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PLC and SCADA based temperature control of heat exchanger system through fractional order PID controller using metaheuristic optimization techniques

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HEAT AND MASS TRANSFER 2024年第9期60卷 1585-1602页

作者： Tomar, Basant Kumar, Narendra Sreejeth, Mini Delhi Technol Univ Dept Elect Engn Delhi 110042 India

SCADA systems play an important role in tracking the behaviour of critical process variables and connecting geographically dispersed subsystems at the industrial plant level. This article presents a PLC and SCADA-based control framework to automate and supervise the temperature control processes in the heat exchanger plant. The OMRON (NX1P2-9024DT1) PLC is interfaced with the Wonderware InTouch SCADA system to gather data, create a simulated temperature control prototype and carry out the necessary control operations within the heat exchanger plant. The PLC controls the entire process and programming of PLC is done using Sysmac studio automation software using the ladder programming language. The proposed system controls the temperature of the heat exchanger system through PID and Fractional Order PID (P I lambda D mu\documentclass[12pt]{minimal} \usepackage{amsmath} \usepackage{wasysym} \usepackage{amsfonts} \usepackage{amssymb} \usepackage{amsbsy} \usepackage{mathrsfs} \usepackage{upgreek} \setlength{\oddsidemargin}{-69pt} \begin{document}$${\text{I}}<^>{\uplambda }{\text{D}}<^>{\upmu }$$\end{document}) controllers with Integral Anti-windup technique. Various control strategies like Cascade Control, Feedforward Control and Smith Predictor for time delayed process are discussed for controlling the temperature of the process. The performance of both PID and fractional order PID controllers is optimized using adaptive heuristic optimization techniques like Genetic Algorithm (GA), Ant Colony Optimization (ACO) and Particle Swarm Optimization (PSO). In control system design and analysis, the calculated performance indices are used as quantitative measures for evaluating the performance of a system. The combined form of temperature controller with Cascade control, Feedforward control and dead-time compensator is modelled and examined for simulation using MATLAB. Simulation and real-time experimentation analysis of the developed controllers are executed with metaheuristi

关键词： Automation Industry 4.0 Heat exchangers Temperature control Fractional Order PID controllers programmable logic controller Supervisory control and data acquisition Metaheuristic optimization techniques

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Domain-specific translation tool from structured text to C source code with code readability enhancement in programmable logic controllers

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CONCURRENCY AND COMPUTATION-PRACTICE & EXPERIENCE 2024年第15期36卷 e8100-e8100页

作者： Han, Bing Li, Congfei Deng, Hua Liu, Guowei Zheng, Ze Guodian Nanjing Automat Co Ltd Nanjing Peoples R China

The Industrial Internet has emerged as a key technology in the field of industrial automation, revolutionizing traditional manufacturing processes and enabling advanced control systems by integrating machines, sensors, and software systems through network connectivity, allowing for real-time data exchange, analysis, and decision-making in industrial environments. programmable logic controllers (PLCs) play a critical role in industrial automation systems, which are specialized digital computers designed to control various manufacturing processes and machinery. As a promising language, Structured Text (ST) is of paramount importance for industrial Internet, and it is essential to translate ST into C, which is widely used in various industries for implementing control systems. However, due to differences in syntax, data types, and programming paradigms between the two languages, the translation process is facing several challenges. In this paper, we present a domain-specific translation tool that automates the process of converting ST code to C code. This tool incorporates advanced AI techniques, particularly leveraging the capabilities of NL-PL LLMs, to facilitate accurate and efficient translation while generating comprehensive documentation to assist developers. Finally, the evaluation and case studies conducted validate the effectiveness of the tool, demonstrating its practical applicability and benefits in real-world industrial settings.

关键词： IEC 61131 NL-PL LLMs programmable logic controller structured text language

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Analysis of programmable logic controller Firmware for Threat Assessment and Forensic Investigation

Analysis of Programmable Logic Controller Firmware for Threa...

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8th International Conference on Information Warfare and Security (ICIW)

作者： Basnight, Zachry Butts, Jonathan Lopez, Juan Dube, Thomas USAF Inst Technol Wright Patterson AFB OH 45433 USA

ISBN: (纸本)9781909507111

Modern industrial control systems (ICSs) regulate operations over a variety of different applications. Of most interest to national security is the role ICSs play in the management of critical infrastructure (CI) such as the national power grid, water treatment, and chemical industry. The control systems used in such sectors are developing into highly networked collections of distributed devices. Unfortunately, security has only recently become a topic of major concern for these devices. This leaves many implementations without secure configurations due to their long lifespan compared to the rate of advancing threats. In the paradigm of ICSs, programmable logic controllers (PLCs) represent the front line between the cyber world and physical systems. Attacks like Stuxnet have already proven the effectiveness of cyber-physical attacks by altering and disguising PLC programming, but the next generation of threats will likely focus on PLC firmware. Just as traditional computer malware evolved to hide itself using operating system-level rootkits, so will ICS attacks evolve to embed themselves in the PLC equivalent: the firmware. Since little research has been done in the area of PLC firmware security, this paper begins by addressing the related security concerns. One such concern is the application of digital forensics to a potential incident of ICS attack. Forensic investigations of digital devices have traditionally been limited to the analysis of typical computer systems like desktops or laptops. As forensic capabilities begin to expand into the scope of embedded devices like smartphones, parallels can be drawn to PLCs that will enable the development of more advanced forensic tools and processes. By performing a firmware analysis through reverse engineering, a PLC can be exploited for both malicious and forensic purposes. This paper discusses the techniques and procedures required to access, inspect, and manipulate firmware for an Allen-Bradley PLC to suit the purpos

关键词： industrial control system programmable logic controller firmware embedded device forensics threat assessment

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A Reinforcement Learning Approach to Robust Control in an Industrial Application

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ARABIAN JOURNAL FOR SCIENCE AND ENGINEERING 2025年第8期50卷 6083-6094页

作者： Bingol, Mustafa Can Aydogmus, Omur Burdur Mehmet Akif Ersoy Univ Fac Engn Architecture Dept Elect Elect Engn TR-15100 Burdur Turkiye Firat Univ Fac Technol Dept Mechatron Engn TR-23200 Elazig Turkiye

The objective of this study was to design and implement a reinforcement learning-based controller for a nonlinear industrial system, specifically a liquid water tank controlled via a programmable logic controller to achieve robust control in the presence of disturbances from the outlet drain valve at various ratios. Initially, the system's model parameters were determined, and a mathematical model was developed using the OpenAI Gym open-source platform. Subsequently, multilayer perceptron-based reinforcement learning (RL), adaptive proportional integral (A-PI), and reinforcement learning-integral (RL-I) controllers were trained and validated using the developed software model. The designed controllers were then implemented on the real system both fixed and variable drain valve ratios. Tests conducted with a fixed drain valve ratio revealed that the proposed RL-I controller outperformed the RL and A-PI controllers in terms of transient and steady-state responses. The error values of the RL-I controller were significantly lower than those of the other algorithms (p = 0.000). In the final test, where the drain valve was adjusted to different ratios, the RL-I controller demonstrated robust performance. This study successfully developed a novel, robust controller for nonlinear systems commonly encountered in industrial applications.

关键词： Liquid level control programmable logic controller Proximal policy optimization Reinforcement learning

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PLC and SCADA based Real Time Monitoring and Train Control System for the Metro Railways Infrastructure

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WIRELESS PERSONAL COMMUNICATIONS 2023年第1期129卷 521-548页

作者： Tomar, Ishu Sreedevi, Indu Pandey, Neeta Delhi Technol Univ Dept Elect & Commun Engn Delhi 110042 India

Industrial Control Systems (ICS) and SCADA systems play a critical role in the management and regulation of critical infrastructure. SCADA systems brings us closer to the real-time application world. All process and equipment control capability is typically provided by a Distributed Control System (DCS) in industries such as power stations, railways, agricultural systems, chemical and water treatment plants. This article proposes to adopt SCADA and PLC technology in the improvement of the performance of real time signaling & train control systems in metro railways infrastructure. The main concern of this work is to minimize the failure in automated metro railways system operator and integrate the information coming from Operational Control Centre (OCC), traction SCADA system, traction power control, and power supply system. This work presents a simulated prototype of an automated metro train system operator that uses PLC and SCADA for real time signaling, monitoring and control of metro railway systems. Here, SCADA is used for the visualization of an automated process operation and then the whole operation is regulated using OMRON (NX1P2-9024DT1) PLC and OMRON's Sysmac studio programming software is used for developing the ladder logic of PLC. The metro railways system has deployed infrastructure based on SCADA from the power supply system, and each station's traction power control is connected to the OCC remotely which commands all the stations and has the highest command priority. An alarm is triggered in the event of an emergency or system congestion. This proposed system overcomes the drawbacks of the current centralized automatic train control (CATC) system. This system provides prominent benefits like augmenting services which may enhance a network's full load capacity and network flexibility, which help in easy modification in the existing program at any time.

关键词： Automation Train control system programmable logic controller Operations control Supervisory control and data acquisition

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Productivity enhancement using low-cost smart wireless programmable logic controllers: A case study of an oyster mushroom farm

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COMPUTERS AND ELECTRONICS IN AGRICULTURE 2022年 195卷 106798-106798页

作者： Thong-un, Natee Wongsaroj, Wongsakorn King Mongkuts Univ Technol North Bangkok Dept Instrumentat & Elect Engn 1518Pracharat 1 Rd Bangkok 10800 Thailand

This research work proposes the installation of a smart oyster mushroom farm combining sensory devices, a programmable logic controller (PLC), and wireless module. The smart wireless PLC encourages high-quality mushroom yield. The system is capable of wirelessly monitoring, controlling, and propagating information to a database. The smart wireless PLC adjusts the mushroom watering according to the temperature and humidity measurements and controls the ventilation by employing a cooling fan with fuzzy logic. The system uses mesh networks on the message queuing telemetry transport (MQTT) protocol to display real-time values and control mushroom cultures. Monitoring is executed via a web application on the PC, smartphone, and the HMI of the PLC. Measurement values are recorded on the database instantaneously for productivity prediction and cultivation planning. The mushroom cultivation controlled by the proposed system offers a higher yield than that of farm crops produced in the traditional way. Furthermore, the mushroom quality obtained is also better. In summary, the effectiveness of the smart wireless PLC enhances the quality and productivity of oyster mushroom cultivation.

关键词： Fuzzy logic Internet of things Oyster mushroom Message queuing telemetry transport programmable logic controller Smart farm

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Automatic berthing control under wind disturbances and its implementation in an embedded system

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JOURNAL OF MARINE SCIENCE AND TECHNOLOGY 2023年第2期28卷 452-470页

作者： Sawada, Ryohei Hirata, Koichi Kitagawa, Yasushi Natl Maritime Res Inst 6 38 1 Shinkawa Mitaka Tokyo 1810004 Japan Osaka Univ 2 1 Yamadaoka Suita Osaka Japan

This paper proposes a practical algorithm and its implementation of automatic berthing in wind disturbances environments. Berthing operation is one of the most complex tasks for seafarers. Automation of the highly burdensome berthing maneuver can be used to assist seafarers. In this study, we analyze the effect of wind disturbance on path following and propose a new path following control algorithm using a 2-DoF controller that introduces a feed-forward control. We also propose a method to reduce path deviation by introducing a runway in path planning. The effectiveness of the proposed method is verified by numerical simulations and shipboard tests using an experimental ship, and the proposed method shows higher performance under wind disturbance than the previous methods. The algorithm verified in this study is implemented as a PLC system, AutoBerth PLC. A PLC is an industrial computer, stable in operation. Using the AutoBerth PLC, we conducted an experiment of automatic berthing by an actual ship and confirmed that the system can be controlled faster and more stable than when controlled by a laptop. To realize a practical system, an alert function for the ODD, an alert function for fallback response regarding self-diagnosis of PLCs and communication monitoring functions were implemented as required functions in a maritime autonomous surface ship (MASS), and these functions were verified on the experimental ship.

关键词： Automatic berthing Wind disturbance programmable logic controller Autonomous ship Operational design domain

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Petri net models of discrete logics used in control algorithms developed in ladder diagram language

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INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY 2023年第7-8期124卷 2597-2612页

作者： Carlos Quezada, Jose Flores, Ernesto Banos, Esperanza Quezada, Victor Autonomous Univ Hidalgo State High Sch Tizayuca Km 2-5 Highway Tizayuca Pachuca Tizayuca 43800 Hidalgo Mexico

Control algorithms for programmable logic controllers are still developed based on the experience of those responsible for control in the industry. The IEC-61131-3 standard considers five programming languages: Ladder Diagram, Structured Text, Function Block Diagram, Instruction List, and Sequential Function Diagram, which use different function blocks to develop control algorithms. Within the control algorithms for discrete event systems, there are two types of blocks: those with discrete inputs and outputs, and those with discrete and analog inputs and discrete output. Of the latter, the present research shows the analysis and formal model of the blocks including the problems of accumulation of tokens and the restoration of the coils. This proposal includes logical blocks of timers, counters, positive and negative transition detectors and bistable elements, which, together with the AND, OR, AND-OR, contact lock, auto-loop and Set-Reset logics, can be modeled and analyzed control algorithms with a greater degree of complexity. This guarantees the safety of workers as well as machines.

关键词： Control algorithms Discrete event system Function block diagram language Ladder diagram language Petri nets programmable logic controller Structured text language

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Formal Semantics and Analysis of Multitask PLC ST Programs with Preemption 26th

Formal Semantics and Analysis of Multitask PLC ST Programs w...

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26th International Symposium on Formal Methods (FM)

作者： Lee, Jaeseo Bae, Kyungmin Pohang Univ Sci & Technol Pohang South Korea

ISBN: (纸本)9783031711619;9783031711626

programmable logic controllers (PLCs) are widely used in industrial applications. Ensuring the correctness of PLC programs is important due to their safety-critical nature. Structured text (ST) is an imperative programming language for PLC. Despite recent advances in executable semantics of PLC ST, existing methods neglect complex multitasking and preemption features. This paper presents an executable semantics of PLC ST with preemptive multitasking. Formal analysis of multitasking programs experiences the state explosion problem. To mitigate this problem, this paper also proposes state space reduction techniques for model checking multitask PLC ST programs.

关键词： programmable logic controller Structured Text Formal semantics Preemptive multitasking Partial order reduction

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A Platform-Independent Code Model for Operation and Information Technologies Convergences in Industrial Edge Applications 33

A Platform-Independent Code Model for Operation and Informat...

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33rd International Symposium on Industrial Electronics (ISIE)

作者： Lin, Maodong Zhang, Yingyue Hu, Qinyun Dai, Wenbin Shanghai Jiao Tong Univ Shanghai Peoples R China

ISBN: (纸本)9798350394085;9798350394092

With the increasing computing power of edge devices in industrial automation, programming languages from information and operation technologies can be used to solve new tasks from the shop floor. A virtualized controller can handle both parts due to its flexibility, high performance and lost cost. However, to migrate numerous legacy programmable logic controllers to new edge controllers, massive software development efforts must be put in during the upgrade process due to the variety and complexity of existing programs. To address this challenge, this paper proposes a platform-independent code model to automatically extract existing logic from legacy programs. Subsequently, programs can be generated automatically in the target programming language according to the target platform. This approach enables cross-platform program migration by facilitating programming language conversion, reducing the time and effort required.

关键词： Model Transformation Migration IEC 61131-3 programmable logic controller Industrial Edge Computing

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