In the recent industry field, automation has become the most important role in production processes to improve efficiency, increase production, and reduce workers. Sorting the products based on their ...color is a common task in the industries, but using manual sorting may take a longer time and human error may occur, especially if the production quantities are very large. To contribute to improving the quality and speed of production, we have proposed a new system to automatically separate products based on their color. This article presents a new system for identifying and separating industrial products based on their colors. The implemented system consists of three sensors used to detect the colors of the products, four chutes, and two conveyor belts designed to guide objects along the manufacturing path, and three push mechanisms to place objects in their designated places. The system includes an emergency interface, a reset interface, a stop interface, as well as communication using the PN (PROFINET Process Field Net) protocol, a programmable logic controller, and a 1511-1 central processing unit. This system has been precisely programmed and simulated using FACTORY I/O software and TIA PORTAL software to control and monitor the system effectively. The Supervisory Control and Data Acquisition system also includes a Human–Machine Interface user interface for maximum control. The performance of this system was tested by sorting 250 objects of different colors. These tests resulted in the successful separation of a total of 85 blue objects, 89 green objects, and 86 gray (metallic) objects within a time period of 20 min. This system shows wide applicability in various industries including diamond mining, recycling, and grain manufacturing sectors.
Existing monitoring and control of an induction motor systems must be interoperable with next generation products to ensure smart integration in order to update existing system by reducing the cost ...and increasing the reliability. The best method must be chosen for efficient use of energy in some cases such as speed control, switching-on or switching-off, or in controlling the speed of induction motors, which make up a large part of the load group in industrial field. In this study, the controlling and monitoring of an induction motor parameters were carried out over a computer by using the Profibus (Process Field Bus) communication method through the TIA (Totally Integrated Automation) Portal program used to program all Siemens PLCs (Programmable Logic Controllers). The induction motor parameters were obtained over the frequency converter without using additional cards such as current, voltage, frequency and speed measurement. In this way, cables and electronic cards confusion were avoided and a safer, faster and more functional application was implemented compared to classical methods. KEPServerEx OPC (Ole-for Processing Control) Server program by OPC Foundation was preferred for the communication of computer with a PLC. Profi-Lab editor program was used for monitoring and controlling the system over a computer.
•Monitoring and controlling of the electrical parameters of an induction motor.•The SCADA based automation and hardware configuration in TIA portal platform.•Profibus communication feature and the system with ProfiNET communication.•Remote control of the induction motor with frequency converter.•Technical characteristics of Profibus-DP communication.
Актуальність. Моделювання систем регулювання в середовищі розробки програмного забезпечення контролерів, наприклад в Step 7 TIA Portal, дозволяє провести налагодження параметрів функціональних блоків ...ПІД-регуляторів, перевірку грубості САР до варіацій параметрів об’єкта керування та безударність переходів між ручним та автоматичним режимом роботи. Мета. Показати приклади корекції програмного коду функціональних блоків бібліотеки “LSim”, які фірма Siemens рекомендує для моделювання об’єкта керування, що забезпечують встановлення довільних початкових умов в цифрових аналогах диференційних рівнянь динамічних ланок. Метод. Аналіз оригінального коду функціональних блоків бібліотеки “LSim” та його подальша корекція, моделювання скоригованих функціональних блоків в середовищі Step 7 TIA Portal. Результати. Наведені фрагменти кодів функціональних блоків, які дозволяють моделювати ланку запізнення, інерційну ланку першого порядку, інтегруючу ланку з довільними початковими умовами. Проведено моделювання скоригованих функціональних блоків в середовищі Step 7 TIA Portal та співставлення результатів із результатами моделювання аналогічних динамічних ланок в середовищі Simulink/MATLAB. Проведено моделювання САР із використанням зазначених блоків. Висновки. Запропоновані зміни коду функціональних блоків бібліотеки “LSim”, які реалізують ланку запізнення, інерційну ланку першого порядку, інтегруючу ланку, дозволяють врахувати довільні початкові умови в цих ланках, що забезпечує моделювання динамічно сталих режимів САР в середовищі Step 7 TIA Portal.
Current methods of manually checking whether materials meet the required standards are inefficient and harmful to workers' health. To address the complexity and variability of real-world systems, it ...is imperative to establish highly consistent digital models for subsequent operations. However, there is a challenge in unifying various modules and components into a single system and optimizing them for functionality. A mechatronic solution is proposed for material sorting within the production manufacturing process, leveraging Siemens TIA Portal and NX 2007. The solution involves constructing a physical platform and realizing a digital twin system to enable real-virtual interaction via communication protocols. Initially, a virtual material sorting simulation and debugging platform is established using NX software, while operations are conducted in the TIA Portal. Subsequently, the control program is designed within the TIA Portal, and Virtual PLCs are created using PLCSIM Advanced for virtual debugging and analysis, confirming the solution's feasibility. Following this, the physical material sorting platform is developed, utilizing Siemens S7-1500 PLC to manage inverter and servo motor operations. Ultimately, the OPC UA communication protocol facilitates information exchange between the physical PLC and the virtual platform, establishing effective linkage between the virtual system and the physical model to ensure coordination and consistency. Results demonstrate real-time synchronization and virtual sorting operations during joint real-virtual debugging. This digital twin design solution is poised to significantly enhance manufacturing efficiency, reduce initial hardware costs in factory design, and augment automation and intelligence in production.
Major control systems such as ICS/SCADA are currently being used in the key infrastructures of our society, notably in the energy, transportation, and healthcare sectors. The PLC, which is located in ...the lowest layer of the control system, is directly connected to diverse field devices including sensors and actuators. In the event of a cyber-attack on the PLC, the potential ripple effects, such as a collapse of the national infrastructure, could be very large, making a high level of cyber safety essential. Therefore, it is necessary to apply digital forensic technology to the PLC to respond to cyber-attacks against the control system. However, conventional methods of directly investigating the PLC, such as network and memory forensics, have practical difficulties as they could compromise the availability of the control system. As such, this paper proposes a method of detecting and restoring logic data when the logic data are changed as a result of a cyber-attack, by using the digital forensic technology developed for the Engineering Workstation (EWS), which has been used to develop, manage and set the control system program logic.
•We proposed a method of detecting and collecting data for the PLC forensic investigation of the ICS components.•We presented the method of detecting and restoring the alteration attack of TIA Portal Step 7’s project file used to control a PLC from an EWS and developed monitor and control logic.•We suggested a test environment was built to verify the developed tools, and it confirmed the detection of changes to the project file and its restoration in the following two cases: i) alteration of the control block by an authorized user, and ii) direct access to and alteration of the project file.
This paper details the design and implementation of a virtualized bottle sealing plant using the Hardware in the Loop technique, for which it is divided into two parts: (i) Software consists of a ...virtualized environment in Unity 3D to visualize its behavior in real time; and (ii) Hardware was implemented through a PLC S7 1200 AC/DC/RLY (Programmable Logic Controller), which is responsible for the automation of the plant, programmed through the software TIA Portal V16 (Totally Integrated Automation Portal) and a control panel with buttons and indicator lights. The two developed parts communicate through bidirectional TCP/IP Ethernet, achieving a Server–Client architecture. For real-time monitoring and visualization, a SCADA (Supervisory Control and Data Acquisition) system implemented in InTouch is considered. In addition, the data acquisition is accomplished through the OPC (Open Platform Communication) server; the functionality of the OPC server is to transmit the information generated in an industrial plant at the enterprise level. This allows the process to execute its tasks of connectivity of automated processes and their supervision, as well as having scalability so that more tags can be included in other processes over time and ensure its operability.
Battery energy storage system (BESS) is used in many practical applications including uninterruptible power supplies (UPS), portable devices, electrical vehicles and renewable energy systems. To ...utilize BESS effectively, an efficient control operation is required. Various controllers have been introduced in the open literature. However, they are not considered the best fit due to their limitations. This includes their incapability of handling high-power rating BESS, low noise immunity, short life cycle and limited number of input and output interfaces. In this paper, the programmable logic controller (PLC) is used to control and monitor a 158.8 kWh offline BESS for a typical Malaysian household. TIA Portal V13 software by siemens is used to program the proposed PLC control. Human machine interface(HMI) system is used to monitor and simulate the control performance. The results show that the PLC approach provides an efficient and reliable control of the BESS in which a compact protection against the battery overcharging, under-discharging and overheating is achieved.
There exist numerous modelling techniques and representation methods for digital control algorithms, aimed to achieve required system or process parameters, e.g. precision of process modelling, ...control quality, fulfilling the time constrains, optimisation of consumption of system resources, or achieving a trade-off between number of parameters. This work illustrates usage of Finite State Machines (FSM) modelling technique to solve a control problem with parameterized external variables. The structure of this work comprises six elements. The FSM is presented in brief and discrete control algorithm modelling is discussed. The modelled object and control problem is described and variables are identified. The FSM model is presented and control algorithm is described. The parameterization problem is identified and addressed, and the implementation in PLC programming LAD language is presented. Finally, the conclusion is given and future work areas are identified.
A Probabilistic Approach to PLC Crash Problem Zohra, Fatima Bennani; Larbi, Sekhri; Haffaf, Hafid
Electrotehnica, Electronica, Automatica,
01/2017, Letnik:
65, Številka:
1
Journal Article
Recenzirano
We propose in this work, a new approach based on a probability study to choose the standby Programmable Logic Controller (PLC). Indeed, the solution of standby PLC was adopted by the majority of the ...industrial companies faced to automated production management and scheduling. This solution proved its efficiency by guaranteeing the continuity of functioning of the equipment of production managed by PLC; the latter can be automatically replaced by another in the case of failure. Unfortunately, this solution has shown its limits. Several anomalies have been identified by the automation specialists. The most known are the not starting up of the standby PLC for various causes. The new developed approach allows not only incrementing the number of standby PLC but also choosing the best one in the replacement task. This choice is based on a new probability approach. Simulations are performed through T.I.A Portal platform.
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