Programmable Logic Controller Research Articles

Designing a high-fidelity testbed for 5G-based Industrial IoT

With the rise of the Industrial IoT (Internet of Things) and Industry 4.0 paradigms, many control and sensor systems used for IACS (Industrial Automation and Control Systems) have become more complex, due to the increasing number of interconnected field devices, sensors and actuators often being geographically spread across large areas. Supporting these increasingly sophisticated networked scenarios calls for the involvement of telecommunications and utility providers to better support Machine-to-Machine (M2M) communications and infrastructure orchestration, for which 5G technology is considered a perfect match. Nowadays, such 5G networks empower solutions both for consumer and for industrial IoT scenarios, providing the capacity and the means to seamlessly connect a massive number of gadgets and sensors, with diverse data rate requirements, low latency, and low power consumption. Part of this flexibility is also due to the nature of the 5G Service Architecture (SA), which is based on a microservice concept, dividing its core through multiple functions, allowing it to horizontally scale in a flexible way. Furthermore, the 3GPP specifications encompass specific support for verticals by means of slicing and 5G LANs, paving the way for a paradigm shift in terms of the relationship between service, telecom, and operational infrastructure tenants. However, such benefits come at the cost of extra complexity and, consequently, an increased vulnerability surface. This calls for further research focused on improving 5G infrastructure management, service integration and security, which cannot be safely undertaken in production environments, thus motivating the development of suitable 5G testbeds. This research work, which was developed in the scope of the POWER and Smart5Grid P2020 projects, addresses the creation of a high-fidelity environment for 5G-related research, which encompasses a gNodeB and 5G core, together with emulated User Elements (terminal devices) and IoT nodes (in this specific case, Programmable Logic Controllers), constituting a 5G Industrial IoT scenario designed for development and validation of new solutions, security research, or even advanced training purposes. The entire infrastructure is supported via container orchestration technology, providing enhanced scalability and resilience characteristics.

Experimental design and optimization of a novel solids feeder device in energy efficient pneumatic conveying systems

Pneumatic conveying of powders is an engineering process used for conveying dry granulate or powder material where energy consumption is a significant cost factor and contributes to greenhouse gas emissions. In this RD&I project, work was conducted to model pneumatic conveying and bulk characteristics of the particulate product being conveyed. Because pneumatic conveyance is highly empirical, general models are difficult to establish. Due to these limitations, evaluating energy efficiency is usually limited to a specific experimental range of conditions. This work is based on engineering optimization of a workflow with data from an industrial operation commanded by a Programmable Logic Controller (PLC) with a control algorithm, performing logical, sequential, and timed tasks for plant control. The PLC communicates with a Human–Machine Interface and a Supervision and Control System, which are the means of interaction through a graphical environment interface with the process operator. By applying mathematics to introduce a systematic method to select the gas (air) pressure and flow necessary to operate a pneumatic conveying system in dense phase mode, it has been shown, on an industrial scale of 10 t/h, the feasibility of controlling an efficient pneumatic conveying system manipulating only two input parameters. This allows operation at pre-determined conveying rates with lower operational expenditures. The same methodology can be explored for several other systems.

PLC-BASED SIMULATOR TO CONTROL THE ROAD TRAFFIC THROUGH OPERATING THE ANALOGOUS OF BRIDGE BODIES ON TWO WATER CANALS FOR THE SHIP-PATH SYSTEM

The essence of this research relates to the redesign for the acquisition of a simulator based on an embedded system in general and specifically to the utilization of a set of programmable logic controllers (PLCs). The research was chosen on the use of instrumentation systems and controlled automation mechanisms by a PLC which functioned as a simulator to operate the double bridge bodies analogy for road traffic lanes, i.e., highways on crossings with dual water canals as the ship-path system or ship crossings. Some results are (i) the operating principle of the simulator, it is observed for the sensors installed on the simulator, whether they are functioning as programmed into the PLC; (ii) when the auto mode of lifting the bridge body, both on bridge bodies #1 and #2, is longer than the process of lowering the bridge bodies, it is more emphasized on the existence of a gravitational force; and (iii) there is no significant time difference compared between the auto and manual mode selection. Concluding based on the four main research objectives and topics carried out that the stages for performing the simulator assisted by PLC and driven by GX Work of Mitsubishi can be realized according to the initials of idea and design for selecting and determining the hardware and software.

Efficient Revocable Anonymous Authentication Mechanism for Edge Intelligent Controllers

In the field of industrial control, edge computing puts forward higher requirements for the local processing ability of data. The traditional industrial Programmable Logic Controller (PLC) cannot complete this task. Edge Intelligent Controller (EIC) is developed according to the demand for edge computing. As the core component of edge computing, the security and reliable operation of EIC has great significance and influence on the promotion and development of edge computing. For the access authentication of EIC, an efficient revocable anonymous authentication scheme for EICs by utilizing a group signature technique is proposed in this paper, which can trace the identity information of the EIC and protect the privacy of the EIC, and apply an efficient revocation mechanism to revoke any illegal or abnormal EICs. Through security analysis, we prove the authentication scheme is anonymity, integrity, traceability, forward secrecy, resistance to the replay attack and efficient revocability. Furthermore, the performance analysis and comparisons show that the authentication scheme is efficient and feasible for EICs.

Design and development of a multifunctional moxibustion treatment machine based on heat-sensitive moxibustion therapy

A multifunctional moxibustion treatment machine is designed and developed to assist the heat-sensitive moxibustion therapy. Through the motion control of the stepping motor by programmable logic controller (PLC), the automatic control is obtained for the acupoint detection of heat-sensitive moxibustion therapy and the manual operation of moxibustion. The skin temperature is monitored in real-time, using infrared non-contact temperature measurement technology. Based on the deviation of the temperature set value and the monitoring one, the distance between the moxibustion device and the exerted region is adjusted automatically by PLC so that the temperature is controlled practically. The multifunctional moxibustion treatment machine based on the heat-sensitive moxibustion therapy is capable of the operation control of mild moxibustion, circling moxibustion, sparrow-pecking moxibustion and along-meridian moxibustion techniques, as well as real-time monitoring of skin temperature. The temperature change curve of this machine is coincident with that obtained by the manual operation of heat-sensitive moxibustion. This multifunctional moxibustion treatment machine assists the delivery of heat-sensitive moxibustion therapy and it is satisfactory in temperature control and precise in operation.

An efficient intelligent control algorithm for drying rack system

AbstractWith the development of the drying rack system, users with limited time tend to use the fully functional drying rack system to realize various intelligent control functions. However, the existing control methods for drying rack system has some defects such as, low intelligence and system delay, which are unsuitable for most users. In this paper, an efficient intelligent control algorithm based on the back‐propagation (BP) neural network is proposed. In this system, STM32F103 is first utilized as the central controller and multiple sensors are used to collect environmental information. Then, the remote control, voice keywords, and buttons can be used to achieve intelligent control. Subsequently, a motor drive intelligence control algorithm based on the BP neural network (MCBP) is proposed to improve the accuracy of the intelligent control. Next, an Application (APP) that can display environmental data such as wind speed, temperature, and humidity is developed. The APP can realize various intelligent control functions such as lifting, panning, rotating, and harvesting. Finally, MCBP is compared with normal control and programmable logic controller control. The accuracy of the MCBP is higher than other two control methods. The final extensive experiments confirm the accuracy and efficiency of the proposed intelligent control algorithm.

Smart factory for future industry development

The paradigm of the smart factory is thought of as an innovative outline for the fourth industrial revolt. The GLOVA G7-DR20U is set as a programmable logic controller (PLC) for monitoring the performance of the smart factory while using the NodeMCU-V3 esp8266 as the internet of things (IoT) board for interaction between managers and the factory using the personal digital assistant (PDA) programming that has been written in the RabitMQ platform. The program logged inner PLC by applying ladder language for monitoring the performance of PLC. With the completion of intelligent PLC, it is likely to extend the existing making capability in the factory with simplicity. This work joins a PLC used as a parent control unit, apps, user programs, and human-machine interface, with the Internet. The proposed model of the smart factory holds two motors one for the parallel drive and the other for the upright drive. While running the system, we observe that the proposal is working correctly, and the reply to the interaction method via IoT is excellent.

Decentralized proportional-integral controller based on dynamic decoupling technique using Beckhoff TwinCAT-3.1

An improved technique for the design of decentralized dynamic decoupled proportional-integral (PI) controllers to control many variables of column flotation was developed and implemented in this paper. This work was motivated by challenges when working with multiple inputs and multiple outputs (MIMO) systems that are not controllable by conventional linear feedback controllers. Conventional feedback control design consists of various drawbacks when it comes to complex industrial processes. The introduction of decentralization, decoupling, and many advanced controls design methods overcomes these drawbacks. Hence, the design and implementation of control systems that mitigate stability for MIMO systems are important. The developed closed-loop model of the flotation process is implemented in a real-time platform using TwinCAT 3.1 automation software and CX5020 Beckhoff programmable logic controllers (PLC) through the model transformation technique. The reasons for using the CX5020 as an implementation environment were motivated by the reliability, and is built according to new industry standards, allowing transformation, which makes it more advantageous to be used more than any other PLCs. This is done to validate the effectiveness of the recommended technique and prove its usability for any multivariable system. Comparable numerical results are presented, and they imply that industrial usage of this method is highly recommended.

INDUSTRIAL ASSEMBLY LINE OPERATION

The idea of this paper is to present basic components of a flexible assembly system (FAS), discuss it characteristics, classify the systems and describe an application. This equipment offers professional training according to the industrial reality, simulating a real assembly process and including different technologies from Industry 4.0. The FAS consists of an automated flexible assembly cell with five different stages: assembly, handling, quality inspection, transfer and warehouse. It is the ideal answer to research and training in industrial automation. The main advantage is that it has fully modularity in keeping with industrial reality. The technologies included in its different assembly modules, as well as the assembly process with several variants, allow the user to develop the professional skills required by advanced automation. In this work the conventional control approach is presented with programmable logic controllers (PLC) and SCADA level.

Pick and place operation by collaborating electromagnetic and pneumatic gripper robots

Recently, the use of robot has become significant to industries, especially when involving the routine works in industries. A robot is a device designed to execute one or greater tasks robotically with velocity and precision. In the present work Pick and place of metal components are planned by collaborating electromagnetic and pneumatic gripper IGUS robots. CProg software is used to program the logic and programmable logic controller is used for making the necessary collaboration between the robots. Here the electromagnetic gripper robot is first picked the metal object of flat type and it reach the target and wait for the pneumatic gripper robot to come. Once the pneumatic griper robot is reached, the electromagnetic gripper robot send the signal then, pneumatic gripper robot will take the object from electromagnet gripper robot. Once pneumatic gripper robot pick the object and send signal then, electromagnet gripper robot will goes to its position and pneumatic gripper robot will place the object at desired location the entire communication is done through CProg software along with PLC connections. This program will be repeated till the work completes. This program is suitable for different environments and which can eliminate repeated works done by human operators. These robots are best suitable for automation of industries with low cost.

Test Automation of Motor Over Temperature Protection Extension Module of Drive

In industries, for releasing any product into the market, various stages of testing procedure must be done on the product to test its functionality and reliability. The testing procedure has to be frequent and accurate enough to enable early defect detection. Manual testing procedures are time-consuming, need more human resources at the place of testing, have no concept of documentation, and have more chances of human errors. To overcome the variously described limitations of manual testing, test automation is a key tool for providing prompt feedback, tracking of developed firmware versions time-to-time and reducing the tester’s efforts to perform tests task repetitively. The main goal is to speed up test execution cycles and improve the accuracy as well as the performance of the module for end-user customer satisfaction. The proposed system works based on replacing the potentiometer with a relay configuration controlled by the digital output signal of the Programmable Logical Controller and Automated Test Framework. The study describes the transition from manual testing of modules with complex setup environments to automatic testing of modules with implemented hardware changes.

Services interfaces for interoperability of signaling computer interlocking on borders

<p>Technological developments in the field of railway signaling have allowed more and more flexibility in the management of rail traffic, especially with computer interlocking. However, differences in signaling principles from one country to another as well as differences in the structure of interlocking software and communication protocols depending on suppliers lead to interoperability difficulties at the borders between computer interlocking. Some deployed projects deal with interoperability issues regarding the communication of signaling information between the train and interlocking like the European rail traffic management system (ERTMS) project. Unfortunately, the interoperability between interlocking themselves is still not achieved. Some deployed projects deal with interoperability issues regarding the communication of signaling information between the train and interlocking like the ERTMS project. Unfortunately, the interoperability between interlocking themselves is still not achieved. This article draws up a proposed model for interfacing at the interlocking boundaries based on service-oriented architecture (SOA). In addition, to ensure the coupling of SOA services to the internal functions of the signaling computer interlocking, a distributed architecture of programmable logic controller according to the IEC 61499 standard is suggested.</p>

Implementation of FATEK PLC Based Three Floor Elevator System

The implementation of a low-cost FATEK PLC-based three-floor lift system is described in this study. Elevator systems are critical for vertical mobility in buildings, and their control methods have been revolutionized by the use of programmable logic controllers (PLCs). To control the motion of the lift, we use a DC geared motor. In this example, push buttons are used to direct the elevator to the desired floor. In this scenario, ladder diagram programming was utilized. Because the PLC is easy to programme.

Contributing factors in learning programmable logic controller using path analysis

Learning Programmable Logic Controller (PLC) programming is influenced by several factors, that is: lecturer competence in PLC programming, adequacy of information technology infrastructure in learning, availability of learning media, vocational guidance procedures, and learning motivation. The purpose of this study: (a) to describe the factors that contribute to PLC programming learning, (b) to formulate a PLC programming competency model, and (c) to examine the determinants of PLC programming learning. Model testing method using Path Analysis. The results of this analysis are expected to be able to describe the relational patterns between variables in learning PLC programming, as well as the direct and indirect impacts on the mastery of PLC programming competencies. Keywords: PLC programming competency, path analysis, vocational education.

Real-Time Monitoring of Gas Fields: Prototype at Pt Gamma Energi Pratama Bogor

PT Gamma Energi Pratama is a company engaged in the instrumentation sector. One of the projects undertaken by PT Gamma Energi Pratama is on an oil and natural gas drilling site. The oil drilling process involves a tool called a Gas Jack Compressor originating from the United States. At first, the technician there used the local panel that came with the compressor. But procuring spare parts takes a long time. At the same time, the needs in the field demand to be met immediately. Therefore, the Programmable Logic Controller (PLC) was chosen as a special microcontroller device that can access the compressor via the Modbus Protocol. PLCs can also be connected to Supervisory Control and Data Acquisition (SCADA) applications via Ethernet. This solution monitors data from sensor readings installed on the Gas Jack Compressor. The system is already running with its use only on the local scope. For the development of the system so that monitoring can be carried out in real-time and online, it needs to be linked to flow control devices, database systems, and interfaces for data visualization. Thus, monitoring gas fields can be done in real-time online.

Research on Oxygen Supply System of Coal Mine Refuge Chamber Based on Personnel location and Programmable Logic Controller

The refuge chamber provides a safe space where people can stay safe when they are trapped by an accident in a coal mine. The refuge chamber includes several systems such as oxygen supply, air purification, cooling, and dehumidifying. The oxygen supply system is the core of the refuge chamber because it is a closed environment. The oxygen supply time is 96 h according to the relevant standards in America and China. If people stay in the refuge chamber for more than 96 h, the oxygen supply may not be enough, and they can be in danger. It is necessary to efficiently use oxygen and extend the oxygen supply time. Based on the experimental platform of the refuge chamber, this paper conducts an in-depth study on the automatic control of the oxygen supply system. The oxygen supply system and the harmful gas removal system can be automatically and efficiently controlled by the programmable logic controller (PLC) according to the personnel number and the oxygen concentration. The experiment has proved that the system is good and reliable.

Kinerja Training Kit Mesin Pengisi dan Penutup Botol otomatis Sebagai Media Praktik Programmable Logic Controllers di SMK

This research aims to: (1) develop a prototype of an automatic bottle filling and capping machine training kit as a Programmable Logic Controllers (PLC) practice tool in vocational high schools (SMK), and (2) assess the performance of the automatic bottle filling and capping machine training kit as a PLC practice tool in SMK. This research adopts the research and development methodology in the field of education. The development model used is the ADDIE model by Robert Maribe Branch. The research consists of the following stages: Analyze, Design, Develop, Implement, and Evaluate. The data collection techniques employed in this study are interviews and questionnaires, using interview guides and questionnaires as instruments. The data obtained were analyzed descriptively. The results of the research indicate that: (1) a training kit for an automatic bottle filling and capping machine has been developed, which consists of main components such as the Conveyor Unit, Water Filling Unit, Water Capping Unit, OMRON CP1E N40 PLC Unit, Training Kit Components Unit, and Input/Output Terminal Block. This training kit serves as a PLC practice tool in SMK; and (2) the automatic bottle filling and capping machine training kit exhibits good performance, as demonstrated by the testing of 43 components, all of which functioned properly. The functional testing conducted under Initial Condition, Watertank Condition, Run Cycle Condition, Stop Condition, and Emergency Condition showed that all components (100%) performed well.

INTELLIGENT PROCESS CONTROL SYSTEM IN AUTOMATION INDUSTRY

Intelligent process control (IPC) has indeed been identified as one of the most promising and essential technological techniques for achieving enterprise digitalization. This study covers key principles for developing IPC in industry and provides a framework for effectively implementing IPC technology. Today, operators in the control rooms of large plants are expected to rely heavily on their own judgement and experience. The present hot point intelligent control technology and means are outlined in conjunction with the forefront of industrial process automation development. As management criteria, technical and economic indicators can serve, for example, increasing productivity, improving product quality, reducing losses, reducing the cost of production, etc. The transition from automation systems in industry to the intelligent process control systems at one time was caused by the intensification of technological processes, the use of high-power units, as well as progress in the development of control systems. An intelligent process control (IPC)system is a set of technical means and algorithms for collecting, processing and presenting information that provides control of an industry, production, enterprise or individual processes based on cybernetics methods and partially using artificial intelligence. The specific use of intelligent control is then explained. Keywords: Controller, Intelligent Process Control (IPC), System, Software, Programmable Logic Controller (PLC).

Measurement of Water Depth in a Class A Pan Using Ultrasonic Transducer and Programmable Logic Control (PLC)

The aim of this study is to compare water depths measured by manually and PLC from a Class A Pan in field conditions using ultrasonic transducer. The study was conducted in garden of Faculty of Agriculture, University of Kahramanmaras Sutcu Imam in the summer season of 2019. A steel meter was used to measure water depth manually in the evaporation pan. Using the ultrasonic transducer, PLC measured water depth from the evaporation pan between 140 and 223 mm water depth at 8:00 am. An ultrasonic transducer is attached one end of sliding buttress, at which was 50 cm above from its inner-bottom at the center of the evaporation pan. The ultrasonic transducer was set to be able to read water depth and calibrated using sliding buttress. A program was written in CODESYS-ST language to measure the water depth from a Class A Pan using PLC, which was connected the ultrasonic transducer and uploaded to PLC. With the program, digital water depths were converted to millimeter water depths. To be able to read the water depth more accurately, each depth value read by the PLC was determined by averaging 30 measurements made successively at 300 millisecond intervals. In this processes, moving average method was used. Water depth measured by PLC was saved on the SD (secure digital memory) card. In the manual water depth measurements, there were 26 observations. The water depths on the manual measurement dates were matched with the water depths measured by PLC. A regression analysis was performed between the water depths measured by the steel meter and PLC in the pan, and determination coefficient (R2) was result as 0.96. The Mean Absolute Percent Error (MAPE) of these two data sets was calculated as 2.3%. The level of agreement between the two data sets; if the MAPE is below 10%, it is considered “very good”. The results of this study revealed that the PLC could measure the water depth close to the measured manually water depth in the evaporation pan with an ultrasonic transducer.

IMPLEMENTATION OF PLC BASED AUTOMATIC SORTING SYSTEM

The sorting system is usually used as a load handling system in the industrial applications in order to increase the production rate, reduce human error, and increase the efficiency. There are two types of sorting system applied in the industrial applications such as manual sorting system and automatic sorting system. This project presents the design and implementation of PLC based automatic sorting system in mini scale size. The system consists of a conveyor, limit switch, double acting cylinder, and Programmable Logic Controller. Omron PLC CPM2A was used to control the system based on the height of the box. The resulting box sorting system was capable to separate the height of 4 cm block and the height of 1 cm block into their respective location.