Programmable Logic Controller Research Articles

Multi-objective trajectory planning in the multiple strata drilling process:A bi-directional constrained co-evolutionary optimizer with Pareto front learning

Trajectory planning is essential to ensure the safety and efficiency of the drilling process within varying downhole geological conditions. However, numerous constraints and dispersed objectives make this task challenging, resulting in a broken constrained Pareto front (PF) in the objective space. To address this issue, we present a novel multi-objective optimization algorithm (MOEA), the Bi-directional Constrained Co-evolutionary Optimizer (BCCO), for reducing the friction torque of the drilling string system and maintaining the wellbore stability of the directional drilling process in multiple changeable strata. Inspired by dual-population co-evolutionary mechanics, BCCO is thoughtfully developed to enhance complex constraints handling. An ESOINN is introduced to guide the population in exploring the irregular PF and adaptively approximating to it. In addition, a flexible constraint dominance principle is devised to filter out non-inferior infeasible solutions that fully balance feasibility, diversity, and convergence by combining constraint violation, minimum vector angle, and angle-penalized distance. Moreover, we adopt a minimum Manhattan distance (MMD) decision-making method to select the final reference solution for trajectory tracking control. To verify the effectiveness of BCCO, we compared it with seven state-of-the-art constrained MOEAs, four latest published MOEAs used in drilling trajectory planning (DTP) applications, and three ablation MOEAs revised from original BCCO on real-world constrained test instances and four different types of designed standard benchmarks. Extensive testing confirmed adaptability to diverse constrained PFs. BCCO displayed strong convergence and diversity when applied to real-world engineering problems while maintaining feasibility. To evaluate BCCO’s DTP performance, we built a wellbore stability model on actual geological formations and empirically tested it with both composite natural curves and third-order Bézier curves in various drilling trajectory scenarios. We established a comprehensive cloud-based DTP test system with the on-site Programmable Logic Controller (PLC) and the workstation via Data Transfer Unit (DTU) communication. Actual DTP cases confirmed the feasibility of BCCO’s Pareto solutions, with MMD-selected trajectories ensuring a harmonized drilling process.

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.

DESIGN OF A SCADA SYSTEM FOR A SOLAR PHOTOVOLTAIC POWER PLANT

This paper presents the design and implementation of a solar panel data monitoring system using a SCADA (Supervisory Control and Data Acquisition) system. The system is built via the Siemens S7-1200 Programmable Logic Controller (PLC) and programmed using TIA (Totally Integrated Automation) Portal V17 software. The system includes various sensors and instrumentation for monitoring solar panel performance, such as temperature sensors, current and voltage sensors, and irradiance sensors. The PLC collects data from these sensors and transmits it to the SCADA software, which displays real-time data on the graphical user interface (GUI). The system also includes features such as alarms and notifications for abnormal conditions, data logging for historical analysis, and remote access for monitoring and control from a central location. The system's reliability and efficiency are enhanced through the use of the S7-1200 PLC and TIA Portal V17 software, which provide advanced programming and automation capabilities. Therefore, this solar panel data monitoring system provides a comprehensive solution for monitoring and optimizing the performance of solar panel systems, helping to increase efficiency, reduce downtime, and improve overall system performance.

FPGA Implementation of IEC 61131-3-Based Hardware-Aided Timers for Programmable Logic Controllers

Designs of timer function blocks (FBs) are presented in the article. The developed modules are IEC 61131-3. An analysis of IEC 61131-3 in terms of timer functionality and implementation options is presented. Three types are presented, timer-on, timer-off, and timer-pulse, with each type designed to be fully hardware or software-like. Both designs, hardware or software-like, can operate as multi-channel timers. Particularly noteworthy is the software-like design, for which a solution without edge detectors was achieved. Such a feature was obtained by reversing the method of time determination by counting the difference between the start and end times and by using specific features of the D flip-flops, that is, clock-enable inputs. The presented timers were written in Verilog language and implemented in an FPGA chip. Thanks to the universal design of the interface, the proposed FBs can be used for the hardware support of existing programmable logic controllers (PLCs) or as an integral part of newly built PLC CPUs. The idea of a CPU architecture with hardware support is proposed. The paper presents the results of the implementation in an FPGA of the Kintex UltraScale+ family from AMD-Xilinx.

Autonomous control of shore robotic charging systems based on computer vision

Recently, there has been a rapid increase in electric vessels as in electric land vehicles. Since vessels such as ferries and ships operate on a specific schedule, the time to be spent for charging on the shore is limited. The charging process involves connecting equipment, transferring energy, and disconnecting equipment. The faster and easier connection and disconnection process is, the more time is for energy transfer. This paper introduces a novel autonomous robotic charging system that combines Programmable Logic Controller (PLC), embedded platform, camera, and lasers to detect the vessel's charging socket in the charging area by computer vision. Initially, the embedded platform detects the charging socket and position of the electric vessel with the camera using You-Only-Look-Once (YOLOv5). After that, when the charging socket is detected, laser sensors control it more precisely to align the robotic charging station and move it closer to the socket on the ship. Finally, the precise location information is transmitted to the PLC, and the robotic charging station transfers energy until the charging process is completed. Consequently, the proposed system achieved 94% accuracy in charging socket detection. This research can be a guide in demonstrating the shore-to-ship socket detection efficiency of autonomous and computer vision-based ship charging systems.

A novel fault diagnosis method for PV arrays using convolutional extension neural network with symmetrized dot pattern analysis

AbstractPV fault diagnosis remains difficult due to the non‐linear characteristic of PV output, which makes PV output to be likely disturbed by the ambient environment. This study proposes a novel convolutional extension neural network (CENN) algorithm, which is a jointed architecture based on convolutional neural network (CNN) and extension neural network (ENN), takes advantage of CNN and ENN. The CENN is combined with the symmetrized dot pattern (SDP) analysis method to diagnose the common eight PV array faults. The SDP is used to transform the measured PV signals into the point coordinate feature image; then, the CENN is trained to identify the different PV faults. Experimental results show an obvious improvement in short detection times and high accuracy compared with traditional CNN and the histogram of oriented gradient (HOG) extraction method with support vector machine (SVM), K‐nearest neighbours (KNN), and back propagation neural network (BPNN) classifiers, with 95.3%, 94%, 93.5%, and 93.3% accuracy, respectively. Using the proposed CENN, the accuracy can be raised to 97.3%. Additionally, the signals measured by various sensors are collected using programmable logic controller (PLC). The human–machine interface (HMI) and the proposed algorithm are developed using LabVIEW for graphical design. Finally, the information is transmitted to a tablet PC for performing real‐time remote monitoring.

Design of the Urban Lighting Control System Based on Optical Multisensor Technology and the GM Model

Lighting has emerged as a central concern in the domain of city planning and design in recent decades. Better lighting does more than just make cities safer and more secure; it also makes them more aesthetically pleasing and easier to live in. A single type of optical sensor is no longer sufficient to meet the needs of intelligent lighting for urban roads, and as such, there is a growing demand for cutting-edge control systems that can adapt to the dynamic lighting needs in urban environments. This paper’s goal is to create an intelligent urban lighting control system by integrating optical multisensor technology and the gray model (GM model). Programmable logic controller (PLC) serves as the system’s central processing unit, with light intensity sensors and color sensor-detecting devices placed strategically throughout each city and linked directly to the controller. Each road streetlight is equipped with a motion sensor detection device that is tasked with identifying the presence of vehicles and pedestrians within its field of view. Data fusion technology is utilized to process the environmental data gathered by optical multisensors, the collected data are then used to control and predict outcomes using the robust prediction capability of the GM model, and the result is a lighting control strategy that is both efficient and intelligent. In the end, the strategy presented in this paper is applied to improving the management of an industrial park lighting system’s energy consumption. The results of the evaluations show that the fresh method is successful in dimming, prediction, and control. This conclusively demonstrates the efficacy of the paper’s proposed design solution, which integrates optical multisensor technology with sophisticated control algorithms and data analysis to improve the quality of life in urban areas by boosting the efficiency and sustainability of the urban lighting system.

Container-based Virtualization for Real-time Industrial Systems—A Systematic Review

Industrial Automation and Control systems have matured into a stable infrastructure model that has been kept fundamentally unchanged, using discrete embedded systems (such as Programmable Logic Controllers) to implement the first line of sensorization, actuation, and process control and stations and servers providing monitoring, supervision, logging/database and data-sharing capabilities, among others. More recently, with the emergence of the Industry 4.0 paradigm and the need for more flexibility, there has been a steady trend towards virtualizing some of the automation station/server components, first by using virtual machines and, more recently, by using container technology. This trend is pushing for better support for real-time requirements on enabling virtualization technologies such as virtual machines and containers. This article provides a systematic review on the use of container virtualization in real-time environments such as cyber-physical systems, assessing how existing and emerging technologies can fulfill the associated requirements. Starting by reviewing fundamental concepts related to container technology and real-time requirements, it goes on to present the methodology and results of a systematic study of 37 selected papers covering aspects related to the enforcement of real-time constrains within container hosts and the expected task latency on such environments, as well as an overview of container platforms and orchestration mechanisms for RT systems.

Web Server Based Data Monitoring System of PV Panels Using S7-1200 PLC

This This paper presents the design and implementation of a solar panel data monitoring system using a Web Server as a real-time operating system. The system is built via the Siemens S7-1200 Programmable Logic Controller (PLC) and programmed using TIA (Totally Integrated Automation) Portal V17 software. This approach enables real-time data collection and visualization of essential parameters such as voltage, current, power output, temperature, irradiance, and environmental conditions. The S7-1200 PLC serves as the central control unit, interfacing with the PV panels and gathering data. The acquired data is then transmitted to a web server, which hosts a user-friendly interface accessible through web browsers. Users can remotely monitor the performance of PV panels, track historical data trends, and receive alerts in case of anomalies. This web server-based system offers a convenient and efficient solution for effective PV panel management, enabling users to optimize energy production, detect issues promptly, and make informed decisions for maintenance and operational improvements.

Design and implementation of PID based flow rate control using PLC

Industrial systems require efficient techniques to observe the stable operation of various industrial processes and to achieve optimal control. Considering the importance of industrial processes, Proportional Integral and Derivative (PID), Adaptive PID, and fuzzy logic are the most utilized control systems. Programmable Logic Controller (PLC) is a low-cost solution for the industrial processes requiring control and having the flexibility of graphical user interface. In this paper, an experimental study on flow rate control system for water flowing in a vessel is realized and implemented using Proportional (P), Proportional Derivative (PD), Proportional Integral (PI), and PID controllers with Programming Logic Controller (PLC). For optimal control, the constants for the PID controller are calculated based on Zeigler-Nichols (ZN) rules. ZN tuning rules can be used to find controller constants where the plant dynamics are not available. The experimental analysis is performed to validate the theoretical concepts. The achieved results and analysis demonstrate that the process variable, which is water inflow rate 4.92L/minute, is equal to the set point without any overshoot and remains controllable at every set point change.

DETECTION OF ADVANCED PERSISTENT THREATS USING SIEM RULESETS

Cyber-attacks move towards a sophisticated, destructive, and persistent position, as in the case of Stuxnet, Dark Hotel, Poseidon, and Carbanak. These attacks are called Advanced Persistent Threats (APT) in which an intruder establishes an undetected presence in a network in order to steal sensitive data over a prolonged period of time. In today's digitalized life, these attacks threaten the main critical life areas. This threat is followed by critical infrastructures, finance, energy, and aviation agencies. One of the biggest APT attacks was Stuxnet which targeted software on computers controlling the programmable logic controllers (PLCs) used to automate machine processes. The other one was the Deep Panda attack discovered in 2015 which compromised over 4 million US personnel records because of the ongoing cyberwar between China and the U.S. This paper attempts to explain the difficulties of detecting APTs and to examine the studies in this area. In addition, this paper presents a new approach to detecting APTs using the SIEM solution. In this approach, it is recommended to establish APT rulesets in SIEM solutions by using the indicators left behind by the attacks. In the rulesets, 3 basic indicator types are considered, and examples are shared. Keywords: Cyber security, cyber war, APT, SIEM, Intrusion Detection System.

Systematic framework to select the sustainable best design for an automated fertiliser blending system

The innovative device to automatically irrigate nutrients and water to the plants without affecting the environment has become increasingly important in sustainable agriculture and food production. This research aims to propose a prototype for a control-based Automated Fertiliser Blending System by investigating a comprehensive conceptual design framework and specific requirements from the market survey in designing the new device. The House of Quality, Morphological Chart, and Pugh tools were adopted to select the best conceptual design among the available design options. The approach of product design selection is based on ranking in engineering characteristics to generate design options. The benchmark design in this study is a timer system with two stock tanks. Conceptual Design 4 was selected as the advanced conceptual design because this system uses a Programmable Logic Controller to control the blending process of fertiliser solutions precisely with minimal nutrient loss and water runoff. A design prototype was developed for Design 4 using SolidWorks by considering all selection parameters of chosen criteria that were analysed based on the HOQ and Pugh methods. Conclusively, the proposed design of the Automated Fertilizer Blending System can provide technological innovation in designing this device. This will assist in coordinating better product development for potential product commercialization toward achieving sustainable and precise agriculture.

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.

Design and simulation of PLC and HMI-Based control and monitoring system of compressed air application in a pineapple cannery industry

Energy Conservation or ENERCON is the main concern of every industry today. With the advent of new technology installed in the process line, the need to address the conservation of applied energy such as steam, water, electricity, and compressed air are still the core to run an industrial plant. The use of compressed air as a blower is widely used now a day for several benefit compared to running the blowing system with the motor. The system presented in this study is used to automatically switch off the compressed air that serves as a can top blower before printing whenever there are no can detected in the conveyors in a pineapple cannery industry. The cutting off of the compressed air used will result in significant saving in the plant-wide drive on conserving energy. The hardware composition, control system design, software application and simulation of the Programmable Logic Controller (PLC) and Human Machine Interface (HMI) - based monitoring and control system of compressed air are present in this work. The system’s main components are PLC, HMI, Inductive sensors and Directional valves. This paper focuses on the application for a pineapple manufacturing plant but not limited to the compressed air application but for all the industrial utilities mention above.

Case study of using KEPServerEX software as a connection tool between Tecnomatix Plant Simulation and a real device

The article focuses on the processing of simulation models, covering their creation methods and exploring the possibilities of collaboration. The author utilized the Tecnomatix Plant Simulation program developed by Siemens to design a visual representation of a production line and provided a detailed description of the steps involved in its creation. To achieve the objectives of the thesis, the author employed KEPServerEX, a software solution enabling the connection and communication between the Tecnomatix Plant Simulation program and the Programmable Logic Controller (PLC). This integration allowed for the successful connection of a CNC device, establishing communication and collaboration with the Plant Simulation program. In summary, the thesis project employed the Tecnomatix Plant Simulation program to create a comprehensive visualization of a production line. The integration of KEPServerEX facilitated seamless communication between the simulation software and the PLC, enabling effective cooperation with a CNC device.

MATHEMATICAL, SOFTWARE AND HARDWARE SUPPORT OF THE CONCEPTUAL MODEL OF THE INFORMATION SYSTEM OF PRECISION AGRICULTURE

This study analyzes the current situation of application of precision farming technologies and solutions by agricultural enterprises of the Republic of Kazakhstan. The main players and used solutions have been identified. The statistics of application, as well as the potential of use is examined. Within the framework of the analysis of the applied solutions the advantages and disadvantages of competitors in the market were determined. It was defined that the applied systems provide the possibility of remote management, but EGISTIC is more focused on the management of all processes of the farm, including the warehouse, while John Deere is focused on the management and analytics of agricultural machinery. EGISTIC offers features for warehousing and inventory planning, something not found in the base version of John Deere Operations Center. John Deere focuses on data sharing which can be important for large farms or groups of farmers. EGISTIC makes extensive use of satellite imagery to analyze field conditions which can be a great asset for identifying problem areas and planning interventions. Depending on the specific needs and priorities of an agribusiness, one system may be preferable to another. If machinery management is the main focus, John Deere might be the best choice. If in-depth analysis of field conditions and inventory control is important, EGISTIC may be more appropriate. By analyzing, the directions for research are highlighted. A conceptual model of information system for precision farming is developed. Hardware for realization of the conceptual model is possible on the basis of universal programmable logic controller of modular architecture being developed. Within the limits of the given research the conceptual model of the universal programmable logic controller of modular architecture and the structural model of the software of the universal programmable logic controller of modular architecture have been developed. The interaction with the conceptual adaptive model of information and communication system is also considered. This paper analyzes the key principles and functions of both the universal programmable logic controller and the information and communication system, as well as their possible integration within a single concept.

Wine Production through Virtual Environments with a Focus on the Teaching–Learning Process

This paper focuses on the application of the hardware-in-the-loop (HIL) technique in the winemaking process. The HIL technique provides an effective methodology to test and verify the automatic control of industrial processes in 3D laboratory environments. Two parts are considered: (i) software, which consists of the virtualization of the wine process in order to generate a realistic work environment that allows the student to manipulate the system while visualizing the changes in the process; and (ii) hardware, through which the process control is implemented in ladder language in a PLC S7 1200 AC/DC/RLY (programmable logic controller). Bidirectional Ethernet TCP/IP communication is established, achieving a client–server architecture. This article highlights the main advantages of the HIL technique, such as its ability to simulate complex and extreme scenarios that would be difficult or expensive to recreate in a real environment. In addition, real-time testing of the hardware and software to implement the control system is performed, allowing for fast and accurate responses. Finally, a usability table is obtained that demonstrates the benefits of performing industrial process control work in virtual work environments, focusing the development on meaningful learning processes for engineering students.

IEC61131-3 Instruction List Language Processor for FPGAs

This paper presents the architecture and field-programmable gate array (FPGA) implementation of a 32-bit central processing unit (CPU) dedicated to programmable logic controllers (PLCs). The CPU instruction set directly matches the instructions of the IEC 61131-3 standard Instruction List (IL) language. The designed IL processor is capable of handling 1-bit, 8-bit, 16-bit, and 32-bit data types. Apart from integer arithmetic operations, the IL processor also performs single precision floating-point operations included in the IEC 61131-3 IL language specification. It also directly performs instructions with a parenthesis modifier for all supported data types and facilitates the fast execution of a code containing Boolean expressions. This paper also presents the performance evaluation results of the developed IL processor. Although the IL processor executed the test algorithms substantially faster than industrial PLCs (e.g., Siemens S7-1200 and Fanux VersaMax), it turned out to be significantly slower than high-performance programmable automation controllers (PACs).

Low-Cost Solution for Adding Safety Functions to Programmable Logic Controllers (PLCs)

Increasing requirements in automation and production make control systems more complex and vulnerable to failure. Breakdowns can cause delays in production, material damage, and above all, work-related accidents. For this reason, directives and legislation have been created at the country, European Union, and global levels that define the essential safety and requirements of industrial equipment. Guidelines must be observed by those involved in the design, supply, purchase, or use of industrial equipment in the European Union and several countries outside the European Union. Some guidelines (CAT, SIL) are created to ensure their safe operation in case of failure of both the hardware and the software. For a reliable operation of a fail safety system together with a system operating at SIL2 or SIL3, it must have Safety hardware and software. Industrial equipment manufacturers are incorporating security features into a variety of devices. Depending on the Safety Integrity Level (SIL) requirements, these features can be used during the design phase to increase safety in the event of failures or malfunctions. With proper design, the process as well as its environment (including people) can be protected by entering a controlled safe state. Manufacturers have approached this problem in a number of ways, including adding redundant Central Processing Units (CPUs), using special hardware to interface input and output signals, and developing secure network protocols for communication. Unfortunately, these features cannot be added to existing machines, at least without upgrading some hardware. As the associated costs lead to slower adoption, manufacturers rely on previous work to support certain security features, notably CPU debugging. This is implemented in the form of software libraries that operate at a low level (logic gate), designed to run on older hardware (PLC) so that they can offer an increased level of security. This study analyzes the required guidelines and legislation that must be followed for the safe operation of a production unit. It describes the mechanisms that basic and specialized PLC systems utilize to ensure the safety of an automation system. The authors have developed algorithms to record behavior measurements of electronic equipment. By further analyzing the results, it is concluded that basic equipment can be reused in these systems to provide safety functions, at the same time conserving both cost and time.

The control of proportional parqmeters helps in production and living

PLC, or programmable logic controller, is a type of microprocessor-based digital computing controller. It can be used for automatic control, storing and executing control instructions loaded into memory at any moment. In the process of classroom learning, the author learned about PLC, and the device to implement PLC is PLD, that is, a programming logic device, whose letters represent proportional controller, integral controller, and differential controller. In the process of learning, people noticed that proportional control is relatively simple compared with integral and differential control, but it is the most frequently used and widely used, so the author can't help but have a strong interest in proportional control. Through research and search, the working principle and working characteristics of the PLC were found because it has high reliability, convenient programming, adaptable setup, full input/output functional modules, and quick processing speed, which are used by many modern precision instruments. In the process of research, it was found that it was the K value that affected the proportional control, and the simulation using the false data image found that the model curve formed under different K values was also very different. Therefore, the research topic of this paper is the transformation of different graphics caused by the change of proportional control K in the PLC. The plots obtained by different K values are different, and the advantages and disadvantages of proportional control can be found.