Programmable Logic Controller Device Research Articles

PLCBlox: Using blockchain-based audit trails to generate secure PLC commands

This research paper discusses security issues with current deployments of Programmable Logic Controllers (PLCs) and Supervisory Control and Data Acquisition Systems (SCADA) in the industry and proposes a solution that enables PLC devices to query a blockchain infrastructure for commands and setpoints. The blockchain assumes a dual role in this context: serving as an immutable audit trail database as well as a trusted source for critical commands and setpoints. In contrast to the conventional paradigm, this novel approach does not require write access at the PLC level, thus minimizes its attack surface and helping to protect against known and zero-day vulnerabilities often used in cyberwarfare, such as in the case of the notorious Stuxnet worm. Applications that enforce the logging of user operations for Good Manufacturing Practices (GMP) or compliance purposes use the blockchain network as an audit trail database for user actions. Any attempt to maliciously circumvent the logging operation would not affect the operation of a critical process. Additionally, a prototype implementation developed as part of this research finds that modern PLC devices are more than capable of interacting with private Ethereum blockchain nodes. The required libraries and user code consume a small percentage of available resources, while the duration of a complete request-response cycle measured around 22msec. The authors anticipate that PLCBlox can be used as a drop-in replacement for applications requiring higher security standards and logging enforcement, such as nuclear power plants or other critical infrastructure.

Design and Construction of a Controlled Temperature Food Product Dryer Based on a Programmable Logic Controller (PLC)

Drying food products using traditional methods relying on sunlight takes a relatively long time, especially with unpredictable weather conditions. Essentially, artificial drying using heat-based equipment provides several advantages, including: independence from weather conditions, adjustable drying capacity, controlled temperature, no need for extensive space, controlled drying conditions, and guaranteed and uniform drying quality. Therefore, this design aims to create a food drying apparatus with PLC control. PLC is used as the controller for this drying apparatus, allowing automatic drying of certain types of food. In this design, we connect a DC motor to rotate the drying cylinder with a PLC device by creating a ladder diagram and determining the inputs and outputs in the CX-Programmer application. The design utilizes three inputs and two outputs. It is important that the I/O is readable by the PLC so that the system operates according to the programmed instructions.

Enhancing Industrial Communication with Ethernet/Internet Protocol: A Study and Analysis of Real-Time Cooperative Robot Communication and Automation via Transmission Control Protocol/Internet Protocol.

This study explores the important task of validating data exchange between a control box, a Programmable Logic Controller (PLC), and a robot in an industrial setting. To achieve this, we adopt a unique approach utilizing both a virtual PLC simulator and an actual PLC device. We introduce an innovative industrial communication module to facilitate the efficient collection and storage of data among these interconnected entities. The main aim of this inquiry is to examine the implementation of Ethernet/IP (EIP), a relatively new addition to the industrial network scenery. It was designed using ODVA's Common Industrial Protocol (CIP™). The Costumed real-time data communication module was programmed in C++ for the Linux Debian platform and elegantly demonstrates the impressive versatility of EIP as a means for effective data transfer in an industrial environment. The study's findings provide valuable insights into Ethernet/IP's functionalities and capabilities in industrial networks, bringing attention to its possible applications in industrial robotics. By connecting theoretical knowledge and practical implementation, this research makes a significant contribution to the continued development of industrial communication systems, ultimately improving the efficiency and effectiveness of automation processes.

Water Bottle Filling Conveyor Design Based on Programmable Logic Controller

Control systems in industry today are increasingly sophisticated. Many modern factories use automatic equipment control systems, such as the water factory industry, which uses a programmable logic controller (PLC) based control system because its use will be more efficient and more practical. A programmable logic controller device can be used to control mineral water bottle-filling devices by utilizing the input-output (I/O) facilities contained in the device. The input devices on the PLC can be push buttons and infrared sensors, while the PLC output can be actuator components such as DC motors that function as conveyor drivers, solenoid valves and linear solenoids. The system for filling water into bottles is very important in the production of drinking water because it can optimize the final production process. So that when filling bottles, the volume of water corresponds to what is released and does not exceed the capacity of the bottle, automatic filling is needed. Filling water into bottles is done by storing the water in a water tank before the water is put into bottles. This water-filling system is very useful, both in terms of production effectiveness and saving production costs. By using this system, the production process is more effective, more efficient and easier to carry out because filling times are accurate and do not require much human labour, which ultimately results in savings in production costs.

Trainerprogrammable Logic Controller Dilengkapi Human Machine Interface (HMI) Guna Penguatan Praktek Otomasi Industri

The learning system in vocational education is more directed to practical learning. Therefore, learning media is needed that can make students learn interactively and independently. The research aims to create an industrial automation system learning media as a learning medium for industrial automation courses. The learning media is in the form of a programmable logic controller (PLC) trainer equipped with sensors and combined with a human machine interface (HMI). PLC trainer is made because PLC devices are widely used in industrial automation systems. The PLC component has not been equipped with a display, therefore in this study PLC is combined with HMI. HMI is an interface that connects machines with humans. The Outsel PLC was chosen because the price is very affordable and developed by domestic developers. Trainers are made in a compact form, and easy to carry anywhere. Several simulations were carried out to test the function of the trainer. The test results of the PLC trainer show that the PLC trainer is able to control the process according to the logic programmed, and the HMI is able to display the ongoing process, thereby increasing the interaction between machines and humans.

Improving the performance of industrial mixers that are used in agricultural technologies via chaotic systems and artificial intelligence techniques

In this study, it is aimed to show how important to apply chaotic systems and Fuzzy Logic artificial intelligence technique to increase the production performance of industrial mixers used in agriculture in terms of important criteria such as product quality, homogeneity, time, and energy saving by using. A PLC (Programmable Logic Controller) controlled mixer whose all functions can be controlled by the HMI (Human Machine Interface) operator panel is designed and manufactured for experimental studies. Water, leonardite and potassium hydroxide (KOH) mixture components are mixed in a newly designed mixer in three different ways by using traditional, chaos, and artificial intelligence techniques in order to obtain liquid humic acid which is used as plant nutrition and soil modulator in agriculture. For the chaotic mixing option, chaotic systems with different dynamic features are chosen from the literature. After converting the time series values of chaotic systems to the frequency values with the program written on the PLC device, it is provided to rotate at variable speeds according to different chaotic systems of the mixer motor connected to the frequency inverter. Fuzzy Logic is chosen for the artificial intelligence mixing option. Fuzzy Logic membership functions and rules are established in accordance with the results of the chaotic systems mixing experiments and the data obtained from experts in humic acid production. Mixing experiments are carried out by using an interface program that makes the choice of chaotic systems and motor rotation speed range. By mixing humic acid components with traditional methods, the comparison is done in terms of product quality, solute ratio, pH values and total energy consumption. When the developed mixer is provided to operate with chaos and artificial intelligence methods, it is observed that more efficient results are obtained in terms of criteria such as product quality, homogeneity, time, and energy savings compared to the traditional mixing methods.

CAN Controller Design for Diagnosing Automation System Failure

This paper proposes a controller area network (CAN) controller design for monitoring the state of a programmable logic controller (PLC) system and predicting its failure. The PLC system is the main device used in production automation equipment based on a large amount of sensor data. The proposed controller collects and stores the status data of multiple PLCs and sensors, and sends the collected data to the host system through the CAN interface. Then, the host system analyzes the transmitted data and predicts whether the PLC system will fail. Moreover, the host system informs the user of the risk of system failure. The proposed controller is composed of a processor block and CAN communication module. It was tested by connecting a PLC device. Consequently, a diagnostic message was received per a period of 500 ms.

Humik Asit Üretiminde Kullanılan Karıştırıcıların Kaotik Sistemler İle Performanslarının İyileştirilmesi

Bu çalışmada; ülkemizde ve dünyada en çok kullanılan bitki besleme ve toprak düzenleyici ürünlerden biri olan humik asitin üretiminde, geleneksel karıştırma metodları yerine kaotik sistemler kullanılarak, ürün kalitesi, homojenlik, zaman ve enerji tasarrufu gibi önemli kriterler açısından karıştırıcıların verimlerini arttırmak hedeflenmiştir. Kaotik sistemlerin bu özelliklerinden yola çıkılarak deneysel çalışmalar için; tüm fonksiyonları HMI (Human Machine Interface) operatör panel tarafından kontrol edilebilen, PLC (Programmable Logic Controller) kontrollü bir karıştırıcı tasarlanarak imalatı gerçekleştirilmiştir. Bu karıştırıcıda, su, leonardit ve potasyum hidroksit (KOH) karıştırılarak, sıvı humik asit elde edilmiştir. Karıştırma işlemi için literatürden farklı dinamik özelliklerde kaotik sistemler seçilmiştir. Bu kaotik sistemlerin diferansiyel denklemleri, Labview programında geliştirilen bir ara yüz programında Runge Kutta 45 (RK45) sayısal çözüm algoritmasına göre çözdürülerek her kaotik sistemin kaotik zaman serisi sonuçları elde edilmiştir. Bu sonuçlar, PLC cihazına yazılan program ile frekans verilerine dönüştürülerek frekans invertörüne bağlı karıştırıcı motorun, seçilen kaotik sistemlere göre değişken hızlarda dönmesi sağlanmıştır. Aynı karışım geleneksel yöntemlerle (sabit hız) de elde edilerek, ürün kalitesi, çözünen madde oranı, pH değerleri ve toplam enerji tüketimi açısından karşılaştırmaları yapılmıştır. Elde edilen sonuçlara göre; kaotik sistemler kullanılarak yapılan karıştırmanın, ürün kalitesi, homojenlik, zaman, enerji tasarrufu gibi kriterler açısından geleneksel karıştırma yöntemlerine göre daha verimli olduğu gözlemlenmiştir.

Industry 4.0 technologies incorporated with Delta PLC based Smart Home Automation for Rural Development

The Programmable Logic Controller (PLC) is commonly used for electromechanical process automation. A home automation system is being developed using PLC. The proposed control module will consist of Model Functional Blocks device emulation. Upgrading human standards of living is the most important source of inspiration for the continuation of technological advances. Technology innovation directly and indirectly offers and enhances the protection and comfort of human beings. The advancement of technology for this reason directly affects the quality of living through the design of smart home systems. Smart home systems can be classified as local and remote in two ways. In this research, a smart home automation system design was carried out by using Delta PLC (Programmable Logic Controller). The control module provides fault detection, tolerance and switching on or off in sensitive areas for multiple components. Combining the PLC model with other devices, such as GSM is also possible. By supplying voice control and protection products, such a form of application would be highly helpful for the elderly and disabled persons. World is developing increasingly across the Internet of Things (IoT). In this paper, we are designing a system that will track home appliances automatically and generate email or messanger notifications or make smart decisions using the IoT model. The key contribution of this paper is that it summarizes the use of IoT to track and regulate the market in industries with artificial intelligence. By optimizing the entire hardware assembly and software algorithms, the Delta PLC device is adjustable to satisfy demands, incorporating distinct home appliances in a short time. The PLC is simple to understand, and by using a single model, the system offers several solutions. The PLC will become the epic center for many new applications, as it is new but more powerful than previous systems.

Conveyor belt experiment setup for programmable logic controller education

Programmable logic controllers (PLC) have been one of the most widely used controllers in industry. They have a graphical programming language interface resambling the relay panels which they are intended to replace so that the transition from relay panels might be swift and smooth. Although learning this programming language is easy, real life experiments are essential for students to gain greater understanding of the logic behind the language. However, it is generally too expensive to provide an experimental set-up for students to test their theoretical knowledge. For this reason, a conveyor and feeder system was developed as a low cost 3D printable design using a CAD program and implemented for use in a control laboratory. Using this conveyor set-up, students can experience how to program a practical example of a PLC devices used in industry together with an introduction to actuators and sensors. Reading actual sensors and using actuators via the inputs and outputs of a PLC to control a real life system will be far more effective than simulator alternatives.

Comparison of MATLAB Simulink application with PLC application of real-time classical PID controllers in laboratory

Process control is a common area of study for different engineering disciplines. Controllers working ‎with ‎the ‎proportional–integral–derivative (PID) method are generally used in process control. ‎Parameters like ‎level, ‎flow, position, pressure, and temperature are controlled in-process control. PID ‎algorithm can be ‎formed ‎with different microprocessor-based devices. Process control is ‎implemented by using analog input ‎and ‎outputs terminals of PLCs (Programmable logic controller) ‎which is recently the most commonly used ‎in ‎industries. Also, a real-time PID method can be ‎implemented by using a computer-based ‎MATLAB ‎ ‎program in the laboratory.‎ The liquid level and flow control in the laboratory has been done by using PID algorithms and ‎PLC ‎device ‎and MATLAB real-time interface by using an experimental set. Necessary connections ‎and ‎configurations have ‎been prepared to perform process control. (SIMATIC Manager Step7) is ‎used for ‎programming in PLC. ‎Besides, the MATLAB simulation program is configured to implement ‎real-time ‎control to be ‎compatible with the MF624 data acquisition card. Liquid level and fluid flow ‎control ‎experiments were ‎performed separately for the same PID algorithms formed on two different ‎devices, then ‎liquid level ‎detection and liquid flow control results have been collected and ‎investigated. Based on these ‎results, a total ‎of four experiments were compared with both devices ‎considering the ease and difficulties of ‎using PLC and ‎MATLAB.‎

Automatic Configuration of OPC UA for Industrial Internet of Things Environments

Software technologies play an increasingly significant role in industrial environments, especially for the adoption of Industrial Internet of Things (IIoT). In this context, the application of mechanisms for the auto-configuration of industrial systems may be relevant for reducing human errors and costs in terms of time and money, improving the maintenance and the quality control. OPC UA (OLE for Process Control Unified Architecture) systems are usually integrated into an industrial system to provide a standard way for setting a secure and reliable data exchange between industrial devices of multiple vendors and software systems. In this paper, a novel mechanism for the auto-configuration of OPC UA systems is proposed from an initial setup of industrial devices interconnected to a basic Ethernet network. The auto-configuration of the OPC UA is self-managed over the TCP/IP protocol. This mechanism allows automating the configuration process of the OPC UA server automatically from the programmable logic controller (PLC) devices connected to a basic Ethernet network. Once the PLC devices are identified, they exchange information directly with OPC using a Modbus protocol over the same Ethernet network. To test the feasibility of this approach, a case study is prepared and evaluated.

A Low Overhead Solution to Resilient Assembly Lines Built From Legacy Controllers

As frequently buying, programming, testing, and utilizing new programmable logic controllers (PLCs) is cost and time prohibitive, many factories utilize legacy systems which are potentially insecure. This letter presents a PLC error detection and correction technique utilizing shifted time redundancy, enabled by a full crossbar connection network. It aims to successfully detect, isolate, and mitigate cybersecurity attacks and faults in PLC devices in a factory setting where multiple parallel assembly lines complete the same task. A trust scoring system is utilized in order to rate each PLC’s trustworthiness and reduces necessary overhead.

On PLC network security

Programmable Logic Controller (PLC) is an important component in modern Industrial Control Systems (ICS) particular in Supervisory Control and Data Acquisition (SCADA) systems. Disturbing the normal operation of PLCs can lead to significant damages ranging from minor annoyance to large scale incidents threatening the life of people. While most of existing work in the SCADA security literature focuses on the communication between PLCs and field devices, this paper presents a network security analysis of the communication between PLCs and the engineering stations in charge of setting up and configuring them. Interestingly, this aspect of SCADA security was exploited by the most famous SCADA attack, namely, Stuxnet. Using a testbed with a common PLC device, we successfully carried out three network attacks leading to serious compromise of typical PLCs.

Attack detection/prevention system against cyber attack in industrial control systems

Industrial control systems (ICS) are vital for countries’ industrial facilities and critical infrastructures. However, there are not enough security assessments against cyber attacks carried out on ICS for not preventing business continuity. New attacks are being made every day against these systems. Threats and attacks against critical infrastructures must be detected for protecting human life and assets. For this reason, detection has become more important than the prevention of attacks. In this study, vulnerability and attack detection analysis was carried out on programmable logic controllers (PLCs), one of the most important components of ICS, in the testbed and a rule set was created to detect active start/stop attacks. In this case, with writing this rule table, similar attacks will be prevented without harming the critical systems. In the analysis, mirroring technique was used to prevent the detection system from imposing additional load to the existing system and affecting the operation of the system negatively. In the test environment, Siemens S-7 1200 (Firmware 2.2) PLC devices were used. Smoothsec system, which is not used in industrial systems, is used for detection and rule table. It is assessed that this novel approach will provide significant contributions to attract attention to vulnerabilities and the security analysis of industrial control systems.

PC-Based Automated Control System for Jordan Northern Grain Silo

This paper presents a PC-based automated control system operation of the Northern Grain Silo of Jordan. The system connects to a PLC (programmable logic controller) device, and combines operator interface, PLC programming and monitoring functions into one platform. The PLC portion handles direct operations control, while the PC portion handles interfacing and data intensive functions. A simulation package is developed. The package generates a graphical user interface for real-time graphic animations of the Grain Silo operation. We discuss anticipated benefits of such a system and phases of implementation.

Structural planning and implementation of a microprocessor-based human–machine interface in a steam-explosion process application

In this paper, small-scale microprocessor-based human–machine interface (HMI) and programmable logic controller (PLC) standard software libraries are applied to plan, design, implement, and construct models for creating the modular application software. The graphical user interface (GUI) functions used in a specific biomass steam-explosion process, intended to be integrated with the PLC device for HMI, thereby providing excellent GUI-based supervision and control functions. Reviewing these specific case study results, we find that the major advantage is maximum system operating performance at minimum cost. Also, the GUI/HMI operation effectively provides user-friendly and reliable interactions. This GUI/HMI approach is a very cost-effective technique.

Auto-generation of IEC standard PLC code using t-MPSG

The objective of this paper is to reduce the development time of a PLC (Programmable Logic Controller) by automating the task of code generation. For this purpose, we applied t-MPSG (Timed-Message Based Part State Graph). The t-MPSG is an extended finite state automata used to model and generate an execution module for a real-time shop floor controller system. In our proposed method, t-MPSG is used to model the formal specification of the controller system that can be translated into textual structure. After the verification of the t-MPSG model, it can be used as an input to the plc-builder tool. The plc-builder tool is an extended version of a conventional MPSG simulator. It can be used to translate the textual structure of the t-MPSG into an IEC standard PLC code. Finally, the generated code can be downloaded to a PLC emulator or a PLC device for the purpose of simulation and execution. The similarity in the hierarchical structure of the t-MPSG and the IEC standard PLC program has made it convenient to transform from one form to another. Furthermore, an illustration of the methodology to auto-generate IEC standard PLC code using t-MPSG is explained with a suitable example.

Integration of autonomous systems for remote control of data acquisition and diagnostics in the TJ-II device

The data acquisition system for TJ-II will consist of a central computer, containing the data base of the device, and a set of independent systems (personal computers, embedded ones, workstations, minicomputers, PLCs, and microprocessor systems among others), controlling data collection, and automated diagnostics. Each autonomous system can be used to isolate and manage specific problems in the most efficient manner. These problems are related to data acquisition, hard (μs–ms) real time requirements, soft (ms–s) real time requirements, remote control of diagnostics, etc. In the operation of TJ-II, the programming of systems will be carried out from the central computer. Coordination and synchronization will be performed by linking systems to local area networks. Several Ethernet segments and FDDI rings will be used for these purposes. Programmable logic controller devices (PLCs) used for diagnostic low level control will be linked among them through a fast serial link, the RS485 Profibus standard. One VME crate, running on the OS-9 real time operating system, will be assigned as a gateway, so as to connect the PLCs based systems with an Ethernet segment.