporting people with infectious and contagious diseases proves to be effective for what was proposed, promoting technological innovations in the face of what already exists worldwide.

Model checking programs in process-oriented IEC 61131-3 Structured Text

The process-oriented programming is a paradigm based on the process concept where each process is a concurrent finite state machine inside. The paradigm is intended for PLC (programmable logic controllers) developers to write Industry 4.0-enabled software. The poST language is a promising process-oriented extension of the IEC 61131-3 Structured Text (ST) language designed to provide a conceptual consistency of the PLC source code with technological description of the process under control. This language combines the advantages of FSM-based programming with the standard syntax of the ST language. We propose transformational semantics of poST providing rules for translation of poST language statements to Promela — the input language of the SPIN model checker. Following these semantic rules, our Xtext-based translator outputs a Promela model for the poST program. Our contribution is the poST transformational semantics and the method for automatic generation of the Promela code from poST control programs. The resulting Promela program is ready to be verified with SPIN model checker against linear temporal logic requirements to the source poST program. In the paper we provide an overview of related work, as well as a brief description of the poST and Promela languages. Further, the Promela poST translation rules cover control flow statements, process creation and state management constructs, and timeout management. Then we define service processes for modeling the external environment and managing high-level LTL specifications. Then we present the main ideas of implementing the translator poST to Promela. We also illustrate our approach using the example of a system for managing electricity consumption and production, including renewable sources.

PLC BASED SCADA SYSTEM DESIGN FOR INSTANT MONITORING AND EARLY WARNING MECHANISM OF TOXIC GASES IN UNDERGROUND MINES

In this study, a real-time toxic gas measurement and early warning mechanism is proposed to prevent accidents that may occur in underground mining facilities. Temperature, oxygen (O2), hydrogen sulfide (H2S), methane (CH4), carbon monoxide (CO) and dust density sensor data are read via Arduino Mega analog inputs. All sensor data is transferred to the PLC-SCADA (Programmable Logic Controller - Supervisory Control and Data Acquisition) system via ethernet in real time. Thanks to the designed SCADA screen, sensor values can be monitored instantly. In addition, it can be checked whether the system is alarm and whether the ventilation system works. According to the underground coal mine regulations, work cannot be done in places where the mine air contains less than 19% oxygen, more than 2% methane, more than 50 ppm (0.005%) carbon monoxide and other hazardous gases. The highest permissible hydrogen sulfur ratio for 8 hours of operation is 20 ppm (0.002%). An early warning mechanism was created with the algorithm written taking these limits into consideration. The tests of the designed system were carried out in a laboratory environment and successful results were observed.

Design of PLC Electrical Control System

With the continuous expansion and development of factory enterprise scale, the development of automatic batching control system has also been accelerated. Batching mixing control system is a kind of raw materials mixed together according to a certain proportion, processing to produce a certain product process. This paper mainly designs and realizes the batching mixing control system of programmable logic controller (PLC). By precisely controlling the proportion of batching and the mixing time, the system is widely used in chemical, pharmaceutical, food and other fields to improve production efficiency and product quality. PLC system is a flexible, programmable electrical control equipment, because of its powerful, easy to use, high reliability characteristics, often used as the field data acquisition and equipment control. This paper mainly introduces the automatic control of liquid mixing system by Siemens PLC. The control object, hardware composition, software design and system function of the PLC based mixing, automatic mixing and automatic discharging system for two kinds of ingredients can simulate and display the whole working process of the liquid mixing system. The hardware of the system is mainly composed of S7-300 programmable controller, keys, stirring motor, frequency converter, solenoid valve and pump, etc. The programming software adopts Siemens programming software STEP7. The system transmits the collected field data to PLC through the weighing sensor, and after the PLC processes the field data logically, the corresponding control command is issued to complete the automatic control of the system. Finally, the system uses the communication interface to connect with the host computer to realize the communication between PLC and computer. The system has high degree of automation, strong flexibility, and can meet different production process requirements.