SIMATIC S7-300 Research Articles

Формування навичок налаштування промислових контролерів сімейства Siemens Simatic S7 студентів освітніх програм з автоматизації

The work is devoted to the development of a lesson that will allow students of automation educational programs to develop the skills of configuring industrial controllers of the Siemens Simatic S7 family. During developing the lesson, it was decided to use the format of laboratory work with the involvement of modern forms of students' work activation. Structurally, the student's work per class consists of independent and classroom work. Independent work includes watching educational videos and studying theoretical material. Auditory work consists of participation in a master class conducted by the teacher and completion of an individual task, where the teacher acts as a consultant. The developed lesson can be conducted both face-to-face and remotely. Under conducting a distance lesson, the teacher needs to pay more attention to the means of receiving feedback from students, as well as limit the number of participants, in order to improve the uniformity of learning the material by students. Methodical and visual support was developed to support the lesson: the list of video materials for viewing; reference book on theoretical material; the presentation to accompany the creation of a sample software project; individual tasks for students. The developed lesson was approved in remote form, considering the current situation in Ukraine. For the first time, an integrated product was created for training students in the skills of configuring industrial controllers of the Siemens Simatic S7 family, which is characterized by an orientation towards familiarity with the TIA Portal environment, development to support each stage of the lesson with methodical and visual support, a complete structure of information presentation, and the use of such modern forms of education, like a master class. The developed lesson allows students of automation educational programs to develop the skill of configuring industrial controllers of the Siemens Simatic S7 family in a fairly short time at a sufficiently high level. Further work of students consists of creating software projects based on real automation tasks. Key words: automatically integrated technologies, professional competences, master class, methodological support, TIA Portal.

Research on Palletizing Robot System of Multi - axis Synchronous Control Technology

Due to the increasing demand for personalized objects, the palletizing packaging of personalized objects has attracted people’s attention. To improve the efficiency of the palletizing system, a palletizing robot based on multi-axis synchronous control technology is proposed in this paper. The robot takes SIMATIC S7 - 1200 PLC as the control core, uses the master command synchronization method to achieve multi-axis synchronization control, and realizes human-computer interaction through PROFINET communication with the touch screen. The multi-sensor is connected with the input and output modules of the PLC, and the review of the grasping object is realized. After the robot is put into use, the flexibility of the palletizing system is improved, the multi-axis synchronous control technology is improved, and the palletizing efficiency of personalized objects is greatly increased.

FPGA Implementation of IEC-61131-3-Based Hardware Aided Counters for PLC

The article discusses counters defined in the IEC 61131-3 standard. The possible implementations of standard counters function blocks in FPGAs are presented. First, counters are implemented as classical hardware-based modules. Second, counters are designed as the FPGA built-in memory blocks with a single common executing unit. These solutions are compared to each other and compared with counters realized in commercially available PLCs like Siemens SIMATIC S7 controllers. The structure of integrated hardware–software CPU with counters is presented. The paper presents how the designer can take advantage of the specific features of the FPGA devices to optimize both the utilization of resources and speed of realization of the particular blocks. Experimental results prove the high efficiency of the proposed solutions.

The upgraded TOMAS device: A toroidal plasma facility for wall conditioning, plasma production, and plasma-surface interaction studies.

The Toroidal Magnetized System device has been significantly upgraded to enable development of various wall conditioning techniques, including methods based on ion and electron cyclotron (IC/EC) range of frequency plasmas, and to complement plasma-wall interaction research in tokamaks and stellarators. The toroidal magnetic field generated by 16 coils can reach its maximum of 125 mT on the toroidal axis. The EC system is operated at 2.45GHz with up to 6 kW forward power. The IC system can couple up to 6 kW in the frequency range of 10 MHz-50MHz. The direct current glow discharge system is based on a graphite anode with a maximum voltage of 1.5 kV and a current of 6A. A load-lock system with a vertical manipulator allows exposure of material samples. A number of diagnostics have been installed: single- and triple-pin Langmuir probes for radial plasma profiles, a time-of-flight neutral particle analyzer capable of detecting neutrals in the energy range of 10 eV-1000eV, and a quadrupole mass spectrometer and video systems for plasma imaging. The majority of systems and diagnostics are controlled by the Siemens SIMATIC S7 system, which also provides safety interlocks.

Implementation of Stir-Speed Adopted Controllers Onto a Batch Bioreactor for Improved Fermentation

Quality, quantity, and economy of the fermentation product depend on the transient response and the steady-state of the fermentation process. Due to its simple construction, an industrial batch bioreactor cannot be equipped with a closed-loop control system that applies adding or removing substances during fermentation. This theoretical and practical study displays how fermentation can be controlled, in this case by altering the rotational speed of a stirrer system of such a bioreactor. A numerical analysis was employed to set up a mathematical model that describes the impact of the stirrer speed on the fermentation. The model consists of linear and non-linear parts. To determine their parameters, a least square identification and a particle swarm optimization method were utilized. The model was fitted and tested experimentally in a laboratory on the operating batch bioreactor. The design and synthesis of a conventional linear control system and an advanced model reference adaptive control system, which is also convenient for control of non-linear controlled plants, were carried out based on the determined mathematical model. Both control concepts were first implemented into the dSpace 1103 control system, convenient for faster development and prototyping. Finally, they were realized with the Siemens SIMATIC S7 programmable logic controller, which was ideal for industrial environment operation. During the operation of the bioreactor, the control systems were tested along with the acquisition of measured data involving CO2 concentration of a fermentation product. The findings of successfully applying linear and adaptive controllers of the milk fermentation in the batch bioreactor are analyzed and presented.

A High Performance of Induction Motor Drive System

Background: A multi-motor synchronous drive control system is widely used in many fields, such as electric vehicle drive, paper making, and printing. Methods: On the basis of the optimized structure of ADRC, a fuzzy first-order active disturbance rejection controller was developed. Double channels compensation of extended state observer was employed to estimate and compensate the total disturbances, and an approximate linearization and deterministic system was obtained. As the parameters of ADRC are adjusted online by a fuzzy controller, the performance of the controller is effectively improved. Results: Based on the SIMATIC S7-300 induction motor control experimental platform, the performances of anti-interference and tracking performance are tested. Conclusion: The actual experimental results indicated that compared with PID control, induction motor drive system controlled by fuzzy ADRC has higher dynamic and static status and following performances and stronger anti-interference abilities.

Traffic Light Control System Based on SIMATIC S7-300 and WinCC Configuration Software

The old traffic light control systems are mostly realized by digital circuits. With the development of social economy, traffic lights with digital circuit can not meet the increasing traffic pressure. Therefore, a new method must be sought to replace the complex and unstable control system. Nowadays, PLC technology is developing rapidly, and its applicationgs are becoming more and more extensive. It plays an extremely important role in industrial automation and is widely used in various industries. With the development of science and technology, the function of programmable controller is becoming more and more perfect, coupled with miniaturization, low price, and high reliability, tits role in modern industry has become more prominent.

SCADA Implementation of Secondary Voltage Control and Active Power Monitoring of AC Microgrid using SIEMENS SIMATIC S7 300 PLC and Totally Integrated Automation (TIA) Portal

SCADA Implementation of Secondary Voltage Control and Active Power Monitoring of AC Microgrid using SIEMENS SIMATIC S7 300 PLC and Totally Integrated Automation (TIA) Portal

Development of electric drive system with vector control in the facility of inter-stand cooling of sheet rolled product

Modernization of the pusher electric drive of inter-stand cooling facility of sheet rolled product is an actual way to increase efficiency of rolling production. The control by the existing electric drive is accomplished by a system, comprising an asynchronous motor. Problems of automation of the facility of inter-stand cooling of sheet rolled product of JSC “Ural steel” sheetrolling shop considered. Modernization of existing system by implementation of frequency convertor with vector control proposed. To restrict the pusher movement it proposed to use induction sensors and controller SIMATIC S7-300. Algorithm of the pusher operation with induction sensors application considered. The elaborated algorithm of the pusher operation realized on the base of SIMATIC S7-300 controller. Calculation and building of load diagram and the pusher drive tachometric diagram accomplished for one cycle of its operation. Taking into account nominal data of the pusher selected motor and requirements to electric equipment, a frequency convertor with vector control was selected. Implementation ofthe system “frequency convertor – asynchronous motor” with vector control justified. The vector control enables to provide a preset pace of the motor acceleration, its complete protection against over-loading that increases considerably service life of the electric drive system as a whole. Application of frequency controlled pusher drive together with SIMATIC S7-300 controller will enable to automatize the process of the pusher operation. Implementation of the developed automation system of the pusher electric drive operation is possible also at other steel-works.The payback period of the solutions proposed within the frame of the project will be 9 months.

Safety systems in the ITER neutral beam test facility

SPIDER, the experimental device of the ITER Neutral Beam Test Facility (NBTF) devoted to the study of the ion source, has recently started operation. The construction of MITICA, the full-size prototype of the ITER heating neutral beam injector, is in progress. SPIDER and MITICA operation presents many possible hazards including radiation, electrical, explosive gas, laser and fire risks. An integrated approach, referred to as the NBTF Safety System, was chosen to deal globally with all risks for people and environment safety. As many different systems collaborate to guarantee the NBTF safety, a coordinating system, called Central Safety System (CSS), was implemented to supervise safety-relevant systems and provide an effective human interface of the NBTF safety. The CSS is also required to implement directly safety instrumented functions. The requirements of the safety systems derived from the safety risk analysis. The CSS uses the Siemens SIMATIC S7 400FH PLC along with safe input/output remote nodes connected through double ring-topology, redundant Profibus network. Complying with the IEC 61508/61511 standards, the system architecture uses the PROFISafe profile and the human machine interface is based on WinCC Open Architecture. Special provisions are used for communication of safety-related information with the PLC.

Study on designing an automated system of efficient HVAC control for energy saving in industrial buildings

The article is focused on energy efficiency in industrial building automation and control activities. Within industrial buildings, heating and air conditioning systems (HVAC) must be well controlled. The main purpose of our work is to study and design an automated system of efficient HVAC control for energy saving in industrial buildings. Within our research, we have sought to obtain the optimal configuration of the automation network in the SIMATIC S7 programming environment, to realize the automation program, to define the graphical interface with the operator and to realize the configuration of the platform by the process simulation method. The relationship between building and the building’s internal technical system consists of the HVAC system of the building, a system consisting of a series of interior installations, namely the building heating installation; the hot water production installation; the building’s ventilation system; the building’s cooling system. In order to achieve the indisputable level of quality, reliability and efficiency of HVAC equipment, equipments should be considered in their global environment. This means that in addition to the safe operation of equipments and the provision of efficient operating conditions, acoustic performance, energy savings, etc. will be considered. The increased energy efficiency occurs either when energy input is reduced for a given service level or services have been improved or increased for a given amount of energy input. Industrial buildings processes automation strategy is implemented through the Building Management System (BMS). The SCADA (Supervisory Control and Data Acquisition) network in industrial buildings provides an interconnection with the field elements at factory plant level. The SCADA command and control mode is based on the real-time data acquisition system in the process. These field elements, such as sensors, are monitoring in the SCADA network via a PC or a PLC (Programmable Logic Controller). The main results of our research are as following: automation of PLC & HMI processes; determining customer requirements; automation of PLC & HMI(Human Machine Interface) processes; determining customer requirements; realizing the system configuration for the automation process; realization of the process simulation platform architecture with SIMATIC S7-300 automatic programmable equipment. The most important consequence of the paper is the realization of a HVAC automation panel placed in a 4-level industrial hall.

Modeling and control of processes using the EMSO simulator and SIMATIC PLC as OPC interface

This work shows a procedure for modeling and control of level and flow processes. It uses the EMSO simulator to connect to a process by means of a SIMATIC S7-200 PLC as interface for the communication between the process instrumentation and the controller computing system. In order to supervise the variables, a SIMULINK model was connected to a laboratory process module through OPC communication. The model obtained was used in the design of controllers PID and PBSM, which were tested for step disturbances of the set point and an imposed set point trajectory.

Monitoring a Group of Hydraulic Pumps Connected to the Water Feeding System of a Civil Building

The paper describes the method that can be used to monitoring of a water feeding system of a civil building and its subsystems, using a graphic interface of a soft-ware pack – SCADA (Supervisory Control and data Acquisition), WinCC Flexible. The effective adjustment of the pressure of the water feeding system implies using specific elements: sensors, execution elements, programmable automatons and monitoring devices. In the paper, also is analysed the situation in which three centrifugal pumps are utilized as execution elements, a pressure sensor – to measure the pressure of the water feeding system of the consumer, three sensors that detect the presence of water in each well and a Siemens programmable automaton, from the SIMATIC S7-300 series, which controls the process and a PC for the acquisition of data and for monitoring. Thus, it presents a schematic system operating water supply, logic operation sequence control, protection, signage and display alarms

Analog Signal Derivation in the Programmable Logical Controller

Programmable logical controllers (PLC) find ever-widening applications in technological processes of ground operating equipment. Their computing capacity allows additional processing of analogue signals coming from the sensors of physical quantities. In particular, PLC hardware and software enable us to calculate the first derivative of an analogue signal in order to improve the control or prediction quality of the process under control. The aim is to research the singularities in calculating the first derivative of an analogue signal using the SIMATIC S7-200 PLC of Siemens Company. A method of digital differentiation has been decided on the algorithm based on a derivative representation by a final number of return differences of consecutive readout in regular intervals of continuous function. Such an algorithm allows us to find comprehensible accuracy in calculation of the first derivative of an analogue signal in PLC when using the first and second differences of readout. Thus, a choice of the period of digitization of differentiated process is also of great importance. Research of the differentiation process, based on mathematical models of aperiodic chains of the first and second orders, has shown that for used PLC a digitization period should not be less than 50msес. The natural experiment has shown that calculation of the first derivative of a signal from the temperature sensor allows an essential increase in speed of PLC response to the abrupt change of the measured quantity. The research results have shown that SIMATIC S7-200 PLC allow us to provide sufficient accuracy and speed in calculating the first derivative of the low-frequency analogue signals, being specific, for example, for re-fuelling systems or systems of temperature stabilization. The received results are of interest for experts in the field of development and operation of technological systems of the ground operating equipment.

Complete Combustion Control for a Steam Boiler Plant

Steam boiler is one of the most widely used industrial systems. The boiler is used in many industrial applications. It produces steam and is used for many purposes, for example as a heat exchanger used in the refining and separation of oil and is used in electricity production also. Like any combustion system, boilers burn fossil fuels to generate steam. Emissions from fuel include carbon monoxide and nitrogen oxides. Incomplete combustion increases these emissions. The way to reduce these emissions is the control of combustion to make complete combustion by monitoring exhaust components like (NOx, CO2, CO and O2). Steam boilers are usually controlled for steam pressure only without including the exhaust components in the control loop. In this paper, a limiter for exhaust components will be included in the control loop beside the steam pressure control. This paper outlines the various stages of operation involved in the conversion of a manually operated boiler towards a fully automated one. Over the years, the demand for high quality, greater efficiency and automated machines has increased. The first part of the paper focuses on passing the inputs to the boiler at a required temperature, so as to constantly maintain a particular temperature in the boiler. The air preheater and economizer help in this process. The paper mainly focuses on level, pressure and flow control at the various stages of the boiler plant. The temperature in the boiler is constantly monitored. The automation is further enhanced by constant monitoring using a Supervisory Control and Data Acquisition system (SCADA) screen which is connected to the PLC by means of a communication cable. This paper describes the construction of SCADA and the corresponding Human Machine Interface (HMI) for a steam boiler plant. This last consists of the water drum, the air heaters and the main boiler. The control system of the plant is implemented using Siemens SIMATIC S7 PLC with ladder programming and WINCC to create the SCADA/ HMI system.

PLC based Automatic Distillation and Collection of Ethanol-Water Solution

This paper demonstrates the design and implementation of a binary distillation and collection of Ethanol-Water solution. The PLC based distillation and collection of the liquids is one of the innovative industrial automation projects. The conventional design contains a PLC based automated model of liquid distillation and collection systems, where PLC (SIMATIC S7-300) is used as the controlling brain of the system and distillation and collection are the two main units of the designed system. The distillation control system separates the homogeneous mixture of water and alcohol (ethanol) by comparing the current temperature of the solution of the continuous solution feeding to the column with the boiling points of individual compounds and collection system collects the separated solvents into the bottles placed on the conveyor belt. The monitoring and controlling of the whole systems are evaluated on the basis of temperature and level of the specific units under consideration of atmospheric pressure. Thus the accurate working of process control can lead to smooth operation of the system, preventing unwanted failures, shutdowns and providing notable cost saving and reliability.

A Portable Subway Logistics System for the Transportation of Small and Medium-Size Cargo

To satisfy the requirement of short delivery time, this paper proposes subway (light rail transport) as vehicle for city delivery and express. With the convenient service, it will improve the efficiency of city logistics and promote the development of e-commerce. The system can effectively avoid the congestion of trucks on road, reduce fuel consumption and reduce the damage to the environment for the subway is driven by electricity. The automated warehouse management system is proposed in this paper, which is built on Siemenss SIMATIC S7 PLC control system and SQL database, and is designed for small and medium-size cargo to make transportation efficient and timely.

A PC-based operator and diagnostic panel for Simatic S7-200 programmable controllers

Abstract The paper describes a prototype operator panel, which was designed to operate with the S7-200 family of Programmable Logic Controllers (PLC-s) from Siemens. Most of the functionality of the operator panel was implemented in a computer program, which runs on a PC-class computer. The program communicates with a PLC through its communication port configured in the Freeport mode. Two kinds of interface between the PC, and the PLC are supported: wired, and wireless. For wired connection a standard PC/PPI cable supplied by Siemens is used. For wireless connection two communication modules were designed, which operate in the free 433 MHz band. The operator panel program is intuitive, and easy to use. States of PLC inputs and outputs are presented using graphical objects. It is possible to modify states of the outputs, and monitor and edit any variable in the M and V memory in the PLC. The application supports also alarming. The program can be run on any computer with the MS Windows operating system installed. This makes the solution very cost-effective. Providing both wired and wireless communication radically increases flexibility of the proposed solution. The panel can be quickly mounted in areas, where pulling new cables is inconvenient, difficult or expensive.

An Approach to Optimization of Takagi-Sugeno Type Fuzzy Regulator Parameters by Genetic Algorithm from Mamdani Regulation Surface

Many scientific papers deals with the usage of fuzzy rules to implement PID control. Fuzzy models, especially the Takagi-Sugeno-type, have received significant attention from various fields of interest. It is very often very difficult to determine all the parameters of the Takagi-Sugeno-type controller. In this paper we present optimization of Takagi-Sugeno-type fuzzy regulator parameters by genetic algorithm. Implementation of universal fuzzy P/PS/PD function block implemented to the PLC Simatic S7 300/400 is introduced. Mamdani model is used as comparative model. Parameters of Takagi-Sugeno-type fuzzy regulator are determined by genetic algorithm optimization from comparative regulation surface.

Latex Dipping Machine PLC Control and Its Programming

Latex dipping machine is based on a latex patent products new-production condom and the development of the machine. The latex dipping agencies combined with production condom mechanism. First it realized a 3-dimensional accurate localization system using stepping motors. SIMATIC S7-200 series programmable controller, motion module EM253 and stepping motor are tied in wedlock to realize allocation of 3-dimension of X axis and Y axis and Z axis. Through the PTO pulse of Siemens S7-200 PLC controller and combined with the use of EM253 module, through the mould precise control programming soak glue and roll edge to achieve the control mold of rotation and swinging the uniform distributed latex. And the system has applied successfully in foreign-funded enterprise of Singapore.