Programmable Logic Controller Research Articles

Transient hydraulic analysis of the water delivery pipeline in mountainous areas for cascade pressurized pump stations

ABSTRACT Aiming at the problem that cascade pressurized pump stations in mountainous areas are more prone to pump shutdown accidents compared to single-stage pressurized pump stations. Various pump shutdown accidents that may occur in the pressurized water supply system of the terrace pumping station were analyzed in a targeted manner. Additionally, it was also explored that in addition to water hammer protection measures, remote-control measures for water pumps based on PLC (Programmable Logic Controller) may be used to reduce the severity of accidents. A single-factor experimental method was used to numerically analyze various accident conditions of a simplified model of a three-stage series pressurized water delivery system consisting of a water intake pump station, a midway pump station, and a final-stage pump station, without water hammer protection devices. The impact of different control variables on the transient hydraulic calculations of pumping stations at all levels was evaluated. The results showed that optimizing the precedence of shutdowns, and the sequential shutdown times of each stage pump station could be assisted to some extent in water hammer protection by the PLC. This provides technical support and detailed optimization for the scientific control of cascade booster pumping stations in mountainous areas.

Design of Automatic Flood Control System in Kulon Progo, Special Region of Yogyakarta, Indonesia

The construction of Yogyakarta International Airport has resulted in land use changes and increased the topography in the area by up to 9 m, which has led to potential flooding. A spatial analysis was conducted on the flow direction after the airport's construction, specifically in the West Carik watershed. It was discovered that the flow direction was uncertain and trapped upstream of the airport. A polder system with automation is proposed as a solution to the drainage problem. An automation system is designed for pump operation with the objective of improving efficiency. The system is expected to reduce the volume of water in the polder by reducing human involvement and providing ease in monitoring. The results of hydrological analysis with a 50-year return period flood resulted in a design flood discharge of 11.73 m3/s. The polder has a storage capacity of 63,312 m3, a depth of 4 m, and a surface area of 1.58 ha. It requires a total pump capacity of 8.4 m3/s, consisting of three pump units, with one unit having a capacity of 1.8 m3/s and two units with 3.3 m3/s. One additional pump with a capacity of 3.3 m3/s is also planned as a backup pump. The pump automation system simulation employs an Arduino UNO as the controller, water level sensor, and relay. This system successfully fulfills the desired operational system for the pump. In the actual implementation, a Programmable Logic Controller (PLC) is required as the controller, with water level sensors, relays, and contactors as inputs and outputs.

Industrial Sustainable Development: The Development Trend of Programmable Logic Controller Technology

Programmable Logic Controllers (PLCs) are indispensable for current and future industrial development, especially in smart factories, smart home technology, automated production lines, and machinery manufacturing. This study presents the trends in PLC software and hardware development through a technology roadmap and offers relevant suggestions to help industries achieve sustainable development, enhance market competitiveness, and provide references for research. Through expert interviews and fuzzy Delphi analysis, this study points out that future PLC development needs to focus on editing interfaces, syntax, Central Processing Units, Memory Units, and Communication Modules. Specific recommendations include visualizing regional/global label settings and connection settings, adding Python, JAVA, LabVIEW, and Scratch syntax, improving instruction execution speed, expanding program and expansion capacities, and adopting dual-channel Ethernet and connections to external networks and wireless networks. Fuzzy hierarchical analysis shows that Communication Modules are the most important component, followed by Central Processing Units and syntax expansion, and, finally, program and expansion capacity enhancements. These suggestions aim to promote product innovation and social environment demand evaluation, enhance product competitiveness, and achieve sustainable development goals.

A high accuracy Stewart–lift platform based on a programmable logic controller – comparative case studies

The study reports the results of a comparative analysis of advanced high-accuracy Stewart-Lift platform along with a comparative study of dynamic control. A control system powered by a programmable logic controller (PLC) was used. The properties of the system were described using a dynamic model using the Lagrange method. The real object was verified by performing several tests and comparing them using quality indicators. The results of verification tests conclusively demonstrate the system’s suitability for applications within industrial automation and robotics systems.

Intelligent Traffic Signal Management with PLC

This study introduces a Smart Traffic Light Control System (STLCS) that uses advanced technologies to improve traffic regulation. The key components include a camera-based traffic density detection module and a specialized vehicle identification system using Radio Frequency (RF) technology. The system’s core is an Arduino Uno board along with several converters and a Programmable Logic Controller (PLC). Field tests show that STLCS effectively analyses traffic density and prioritizes emergency vehicles, proving its potential for global traffic management improvements

STUDY ON AUTOMATION PROGRAMMING TO MONITOR AND CONTROL A SCREW ELECTRO-COMPRESSOR

The article describes the programming architecture of a programmable logic controller (PLC) and an operator panel that is part of an automation cabinet of a screw electro-compressor. Behind the operation of a screw electro-compressor, there is a programming logic presented in the article that is implemented according to the requirements of each project. The article presents all the states of a screw compressor that are implemented in the PLC by a programmer in the form of software sequences. The article depicts the logic diagrams used to facilitate the software implementation process. Following the software implementation in the PLC of the logic diagrams, the article has a second software that contains a series of screens for the operator panel. The operator panel is a touch-screen type and communicates with the PLC through a defined communication protocol displaying the parameter values in real time on the programmed screens. The software developed for the operator panel by a programmer has the role of facilitating a human operator to monitor parameters and transmit commands to the screw electro-compressor. The article ends by presenting the conclusions that argue the efficiency and safety in operation through the presented software concept of a screw electro-compressor.

A digital twin design and implementation approach for industrial application leveraging programmable logic controllers

A digital twin design and implementation approach for industrial application leveraging programmable logic controllers

Design analysis and development of a gantry robot for multi-layer 3-D concrete printing with simulation and experimental validation

The present study investigates the design analysis and development of a framed gantry robot (FGR) for 3-D concrete printing. Finite element simulations are performed for design validation and parameter estimation to conduct detailed analysis of the concrete printer. The kinematic and dynamic models of FGR are used for workspace analysis, motion control study, and motor sizing for printer development. The motion trajectory of the printer nozzle tip is evaluated using MATLAB simulations. An integrated programmable logic controller (PLC) with an in-built human-machine interface (HMI) through control algorithms has been implemented for interactive, user-friendly, and precise motion control. A separate control system is developed to monitor the pumping power and feed rate of mortar mix during printing. The simulated control scheme is validated experimentally using trajectory tracking for various input printing paths through HMI, with a maximum tracking error of 1 mm. Successful concrete printing trials have been conducted using various mix-design, following extensive evaluation of different printer and material parameters at the laboratory scale. The proposed design concept, mechanisms, interactive control interface, and tracking accuracy have been validated through simulation and experimental results, for ensuring quality concrete prints by the developed printer. Material testing parameters have been evaluated experimentally for modeling various mix-designs. To further evaluate printing performance, simulations of layer deformation in printed structures are conducted using finite element analysis, incorporating non-linear material models and various contact layer interactions. The simulated results of printed layers of different shapes of structures show a close resemblance with the experimental concrete printing trials.

Sistem Otomasi Untuk Menyortir Barang Pada Ruang Produksi Menggunakan Scada dan PLC

The development of the industrial revolution is progressing. Especially on production performance or machine parts. Industrial revolution 4.0 uses the internet and digitalization. So there are lots of new innovations. In a large-scale company, of course there are many tools and machines that need to be regulated whether they are on or not with regular supervision. With regular supervision, it is impossible for human workers to check one by one, thereby wasting time and reducing production levels. Therefore, it is necessary to develop a control system using PLC and HMI (Human Machine Interface) as the brain or control center for the company. In the industrial sector, PLC (Programmable Logic Controller) is an important factor in the operation of automatic machines in factories replacing relay control systems. So that PLC as a control system in the industrial sector can move machines according to needs. One part of the industry is the production room. The production room is the part where there are manufacturing materials or goods up to packaging. This research aims to design and implement a PLC (Programmable Logic Controller) and SCADA by adding sensors and actuators as output. The method used is a rule base system, the system runs according to a predetermined sequence and flow. The results of this research are the PLC, the SHT 20 temperature and humidity sensor can produce temperature and humidity values, the capacitive photosensor can detect items with 35 trials accurately but the distance is limited to only 27cm, the proximity sensor can only detect metal objects by attaching to the sensor and The actuator in the form of a stepper motor can run according to the commands given and is well integrated into the HMI (Human Machine Interface).

State of the Art and Future Trends in Monitoring for Industrial Induction Heating Applications

Induction surface hardening (ISH) processes are widely used in the heat treatment of numerous industrial components, especially in the automotive industry. Since this industry operates under very demanding quality standards, it is crucial for these heat treatment processes to meet rigorous specifications to ensure the safety and reliability of the produced components. This implies the precise and repeatable control of certain parameters throughout the manufacturing process of each of the parts treated, through precise and reliable instrumentation in electromagnetically harsh environments. The main objective of this work is to define the monitoring process for an industrial IHS application, determining the control needs and the methods of measurement, recording, and verification of the parameters that ensure the quality of the process. This paper describes the monitoring process of induction surface hardening, emphasizing the use of sensors and modern measurement and control systems. A comprehensive monitoring system supported by a programmable logic controller (PLC) and mixed acquisition and instrumentation systems (analog and digital) implemented with a high-performance Field Programmable Gate Array (FPGA) will be presented.

Study of an auxiliary trimming device for cracked carrots

AbstractCracked carrots account for a large proportion of defective carrots, which are usually discarded or used as feed, resulting in resource waste and economic benefit loss. Cracked carrots can be used as raw materials for further processed carrot products after being trimmed. So, an auxiliary device was developed combining PLC (Programmable Logic Controller) and machine vision to achieve clamping and crack defect localization for intelligent trimming of crack defect. The carrot was orientated based on the area method, rotated by flexible jaws and a rotating cylinder to make the carrot head and tail aligned. The clamping device could non‐destructively clamp carrot in axial and radial direction with a force threshold of 10 and 22 N respectively, and rotate carrot to make the crack defect upwards. The results showed that the recognition accuracy of carrot head and tail orientation was 98%, the average deviation of carrot centroid clamping position was less than 9 mm at a speed of 300 mm/s, the rotational positioning time was less than 3 s and the number of adjustments were no more than 2 at a motor speed of 180 rpm, which could meet the subsequent trimming requirements.Practical applicationsTrimming the cracked area of carrots can reduce bacterial growth and decay, which is beneficial for subsequent processing and reduces resource waste. This article designs a carrot auxiliary trimming device, which uses image processing technology to recognize the orientation of the head and tail of carrots and the cracked area, and uses automated equipment to achieve stable clamping of carrots and make the cracked area face the trimming tool. This study is beneficial for the refined management of agricultural products.

Analisis Sistem Kinerja PLC Pada Air Dryer di Unit Utilities PT. X

The refinery process in PT. X relies on several supporting units, including the air dryer in the utilities section, which is essential for removing water content from compressed air to support refinery operations. This research aimed to analyze the performance of the Programmable Logic Controller (PLC) system in the air dryer units (A, B, C, and D), each comprising two towers that can operate alternately or simultaneously. The conventional TM series controller was replaced with a Schneider Electric Modicon M340 PLC to enhance system reliability and digitization. A methodical approach was adopted, beginning with data collection from sensors connected to the PLC, followed by processing the data using predefined logic instructions. The research findings indicated significant improvements in operational efficiency, response time, and energy consumption with the PLC system compared to the TM series. The PLC system also facilitated continuous and precise control of the drying and regeneration processes. These findings underscore the importance of adopting advanced PLC systems to ensure higher operational efficiency and reliability in industrial applications. Consequently, this research advocates for the comprehensive upgrade of conventional control systems to PLCs in similar industrial settings.

PLC Based Automatic Bottle Filling System

Abstract: Introducing a cutting-edge solution for beverage industries, our paper unveils a revolutionary bottle filling machine employing state-of-the-art Programmable Logic Controller (PLC) technology. Crafted with simplicity and efficiency in mind, this compact system seamlessly integrates a conveyor belt for bottle transportation and a precision DC pump to regulate water flow with unparalleled accuracy Operating with finesse, an infrared sensor precisely detects bottle positions, triggering the pump to commence filling precisely at the opportune moment. Once the bottle is detected, a secondary sensor halts the conveyor, initiating a 15-second pump operation optimized for filling up to 800ml bottles swiftly and flawlessly. Upon completion, the pump gracefully ceases, and the conveyor resumes its smooth operation Notably, our system is designed with user convenience at its core. A dedicated stop button empowers operators to halt operations instantly, ensuring safety and control. With each component meticulously optimized for performance and reliability, our cost-effective filling machine stands as a beacon of innovation, poised to revolutionize small-scale beverage enterprises, from cozy coffee shops to bustling juice bars and beyond.

Expert Twin: A Digital Twin with an Integrated Fuzzy-Based Decision-Making Module

Digitalization and the application of modern Industry 4.0 solutions are becoming increasingly important to remain competitive as product ranges expand and global supply chains grow. This paper presents a new Digital Twin framework to achieve robustness in manufacturing process optimization and enhance the efficiency of decision support. Most digital twins in the literature synchronously represent the real system without any control elements despite the bidirectional data link. The proposed approach combines the advantages of traditional process simulations with a real-time communication and data acquisition method using programmable logic controllers designed to control automated systems. In addition, it complements this by utilizing human experience and expertise in modeling using Fuzzy Logic to create a control-enabled digital twin system. The resulting "Expert Twin" system reduces the reaction time of the production to unexpected events and increases the efficiency of decision support; it generates and selects alternatives, therefore creating smart manufacturing. The Expert Twin framework was integrated, tested, and validated on an automated production sample system in a laboratory environment. In the experimental scenarios carried out, the method production increased production line utility by up to 28% and the number of re-schedules can be halved.

Development of programmable logic controller algorithms for database communication

The present paper provides a brief overview of the possibilities which can arise when outsourc-ing some of the more advanced functionalities usually developed for computers to a programma-ble logic controller. This approach is still being examined to fulfil its aim of improved communi-cation capabilities and provision of effective tools for advanced intelligent control systems. The paper, further, sets out to give an example of one such algorithm which is built upon the MySQL protocol.

Design and Development of Fractional Order Convolutional Neural Network Based Fractional Order Nonlinear Reactor Power Simulator for CANDU-PHWR

A highly complex nonlinear Reactor Regulating System (RRS) of Canadian Deuterium Uranium Pressurized Heavy Water Reactor (CANDU-PHWR) based Nuclear Power Plant (NPP) simulated in the present research. The internal design of RRS is secured and vendor controlled which is embedded in AC-132 Programmable Logic Controller (PLC). Therefore, the problem of the identification of the RRS controller model is addressed. A data-driven Fractional Order Nonlinear MIMO Hammerstein Model (FO-NC-MIMO-HM) of NPP is identified using an Adaptive Immune Algorithm (AIA) based on a Global Search Strategy (GSS) and Auxiliary Model Recursive Least Square Method (AMRLSM). Parameters of FO-MIMO-HM are identified using Innovative Real-Time Plant Operational Data (IRTPOD). The original PLC-based controller is replaced with a new Fractional Order Convolutional Neural Network (FO-CNN) based Fractional Order Nonlinear Controller (FO-NC). Therefore, a visual Simulator is developed for detailed modeling, control, simulation, and analysis of the proposed design scheme for RRS in Visual Basic (VB) Software. The performance of the proposed design scheme is tested and validated for different modes of RRS against benchmark data obtained from Plant Data Recorder (PDR) and found in close agreement well within the design bounds.

Development and Integration of a Digital Twin Model for a Real Hydroelectric Power Plant.

In this study, a digital twin model of a hydroelectric power plant has been created. Models of the entire power plant have been created and malfunction situations of a sensor located after the inlet valve of the plant have been analyzed using a programmable logic controller (PLC). As a feature of the digital twin (DT), the error prediction and prevention function has been studied specifically for the pressure sensor. The accuracy and reliability of the data obtained from the sensor are compared with the data obtained from the DT model. The comparison results are evaluated and erroneous data are identified. In this way, it is determined whether the malfunction occurring in the system is a real malfunction or a malfunction caused by measurement or connection errors. In the case of sensor failure or measurement-related malfunction, this situation is determined through the digital twin-based control mechanism. In the case of actual failure, the system is stopped, but in the case of measurement or connection errors, since the data are calculated by the DT model, the value in the specified region is known and thus there is no need to stop the system. This prevents production loss in the hydroelectric power plant by ensuring the continuity of the system in case of errors.

Biogas production performance using soybean residue and hydrothermal pretreated food waste hydrolysate in a continuously anaerobic two-stage pilot plant

In this study, a continuously anaerobic two-stage pilot plant was established for bioenergy production, comprising 5 major pieces of equipment: a mixing tank, 1st anaerobic digester (AD), 2nd AD, sediment tank, aeration tank, and final sediment tank, all operating at ambient conditions. The operation of the continuously anaerobic two-stage pilot plant was automatically controlled by a programmable logic controller (PLC) using a designed control logic concept to set the hydraulic retention time (HRT) and inlet substrate concentration. The organic loading rate, pretreatment of hydrolysis pressure, and microbial community analysis were investigated for their effects on biogas production performance using different substrates: soybean residue (SR) and food waste hydrolysate (FWH), respectively. It was found that the peaks of biogas production rate on daily volumetric feeding were 1.20 m³·m⁻³·d⁻1, and the biogas yield on VS added was 760 dm³·kg⁻1 from food waste hydrolysate with a pretreatment hydrolysis pressure of 10 kg·cm⁻2, at an OLR in COD concentration of 3.56 kg·m⁻³·d⁻1, and an HRT of 11 days, respectively. The Methanobrevibacter genus was found to be abundant in the 1st AD, approximately 6.7 times more abundant than in the 2nd AD. The continuous anaerobic two-stage pilot plant was properly examined for its application in treating food waste and soybean residue with the goal of obtaining renewable bioenergy.

Design and Construction of a Portable IoT Station.

This paper discusses the design and implementation of a portable IoT station. Communication and data synchronization issues in several installations are addressed here, making possible a detailed analysis of the entire system during its operation. The system operator requires a synchronized data stream, combining multiple communication protocols into one single time stamp. The hardware selected for the portable IoT station complies with the International Electrotechnical Commission (IEC) industrial standards. A short discussion regarding interface customization shows how easily the hardware can be modified so that it is integrated with almost any system. A programmable logic controller enables the Node-RED to be utilized. This open-source middleware defines operations for each global variable nominated in the Modbus register. Two applications are presented and discussed in this paper; each application has a distinct methodology utilized to publish and visualize the acquired data. The portable IoT station is highly customizable, consisting of a modular structure and providing the best platform for future research and development of dedicated algorithms. This paper also demonstrates how the portable IoT station can be implemented in systems where time-based data synchronization is essential while introducing a seamless implementation and operation.

An Automatized Rebalancing System to Address Faradaic Imbalance and Prolong Cycle Life in Alkaline Ferrocyanide – Anthraquinone Redox Flow Batteries

AbstractAqueous Organic Redox Flow Batteries are a family of promising energy storage systems. However, they face various challenges related to their lifetime, such as the Faradaic imbalance due to the occurrence of parasitic reaction leading to the fading of its energy storage capacity. Herein, automatization of a rebalancing system to reverse the detrimental effects of Faradaic imbalance due to the unavoidable presence of small quantities of oxygen in the negative reservoir or hydrogen evolution reaction is developed and implemented in an alkaline flow battery. A membrane‐free rebalancing cell is proposed to promote the oxygen evolution reaction and reverse the accumulated charge in the catholyte showing a 100 % coulombic efficiency. The programmable logic controller monitors the open circuit voltage to calculate the charge stored in each charge/discharge step and closes a circuit so a fixed voltage is applied to the rebalancing cell when the battery needs to be rebalanced. The system is tested using an alkaline flow battery consisting of ferrocyanide and 2,6‐dihydroxyanthraquinone, improving the energy capacity retention from 0.27 % cycle‐1 and 0.47 % h‐1 without rebalancing system to 100 % retention after >850 cycles and >24 days (without Ar‐filled glovebox), demonstrating the feasibility of this proposed system to address the Faradaic imbalance.