Siemens S7-200 Research Articles

Design of Vacuum Pump Control System for Negative Pressure Shale Shaker Based on PLC

In order to improve the solid-liquid separation effect of drilling fluid in drilling operation, a new type of negative pressure vibrating screen was developed. The vacuum pump is its main component. At present, the degree of vacuum has a significant impact on the screening effect and working efficiency of the negative pressure vibrating screen. The value of the vacuum is based on experience, the setting parameters are not adjustable, or changing via the manual adjustment, and the control precision and the degree of intelligence are low. The system of the negative pressure vibrating screen vacuum pump control was designed with the moisture content of the filter cake as the controlled variable. The mathematical model between the moisture content and the vacuum degree of the filter cake was established. The fuzzy PID was studied by using Siemens S7-300 PLC as the controller. Control the law, build a control system based on the inverter as the actuator, and control the vacuum degree according to the drilling fluid quality in real time. The field application shows that the steady state error of the system is 11.1%, which meets the drilling operation requirements.

Comparison of the reliability of programmable logic controller and electromagnetic relay control in industrial production line

This paper is aimed at determining the reliability of Industrial Production Line using Programmable Logic Controller. Production lines in the manufacturing sector are automated using Programmable Logic Controller module, which is programmed using programming software. The programming software used is the Siemens S7-200 while the programming language is the Ladder Programming language. Most manufacturing industries in Nigeria today still use relays for control purposes. The wirings from the control panel are so massive that any fault from the machine usually takes hours to trace and replace using the traditional electromagnetic relay. Alternative and better control methods use Programmable Logic Controller. Research articles on the reliability of PLC in a food production line are scarce. This paper is written to address this gap. The study uses the statistical analytical method, which provides useful and higher accuracy of the result as it allows high tolerance to uncertainties. The study determines the failure rate, the mean time between failures (MTBF), mean time to failure (MTTF), and availability as a means of determining the reliability of the network. Accordingly, the study showed that the mean availability of the Production line using PLC for three consecutive years is 84% while the reliability is 86%. Consequently, the use of PLC should be encouraged in industrial automation as the fault can be detected easily, thereby reducing downtime as compared to the use of electromagnetic relay in the control circuitry. Keywords: Programmable logic controller, availability, reliability, ladder programming language, relay logic

Construction design system of constant pressure control in water distribution system with PID method using PLC based on IoT

The objective of this research is to make a constant pressure control in water supply with the method of PID using PLC Siemens S7-1200 as a controller and also to monitor the process of its work system from a distance through the internet of things (IoT). The water distribution system is created utilizing 3 phase pump which will supply water from the tank. The pressure sensor will be used as an analog input signal of PLC to detect the pressure of water in the pipe. Using inverter, water pressure will be kept constantly matched with the desired set point through the setting of pump speed using the digital PID method that is available on PLC. The score of the set point is done through HMI of touch panel KTP700basic. By using Wi-Fi communication that has been connected to the internet, PLC data can be sent to a cloud server through raspberry pi3 using the MQTT protocol. Raspberry pi3 program is designed using the java script coding language. Research result showing that this system can keep the water pressure at a constant level of 1.2 bar in the water supply. It is also able to monitor the water pressure through HMI and handphone via IoT Technology in the GoIoT server.

Design of Communication Among Vision System, PLC and Industrial Robot based on Modbus-TCP protocol

In order to solve the problems of small system, single machine and single function operation of industrial robots and improve the automation of the system, Modbus-TCP protocol is used as communication platform to realize data exchange among industrial robot, vision system and main control PLC, and an automatic assembly control system composed of Siemens S7-1200 PLC, industrial robot, vision system, conveying line and assembly line is constructed. The application of the system in automatic identification and assembly line will improve production efficiency and reduce labor costs.

Diseño y construcción de un acoplamiento electrónico para realizar conexiones de IoT en un PLC convencional

The growth of the digital industrial technology (Industry 4.0) is a revolution that makes it possible to gather, control and analyze data about several technical procedures. The result of this manufacturing revolution is the higher-quality products being produced at a lower cost. It is becoming increasingly difficult to ignore the role that Internet of Things (IoT) has in the productive processes, however, this technology is expensive and requires an update of the Programmable Logic Controllers (PLCs). This paper will focus on the update of the design and construction of an electronic coupling device to make IoT connections in a conventional PLC. In this work a siemens S7-200 PLC is used, in the inputs and outputs of this device a nodemcu esp32 WIFI card is coupled to monitor and control the process. The electronic circuit and the flow diagram of the coupling between the PLC and WIFI card are included. The evidence from this study suggests that the upgrade of the industrial equipment towards the industry 4.0 is possible without the need to make significant changes.

Design and Implementation of SCADA System for Sugar Production Line

SCADA is the technology that allows the operator to gather data from one or more various facilities and to send control instructions to those facilities. This paper represents an adaptable and low cost SCADA system for a particular sugar manufacturing process, by using Programmable Logic Controls (Siemens s7-1200, 1214Dc/ Dc/ Rly). The system will control and monitor the laboratory production line chose from sugar industry. The project comprises of two sections the first one is the hardware section that has been designed, and built using components suitable for making it for laboratory purposes, and the second section was the software as the PLC programming, designing the HMI, creating alarms and trending system. The system will have two HMI screens according to the two operating states of system (Automatic and Manual), the operator can choose between them by a selector switch, this method helps the operators when fixing a failure and wanting to check it without operating all the process. The result has accomplished the goals of controlling, the parameters (temperature, flow, humidity) were monitored, failure was detected by an alarm.

Automatic Control for Fluorite Floatation Process

According to the conditions of the low level of automation and low laboratory productivity, an automatic control system for flotation process was designed and developed innovator based on the SIEMENS S7 PLC series software and hardware. The structure and function of the control system are introduced carefully. The control strategies of the pulp level the air flow-rate and the flotation reagent feeding are described in detail. The control software and human-machine interface are designed and developed. The actual industrial application results show that the control system operates steadily, safely and reliably, the worker labor intensities are decreased obviously, and the work condition is improved the competitiveness of the enterprise is enhanced. The method can automatically adjust the reagent feeding when the work-condition varies, so that the technical indexes can be controlled within their target ranges. The successful application has shown that the proposed method has practical significance and high potential of being further applied in optimal control of mineral industry.

Design on Monitoring and Controlling System of Blast Furnace Recovery of Waste

A constant temperature and variable flow control system was designed for that blast furnace slag is not continuous and water temperature largely fluctuated , which included hardware and software . Data acquisition module in the hardware part used Siemens S7-300 series PLC. The software part used Wincc and Step7 to realize system configuration and the data acquisition for respectively. The system is verified by experiments. The results show that the system has the characteristics of stable running, easy to operate and maintain. It can realize the function of real-time monitoring of residual heat in B. F. waste water to ensure that system can be run under the optimal conditions.

Control System Design of Microwave Load Water-Cooling for Spacecraft Thermal Vacuum Test

The microwave energy released by satellite transponder in the vacuum heat test needs to be converted into heat energy and dissipated through the water-cooling system. To dissipate this heat energy, a microwave load water-cooling system is designed, which realizes the automatic operation and remote monitoring of the water pump and refrigeration unit through Siemens S7-300 and IFIX 5.0 configuration software.

An Industry 4.0 approach to develop auto parameter configuration of a bottling process in a small to medium scale industry using PLC and SCADA

Recent trends of manufacturing processes, like Industry 4.0 (I4.0), strive to replace existing manual systems with fully self-controlled, reconfigurable processes to improve the overall production system. This paper develops a strategy to track closely the production, reduce the manual control and efficiently monitor the bottling process of a small beverage plant by implementing I40 basic concepts such as decentralization and real-time data analyses. A Siemens S7-1200 PLC communicating via Ethernet TCP/IP with a ZENON SCADA Human Machine Interface (HMI) was used to simulate the operations of a bottling process. The proposed strategy, developed by modeling bottling production as a time function, allows supervisors to be free from manuallyconfiguring bottling process parameters and monitor production steps directly on the SCADA with relevant information.This optimizes production time by reducing users’ interferences with the overall process. At the end of the paper, the experimental results were graphically plotted to illustrate the benefits of the proposed strategy.

Creation of control algorithms thermal vacuum tests in the SimInTech environment

Paper is divote to results of the development of the thermal vacuum tests computer model of allowing to investigate impact of external factors on the devices which are in conditions of own external atmosphere of the spacecraft in the SimInTech environment of the technical systems dynamic modeling. For a solution an objective models of a control object of the thermal vacuum TVAC-1400 camera are created, and the regulators executed on the basis of the programmable industrial controller Siemens S7-300 setup of key parameters is made, control algorithms are implemented by the modes of tests. The developed model allows to exercise control of test programs of the different equipment, prevention of failures at an error of the operator or interruptions in engineering networks, to reveal the most adverse situations which can arise process of functioning of the thermal vacuum camera. Besides, the presented model can be used for a research of behavior of controlled parameters of thermal vacuum tests and working off of control algorithms. In article development process and settings of model of thermal vacuum tests, its submodels and a control bar, implementation of the main algorithms are step by step described. Also results of adequacy check to the developed model are presented.

Simulator Design of Kartini Reactor Based on LabVIEW

Kartini's Reactor simulator design based on LABVIEW. Kartini’s reactor simulator design has been done to provide a system that can be used as a traning hardware for reactor operator by applying PLC Siemens S7 as a control modul and LabVIEW software as a data processor. The purpose of this research is to design a simulator system to operate Kartini’s Reactor based on reactor kinetics modeling using PLC Siemens S7 as a CRDM controller. LabVIEW software is use as data acquisition and data information processing using reactor kinetics formula to convert the change of height position of control Rod into power information. Control Rod position that obtained from CRDM control will be sent to PC and being processed by software to obtain power. Power that obtained from simulation at 100 kW operation are 100% safety Rod, 60% SHIM Rod, and 37.05% regulator Rod.

External resonance magnetic field control system based on the Siemens S7-400 controllers at the T-10 tokamak

A multilevel control system of a tokamak-reactor should provide measurements of the physical and technological plasma parameters in real time under conditions of high radiation fluxs. For the control systems of the ITER tokamak-reactor, it is planned to use automatic control systems based on the Siemens S7 programmable logic controllers (PLCs) which can operate under these conditions. Along with the possibility of multilevel remote control of the equipment, the PLC provides timely responses in emergency situations without human involvement and adaptive control in real time. This article presents results of using the Siemens S7 417-4 controllers for external resonant magnetic field control in the T-10 tokamak in the regimes with increased electromagnetic fields and radiation fluxs in shots with ohmic and additional microwave plasma heating.

Impact of Quality of Service on Cloud Based Industrial IoT Applications with OPC UA

The Industrial Internet of Things (IIoT) is becoming a reality thanks to Industry 4.0, which requires the Internet connection of as many industrial devices as possible. The sharing and storing of a huge amount of data in the Cloud allows the implementation of new analysis algorithms and the delivery of new “services” with added value. From an economical point of view, several factors can decide the success of Industry 4.0 new services but, among others, the “short latency” can be one of the most interesting, especially in the industrial market that is used to the “real-time” concept. For these reasons, this work proposes an experimental methodology to investigate the impact of quality of service parameters on the communication delay from the production line to the Cloud and vice versa, when gateways with OPC UA (Open Platform Communications Unified Architecture) are used for accessing data directly in the production line. In this work, the feasibility of the proposed test methodology has been demonstrated by means of a use case with a Siemens S7 1500 controller exchanging data with the IBM Bluemix platform. The experimental results show that, thanks to the proposed method, the solutions based on OPC UA for the implementation of industrial IoT gateways can be easily evaluated, compared and optimized. For instance, during the 14-day observation period of the considered use case, the great impact on performance of the Quality of Service parameters emerged. Indeed, the average communication delay from the production line to the Cloud may vary from less than 90 ms to about 300 ms.

Initiating predictive maintenance for a conveyor motor in a bottling plant using industry 4.0 concepts

For the past recent years, Industry 4.0 (I40) also known as smart manufacturing, together with advanced manufacturing techniques, has been introduced in the industrial manufacturing sector to improve and stabilize processes. Nevertheless, practical applications of these advanced technologies are still in their early stages resulting in slow adoption of the I40 concepts, especially for small- to medium-scale enterprises (SMEs). This paper proposes the design of an experimental method to integrate the practical use of Industry 4.0 in a small bottling plant; especially by detecting early faults or threats in conveyor motors and generating accordingly a predictive maintenance schedule. Using advanced programming functions of a Siemens S7-1200 programmable logic controller (PLC) controlling the bottling plant, vibration speed data is monitored through vibration sensors mounted on the motor and an efficient predictive maintenance plan is generated. The running PLC communicates with a supervisory control and data acquisition (SCADA) graphical user interface (GUI) which instantaneously displays maintenance schedules and allows, whenever required, flexible configuration of new maintenance rules. This paper also proposes a decentralized monitoring system from which vibration speed states can be monitored on a cloud-based report accessible via the Internet; the decentralized monitoring system also sends instant email notifications to the intended supervisor for every maintenance schedule generated. By its results, this research shows different possibilities of the practical use of Industry 4.0 basic concepts to better manufacturing operations within SMEs and opens a path for more improvement in this sector.

Optimal PI and PID Temperature Controls for a Dehydration Process

In this work, the drying air temperature for an experimental platform of sliced tomatoes dehydration is optimally regulated by using the very well-known integral control approach which could be equivalent to the PI control when the output system is the whole state. In a first stage, the chosen controller is a PI because the plant step response does not present oscillations with low damping. However, obtained experimental results, applying this controller, present some oscillations in the closed-loop transient response. So, in a second stage, a discrete PID controller is applied and its gains are computed by using a numerical optimization algorithm based on the hill climbing method, which considers a quadratic performance index; the proposed procedure assumes an input delayed discrete model of the plant; therefore, the stability is verified by the closed-loop poles location. The reason to apply an optimal control strategy is motivated by the energy saving and the preserving of a desired closed-loop performance of the process. In order to contrast the advantages to use an optimal controller, the obtained experimental results are compared with a PID controller tuned with the improved Ziegler–Nichols rules, which is optimized only considering a criterion depending on the error (the energy consumption it is not involved). Moreover, the performance given by optimal PI control is also compared with an optimal state feedback control. The synthesized controllers (computed gains) are programmed in an industrial programmable logic controller Siemens S7-1200, and they are applied to a sliced tomato dehydration plant. According to the obtained results, when the optimally tuned PID controller is applied, it produces energy saving rates, more uniform drying conditions for the product and a better closed-loop plant performance (shorter settling time and nonovershoot, which are desired features in this type of process), with respect to other tested controllers. The presented experimental results by using the PI and PID optimized controllers allow to verify the feasibility of our proposal.

Energy optimization of chillers by automating a Cooling System

This publication presents the work done on energy optimization of a group of chillers by automating the cooling system of blowing dies in an industry that is entrusted with the manufacture of plastic containers. In a first stage, the preliminary study on the energy analysis of the old system, where each chiller was in charge of cooling a specific group of blow moulding machines, without taking into account whether or not the blow moulding machines are working, is detailed; subsequent to this, the implementation of the automated cooling system was carried out, where all chillers were centralized in a machine room, automation was carried out with a Siemens S7-1200 PLC, switching the chillers on and off is based on the total thermal capacity required by the blow moulding machines. Finally, the energy analysis of the new cooling system was carried out, where the results were compared, and conclusions were drawn.

Effect of ECRH and resonant magnetic fields on formation of magnetic islands in the T-10 tokamak plasma

Experiments in the T-10 tokamak demonstrated possibility of controlling the plasma current during disruption instability using the electron cyclotron resonance heating (ECRH) and the controlled operation of the ohmic current-holding system. Quasistable plasma discharge with repeating sawtooth oscillations can be restored after energy quench using auxiliary ECRH power when PEC / POH > 2–5. The external magnetic field generation system consisted of eight saddle coils that were arranged symmetrically relative to the equatorial plane of the torus outside of the vacuum vessel of the T-10 tokamak to study the possible resonant magnetic field effects on the rotation frequency of magnetic islands. The saddle coils power supply system is based on four thyristor converters with a total power of 300 kW. The power supply control system is based on Siemens S7 controllers. As shown by preliminary experiments, the interaction efficiency of external magnetic fields with plasma depends on the plasma magnetic configuration. Optimal conditions for slowing the rotation of magnetic islands were determined. Additionally, the direction of the error magnetic field in the T-10 tokamak was determined, and the threshold value of the external magnetic field was determined.

Experimental Study for a Micro Smart Grid to Meet the Energy Demand of a Household

Abstract In this research, a smart grid using renewable energy and energy storage unit is studied. The system's storage units applies novel supercapacitor technologies to work with traditional batteries. This study aims at satisfying the dynamic demand of a household and evaluate the performance of the smart grid. The system design and the control strategy design is expressed in the paper combined with the discussion of the system's operation theory. The control panel of the system use SIEMENS S7-200 PLC as the core chipset. Digital software is an auxiliary tool for monitoring the system's operation process. The controlling method is divided into two situations, with renewable energy source and without renewable energy source, and both the operation processes are presented in detail in the results discussion part. After analysing the operation details of the system, the controlling strategy is proven to be useful for the operation of the smart grid system. Future work for the system is combining the electrical smart grid with other energy source. This system is potentially to be developed as electrical part of a multi energy system.

PLC Control System Design for Egg Carton Unloader

An egg carton unloader is a device used to feed eggs loaded in cartons to the clean egg production line, and mainly includes three major components: loaded carton conveying mechanism, carton unloading mechanism, and egg feeding platform. In this paper, based on the mechanical and pneumatic systems designed for the device, the Siemens S7-1200 PLC is selected for control system development for the egg carton unloader, distribution design and program control flow chart design for I/O point, realization of automation control of the carton conveying mechanism, carton unloading mechanism and egg feeding platform. It features high reliability and high cost effectiveness.