Programmable Logic Controller Research Articles

Proposal of a control scheme for testing a centrifuge-based pellet injection system in DIPAK-PET

The envisaged Pellet Engineering Testbed (PET) in the framework of Direct Internal Recycling Integrated Development Platform Karlsruhe (DIPAK) will provide unique opportunities to advance pellet injection technology and its implementation in the fuel cycle as well as into plasma control of EU-DEMO. This work analyses the parameters for Pellet Launching System (PLS) control according to requirements from plasma control. Main parameter is the particle flux and the related accuracy with respect to amount of flux and arrival time of pellets. Others are addressed as well like dynamic response to setpoint changes and adaptivity of isotope composition of the hydrogen ice. The performance of the PLS is limited by the mass loss in the guiding tubes, both by erosion (applies to any pellet) and loss of an entire pellet, that may apply to only a few pellets, provided a suitable guiding tube geometry is selected depending on the required injection speed. DIPAK-PET has to provide data points in order to enable proper guiding tube design activities based on modelling. A short description of the proposed technical solution for the Pellet Launching System is provided and setup for the Programmable Logic Control (PLC) is suggested comprising a MasterPLC and a dedicated Human Machine Interface (operators’ desk). A non-exhaustive proposal of experiments to be performed in DIPAK-PET is listed in order to verify the estimated performance values for the relevant PLS parameters.

ADVANCED AUTOMATIC SYSTEM FOR REMOTE CONTROL IN THE OIL AND GAS INDUSTRY

The purpose of this work is to design and implement a cascade control system of the level with the flow rate, with remote supervision, in an industrial type installation, located in the Laboratory of Measurement Techniques, Department of Automation, Computers and Electronics, within the Faculty of Mechanical and Electrical Engineering. The operating parameters of the installation are as follows: suction pressure: 0 – 2 bar; discharge pressure: 0 -10 bar; water flow: 0-30 m3/h; transported liquid: water. The automation system is structured on three hierarchical levels: level 1: the instrumentation mounted on the installation (transducers, signaling devices, etc.); level 2: includes the TGA System; level 3: constitutes the upper hierarchical level and includes the HMI (Human Machine Interface). The TGA system is a computerized system that ensures the monitoring, command and control functions of all the stand's component elements. It contains a programmable logic controller PLC 1214 – Siemens, which communicates via an Ethernet IP network with an operator interface and with the network of the Faculty of Mechanical and Electrical Engineering, which allows remote control of the installation. It also includes the protection system in case of failure, which involves stopping the rotating equipment, isolating the pipes by closing the control valve and alarming the operators. The HMI (Human Machine Interface) interface presents 3 options on the start page, from where the operator can select which application he wants to test: flow control loop application; level adjustment loop application; cascade adjustment loop application. The HMI equipment integrates SCADA functions, database update, evolution curves of analog quantities, sound and monitor alarm system, keyboard command, periodic records, event records, alarm records and technological schemes at the human-machine interface. The entire software is made in an open architecture, recommended by ISO norms. The PLC communicates in the network by adopting the protocol TCP/IP. An executable program used for the real-time application program was developed.

Simulation of a liquid propellant rocket engine manufacturing assembly line utilizing the PFS/PN methodology

The system addressed in this paper pertains to an assembly line for liquid propellant rocket engines equipped with turbopump. The challenge involves automating the process of metal 3D printing for the turbopump and combustion chamber, followed by heat treatment for stress relief, X-ray computed tomography inspection, and the subsequent movement of components throughout the factory. To achieve this, the PFS/PN methodology was employed to facilitate a detailed analysis of the system, ensuring control over its inputs and outputs. The system was simulated using the ProModel Discrete Event Simulator, and the results were scrutinized, indicating the robustness of the simulation. Following the Ladder methodology, programming for Programmable Logic Controllers was also developed.

ADAPTABILITY IN INDUSTRY 4.0: SERVICE-ORIENTED ARCHITECTURE TO DEPLOY ARTIFICIAL INTELLIGENCE ON INDUSTRIAL AUTOMATION

Industry 4.0 represents a revolution in the business environment, driving the integration of information technologies and industrial automation, with the main objective of reducing latency in decision-making. Artificial Intelligence (AI) plays an essential role in advanced data analysis and resource optimization, allowing accurate predictions and agile decisions, however its implementation presents challenges, such as algorithm complexity and integration with industrial automation systems. An innovative solution to overcome these challenges is the implementation of a service-oriented architecture, which creates modular and interoperable systems, a concept especially relevant in the practical application of industrial automation, in which the integration between Information Technology (I.T) and Automation Technology (A.T) is crucial. This work presents, through experimental research, an innovative solution based on the development of a computer vision application, isolated in a Docker container. This application is designed to inspect the assembly of parts by a robotic system and establish communication with a Programmable Logic Controller (PLC) to approve or disapprove the assembly. The results of the adopted architecture demonstrate a flexible approach that simplifies the operation of AI systems, allowing operation with both AI enabled and disabled, reducing potential disruptions to the workflow. This research promises to open paths for future innovations and advances in the field of industrial automation and Artificial Intelligence, offering a model that effectively combines the agility of AI with the robustness of automation.

Principles of Constructing a HIL Simulation Stand for Debugging Automated Process Control Systems based on the Baget PLC

The problem of constructing a HIL simulation stand for researching a technological process using programmable logic controller (PLC) "Baget" is described in this article. Issues of modeling technological processes are currently extremely relevant, since modeling is a mandatory stage in the automated process control systems development. An adequate model of the technological process allows debugging and verification of automated process control system algorithms without using real equipment, reducing financial costs and the probability of emergency situations. The HIL modeling method involves partial use of real equipment as part of the model. The inclusion of standard components of the original object in the model does not require detailed mathematical model and at the same time provides a more complete correspondence to the original. Due to using a computer from the original object, the stand software operates under conditions close to the real technological process, which improves the quality of the simulation results. The HIL modeling stand includes the following components: control computer of automated process control system; programmable logic controller PLC "Baget"; simulation computer. The stand for the basic element of an automated process control system allows to speed up the process of prototyping and debugging even in the case of complex systems, because it will be easier to build the entire system from correctly functioning elements. Another advantage of this approach is that the stand is not tied to a specific type of technological process or to a narrow area of production — the stand allows the use of ready-made models, the development of new models, and the inclusion of various function libraries. The simplicity of the stand design with this approach is combined with a full range of functionality. By connecting additional software, you can create more complicated and detaild model. This stand is also capable of serving both for debugging PLC algorithms and as a simulator for maintenance personnel of a real control object, because the stand operator can simulate failures and errors of standard equipment, emergency situations at the control object. Using C and JavaScript programming languages for development ensures portability and ease of expanding the capabilities of the modeling software. The development of complex systems based on HIL modeling allows saving resources and effectively solving assigned problems, therefore the proposed approach to building stands will be in demand in the process of developing an automated process control system based on the PLC "Baget".

МАТЕМАТИЧЕСКАЯ МОДЕЛЬ ТЕХНОЛОГИЧЕСКОГО УЧАСТКА МАГИСТРАЛЬНОГО ТРУБОПРОВОДА С РЕГУЛИРОВАНИЕМ ДРОССЕЛИРОВАНИЕМ

The aim of the work is to develop a mathematical model of the technological section of the main pipeline, which reflects the main hydraulic processes in the pipeline, namely Q-H characteristics of pressure and main pumping units, their connection diagrams, characteristics of the electric drive part, characteristics of the linear part (length, diameter, thickness of the pipeline ), shut-off linear valves, throttling valves, including a frequency converter, an electric motor with a gearbox and a hydraulic part (flow characteristic). The task is to develop a mathematical model of the main pipeline technological section for further use as part of a simulation stand for an automatic pressure control system (APCS). Research methods are used such as the system analysis method, technical hydraulics, mathematical modelling of operating the main oil pipeline section, considering the switch on and off of the main pumping units and changes in the opening degree of the throttling unit. The research results state that the developed mathematical model of the main pipeline technological section takes into account the basic hydraulic processes and can be used in the simulator software for automatic pressure control systems. The novelty of the work consists in building a mathematical model of the main pipeline technological section with throttling control, adapted for real-time operation for the simulator programmable logic controller. The paper findings state that the proposed mathematical model of the main pipeline technological section with throttling control has some assumptions necessary for the software to operate in real time and reflects the main hydraulic processes occurring in the oil pipeline. Switching the main pumping units and control valves is successfully modelled. The simulation results can be used in the computer program for the software and hardware complex (SHC) of the automation testing simulator and the SHC for setting up the APCS.

Experimental Investigation of a Hybrid Device Combining a Wave Energy Converter and a Floating Breakwater in a Wave Flume Equipped with a Controllable Actuator

This paper presents a hydrodynamic investigation carried out on the “Wave Attenuator” device, which is a new type of floating breakwater anchored with piles and equipped with a linear Power Take Off (PTO) mechanism, which is typical for wave energy converters. The device is tested in the wave flume, under regular waves, in slightly non-linear conditions. The PTO mechanism, that restrains one of the two degrees of freedom, is simulated through an actuator and a programmable logic controller with preassigned strategy. The paper presents the system identification procedure followed in the laboratory, supported by a numerical investigation essential to set up a credible control strategy aiming at maximizing the wave energy harvesting. The maximum power conversion efficiency under the optimal PTO control strategy is found: it is of order 50–70% when the incident wave frequency is lower than the resonance one, and only of order 20% for higher frequencies. This type of experimental investigation is essential to evaluate the actual efficiency limitations imposed by device geometry.

A Novel Resistive Sensor Network Utilizing an SAP-Enhanced Ionic Layer and CNT Doping for Multipoint Pressure Measurement.

Amidst the rapid advancements in flexible electronics, flexible pressure sensors have achieved widespread applications in fields such as wearable devices and motion monitoring. Nevertheless, it is still a challenge to design a sensor with high sensitivity, cost-effectiveness, and a simplified manufacturing process. This paper introduces a piezoresistive sensor built upon a composite conductive filler. The sensor incorporates a super absorbent polymer (SAP) to absorb a phosphoric acid solution and doped carbon nanotubes as the composite conductive filler. In contrast to conventional rigid conductive fillers, the elastic polymer SAP enhances the sensor's stability significantly by exhibiting superior compatibility with the polydimethylsiloxane matrix, all the while reducing its Young's modulus. This work aims to theoretically elucidate the underlying principles that enable the sensor to achieve high sensitivity. It focuses on the induction of charge carriers due to pressure, which leads to the formation of a conductive pathway and subsequent changes in resistance, thus facilitating precise pressure detection. The paper also discusses the effects of piezoresistive layers with varying thicknesses and conductive fillers on the sensor's output performance. The results highlight the sensor's high sensitivity (0.094 kPa-1), rapid response time (105 ms), and exceptional cyclic load/unload stability (>5000 cycles). Furthermore, this paper establishes a versatile sensing network by integrating a portable inductance, capacitance, and resistance instrument with a programmable logic controller module. Compared to individual sensors, this system enables multipoint measurements, offering high spatial resolution and real-time monitoring capabilities, significantly expanding its overall practicality.

The Role of PLC in Automation, Industry and Education Purpose: A Review

Programmable logic controller (PLC) plays a significant role in every era, either it is in field of automation, industry or educational purposes. As the demand for automation grows exponentially, control systems need to be easy to program, flexible, reliable, and cost-effective. This article provides an overview of PLC implementation in automation, industry, and education. This article reviews an investigation into the role of PLC in automation, industrial, and educational goals. PLC has its own limitations, but research shows that it has more benefits than limitations. After survey it will see that the PLC can be used in any application, either it is simple or complex control systems. The analysis conducted and focuses on the concept, operation, advantages and practical applications of PLC, as well as comparison with other control systems.

Application research of BP neural network PID in control system of heat exchange station

In the direction of better resolution of time lag, nonlinearity and uncertainty in the heating system, a BPNN-PID (BP neural network PID) controller is proposed in this paper. A complete heating auto-control system is designed with the experimental platform of a university heat exchange station in Zhangjiakou as the research background. The auto-control system takes Programmable Logic Controller (PLC) as the control core, uses BPNN algorithm to optimize the PID control parameters, and finally takes outlet temperature of 1# plate exchanger as the main control parameter to conduct experimental research on BPNN-PID control and single-loop feedback control respectively. The results show that compared with the single-loop feedback controller, the PID control based on BPNN algorithm has superior control quality, with shorter adjustment time, smaller overshoot, finer control accuracy and stability.

MODEL-BASED METHODOLOGY FOR DESIGNING AUTOMATED WORKPLACES

The article deals with model-based methodology for designing automated workplaces with control systems using programmable logic controllers. A categorization of some development methodologies and simulations of automated system control is presented. In the case study, a model of the controlled system is created, which is used for control simulations of the designed control system. The developed control system can thus be tested on this model, and any failure will thus only indicate possible errors in the control program or in the control hardware. Accordingly, it is then possible to modify the control system without the risk of possible damages or disasters. With this methodology, it is possible to implement control system training, especially in the case of dangerous and risky applications.

Assessment of Petri nets Regulation Control methodologies for automation systems

Industry 4.0 and smart manufacturing bring new interesting possibilities and challenges, a particular one is the large-scale automation with minimal set-up time and flexibility. To face this challenge, control approaches based on Discrete Event Systems (DES), such as Supervisory Control Theory (SCT), Generalized Mutual Exclusions Constraints (GMEC) and Petri net-based Regulation Control (RC), may provide convenient solutions; however, few works have been reported in the literature describing the application of these approaches. In this work, the RC approach based on Petri nets is applied to three case studies: (1) an electro-pneumatic cell controlled by a Programming Logic Controller device (PLC); (2) a simulated hydraulic process controlled by a PLC (a virtual commissioning scheme); (3) a simulated robotic manufacturing cell controlled by a software tool. In addition, an assessment of the existing methodologies in RC for modelling, specification, control synthesis and control implementation is conducted. The findings of this work provide three contributions: (1) a practical validation of the applied methodologies and the identification of required extensions; (2) a discussion about the validity of frequently considered assumptions and hypotheses in DES; (3) a reference for practitioners on the implementation of the RC approach, as well as its limitations and advantages.

A High-interaction Physics-aware ICS Honeypot for Industrial Environments

Industrial Control Systems (ICSs) are control systems that automate and control industrial processes. ICSs have a high-security risk since most of them are connected to the Internet for remote monitoring and controlling purposes. Compromising ICS can disrupt critical infrastructure supplies, such as water supply, power supply, transportation systems, and manufacturing systems. Programmable Logic Controllers (PLCs) are special computers used in ICSs. Many PLCs do not have built-in security systems. Many ICS application layer protocols are not designed with security in mind. Therefore, external security systems are needed to protect ICSs from cyber-attacks. Identifying the vulnerabilities, malware, and attacking patterns is useful in designing defense-in-depth security systems for ICSs. Honeypots can be used for research purposes as a way of collecting data and can also be used to protect the systems from attackers. In this paper, we present a high-interaction physics-aware ICS research honeypot that has been extended to a production honeypot using Software Defined Networking.

Design of Programmable Logic Controller (PLC) on Smart Fertilizer Distribution System

The control system in agriculture is an important study to regulate the application of fertilizers to plants. The control system can use PLC control system which has good system robustness and easy program language. The purpose of this research is to design a simulated fertilizer irrigation system based on a programmable logic controller (PLC) system. The PLC program used is CX-program and the simulator circuit uses Fluidsim simulator. The system components used are the main reservoir, pump, solenoid valve, valve, level sensor, and light indicator. The system is organized by dividing inputs and outputs that are directly integrated into the PLC system. The components are arranged using fluidsim and the PLC control system using CX-Programmer using ladder logic language. The control system integration and system circuitry are connected using KeepServerEX. The output of this system is a successful operation function and a digital system response to the time of the system. From the results of the system response provides a fairly good timeliness so that this irrigation system can be considered in the implementation of fertilizer delivery system

Design and optimization of automatic solar irrigation-based PLC


 
 
 Irrigation is the most important step in agriculture. In order to obtain a good agricultural crop, water must be used wisely and appropriately without waste. This article presents an automatic solar irrigation system developed and designed by the authors. The system consists of two parts: a photovoltaic water pumping system and a unit of control based on programmable logic controller. The programmable logic controller (PLC) uses two sensors: one is placed in the field to measure the moisture in the soil, while the second is used to control the amount of water in the storage unit. The photovoltaic pumping system was designed to be able to irrigate one-hectare area of henna Lawsonia inermis L. with daily water need of 33 m3/day and total dynamic head (TDH) of 14 m. The region opted for this study and analysis is 34°41.1’ N latitudes and 6°29.6’ E longitudes in Zribet el Oued-biskra, Algeria.
 
 

Robotic inspection and automated analysis system for advanced manufacturing

Companies have developed various systems to improve their processes. These processes’ focus has been to produce more quantity in less time. To accomplish this task, it is important to also consider defects. Defective products can cause delays in the production line, rework, and the loss of money, time, and resources. This project focused on developing an integrated inspection system. Previous research has been done regarding types of vision systems, in-line inspections, and feedback data collection. A programmable logic controller (PLC) was used to control when the conveyor belt starts and stops. When the object has reached a certain position, the camera detects if the object passed or failed the process. If the object fails, the robot will pick up the bottle and take it out of the line. Human-machine interface (HMI) was also integrated, which shows how many bottles have passed and failed with a light that will indicate if a certain object has passed or failed. Feedback from the inspection process can help solve potential issues from different machines and processes. The testbed was designed, integrated, and tested in the paper to perform a feedback analysis for the production line. The setup consisted of MicroLogix PLC, Fanuc robot LR Mate 200iD and Cognex camera.

PLC Controlled Assembly Automation for Spot Welding Work Station

Automation has created an eminent need in the present trend of manufacturing industries to boost its throughput with reduced manual intervention and benefit in terms of good product quality, reduced scrape rate, and efficient usage of resources. Assembly process necessitates more perfection to achieve good quality products, which can only be possible by employing highly skilled and experienced operators which costs more and hence Automation is the best choice to mitigate this problem. The present work is an effort to upgrade the manual assembly station for spot welding process to assemble three sub-components called cup, fastener and mesh together through spot welding process with an automatic part handling mechanism, controlled by sensor-based Programmable Logic Controllers (PLCs). The automated assembly station resulted in flaw less welded components with reduced cycle time, which enhanced the assembly process productivity from 2 parts/min to 6 parts/min.

Improved Methodology for Power Transformer Loss Evaluation: Algorithm Refinement and Resonance Risk Analysis

The decline in power quality within electrical networks is adversely impacting the energy efficiency and safety of transmission elements. The growing prevalence of power electronics has elevated harmonic levels in the grid to an extent where their significance cannot be overlooked. Additionally, the increasing integration of renewable energy sources introduces heightened fluctuations, rendering the prediction and simulation of working modes more challenging. This paper presents an improved algorithm for calculating power transformer losses attributed to harmonics, with a comprehensive validation against simulation results obtained from the Power Factory application and real-world measurements. The advantages of the algorithm are that all evaluations are performed in real-time based on single-point measurements, and the algorithm was easy to implement in a Programmable Logic Controller (PLC). This allows us to receive the exchange of information to energy monitoring systems (EMSs) or with Power factor Correction Units (PFCUs) and control it. To facilitate a more intuitive understanding and visualization of potential hazardous scenarios related to resonance, an extra Dijkstra algorithm was implemented. This augmentation enables the identification of conditions, wherein certain branches exhibit lower resistance than the grid connection point, indicating a heightened risk of resonance and the presence of highly distorted currents. Recognizing that monitoring alone does not inherently contribute to increased energy efficiency, the algorithm was further expanded to assess transformer losses across a spectrum of Power Factory Correction Units power levels. Additionally, a command from a PLC to a PFCU can now be initiated to change the capacitance level and near-resonance working mode. These advancements collectively contribute to a more robust and versatile methodology for evaluating power transformer losses, offering enhanced accuracy and the ability to visualize potentially critical resonance scenarios.

Implementation of model predictive control in a programmable logic controller

The article is aimed at the development of modern automatic control systems, which should provide high-performance indicators in the conditions of variable operating modes of industrial equipment due to effective control structures and algorithms. The purpose of the study is to reduce the cost of the basic oxygen furnace steel, which is a consequence of the increase in the share of scrap metal due to the enhanced post-burning of CO to CO2 in the cavity, by optimal controlling the duty mode parameters using model-predictive control. The blowing mode of the basic oxygen furnace was considered as a technological object of control, and the problem of controlling blowing parameters in conditions of non-stationarity of the rate of metal decarburization was analyzed. The use of a model-predictive controller made it possible to improve the quality of control for the oxygen flow circuit by 39% and the maximum dynamic deviation of the CO2 content in the gases was reduced by 16.5% compared to the PID control. The implementation of a software-hardware control system using model-predictive control based on a programmable logic controller is considered.

Application of Delta PLC on Battery Management System in AC/DC Microgrid

To keep the energy balance and power quality in check, a proper controller must be made for all the parts of the microgrid to work together. The sizing of the microgrid is done by considering the distributed generators and their connected ACDC loads. The performance of DC will obtain according to the state of charge condition of the battery bank. So it is essential to operate the battery bank by observing the state of the charge condition. To maintain the voltage stability of the system the PLC (programmable logic controller) best switching controller is designed to operate the battery bank according to the distributed generators’ demand. The main objective of the present work is to enhance the power conversion efficiency and maintain voltage stability during essential conditions which are fulfilled by the Battery storage and its controller. It must provide effective voltage support in a fault condition.