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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 λ D μ ) 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 metaheuristic optimization techniques based on different performance indices like ISE, IAE and ITAE. [ABSTRACT FROM AUTHOR]

To improve the uniformity of microwave heating and enhance the quality of continuous microwave drying for raspberry pulp, a self-developed programmable logic controller (PLC) control system with pulsed microwave output was implemented. The central composite experimental design method was employed to analyze the effects of four experimental factors, namely microwave duty cycle, pulse period, air velocity and drying time on the average temperature, temperature dispersion value, moisture content, moisture content dispersion value, anthocyanin retention rate, and anthocyanin retention rate dispersion value of raspberry pulp. The optimal process for pulsed microwave drying of raspberry pulp was obtained. Compared with dried pulp quality and uniformity indexes from pulsed microwave drying, commonly used feedback temperature control microwave drying, intermittent microwave drying, and continuous microwave drying processes to develop a continuous microwave drying quality optimization control system for raspberry pulp. The results showed that the magnetron from pulsed microwave drying in the form of pulse output rectangular wave form power through the PLC control system. Turning on the magnetron intermittently was more effective than continuous microwave heating. Pulsed microwave drying of raspberry pulp has better product quality and heating efficiency, lower cost and better reliability than feedback temperature control systems. The optimal process parameters for pulsed microwave drying were microwave duty cycle of 0.6, pulse period of 17 seconds, air velocity of 1.9 m/s, and drying time of 12.5 minutes. Compared with continuous microwave drying, pulsed microwave drying resulted in the highest quality of dried pulp as a 35.31%±0.55% increase in anthocyanin retention, a 33.59%±0.23% increase under feedback temperature control, a 16.42%±0.18% increase under intermittent microwave drying. Pulsed microwave drying can control the power to reduce the dried fruit pulp temperature, improve the uniformity of post-drying quality and provide a basis for the industrial production of dried raspberry products. [ABSTRACT FROM AUTHOR]

A cryptography algorithm for data transfer encryption provides confidentiality, requires considerable computing power, and is not commonly implemented in embedded systems with limited computing power, such as Programmable Logic Controller (PLC). PLC is the core component for automation and control in industrial automation. For decades, PLC has prioritized speed over security; program execution in PLC must be as efficient as possible. The cryptography algorithm uses a seed, the initialization vector, to encrypt the data with the cryptography key to strengthen the encryption. Pseudo Random Number Generator (PRNG) can be used as the initialization vector. This paper proposes the XORasm PRNG algorithm, the lightweight XORshift-based algorithm with a modified seed from the system's clock. The applied methodology generates and visualizes PRNG, tests the randomness, and implements the PRNG on compact PLC. XORasm is evaluated statistically with runs-test in simulation by comparing the algorithm to one of the simulated compact PLC's PRNG implementations. The findings from this research are that p-values demonstrate that XORasm is statistically and significantly more random than the current implementation, and there is evidence that XORasm's generated data distribution is practically random at a 99.95% confidence level, suitable for implementation in embedded systems as a lightweight PRNG. [ABSTRACT FROM AUTHOR]

This research proposes a Programmable Logic Controller (PLC) based system that make black salt. In this system, there exists funnels where the salt is supposed to heat up for few hours and gets converted into black salt afterwards. With every funnel, two burners are connected in parallel with different level of intensity. Then there are also temperature sensors in the funnel to sense the temperature and help PLC to maintain a given range of temperature in the funnel. Both burner and sensor are considered to have multi-state with various performance level, from complete failure to perfectly working and both are connected to each other in series. Set of burners and sensors in a funnel together form one subsystem where the system as a whole is considered a k-out-of-n:G type. So, out of n funnels, k are supposed to work at a time, and if there will be any failure in any subsystem the PLC will automatically starts another subsystem to function. The elements are considered to be repairable, and reliability of the proposed system is computed from universal generating function technique. Also, numerical examples are presented to illustrate the model by taking different functioning conditions and the proposed algorithm. [ABSTRACT FROM AUTHOR]

The paper presents a case study that applies a model predictive control (MPC) approach in a Micro850 programmable logic controller (PLC) to a laboratory pressure swing adsorption (PSA) process used for separating gas mixtures of CO2 and CH4. PLC is an industrial hardware characterized by its robustness to hazardous environments and limited computational capacities, which poses computational challenges for MPC implementation. This paper's main contribution is the application of the modified Takagi–Sugeno–Kang-based MPC (MTSK-MPC) algorithm to this PSA unit, which provides features to investigate and implement feasible MPC designs in PLCs. The investigation consists of a sensitivity analysis of how some design parameters influence the PLC memory and the MPC implementation and a comparative evaluation of the computational processing from different MPC algorithms and simulations. The comparison comprises software-in-the-loop simulations with three algorithms in the PC: an implicit MPC, an explicit MPC, and the MTSK-MPC. Additionally, it includes a hardware-in-the-loop simulation with the implemented MTSK-MPC in Micro850. The results show that the MPC algorithms achieve close performance, tracking setpoint changes and rejecting output disturbances, with the MTSK-MPC presenting the lower processing time among the MPCs in the PC. The study concludes that the implementation of MTSK-MPC in the Micro850 is feasible. [ABSTRACT FROM AUTHOR]

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. [ABSTRACT FROM AUTHOR]

Background: Reference evapotranspiration (ETo), which is used as the basic data in many studies within the scope of hydrology, meteorology, irrigation and soil sciences, can be estimated by using the evaporation (Epan) measured from the class-A pan evaporimeter. However, this method requires reliable pan coefficients (Kp). Many empirical models are used to estimate Kp coefficients. The reliability of these models varies depending on climatic and environmental conditions. Therefore, they need to be tested in the local conditions where they will be used. In this study, conducted in Kahramanmaraş, which has a semi-arid Mediterranean climate in Turkey during the July–October periods of 2020 and 2021, aimed to determine the usability levels of six Kp models in estimating daily and monthly average ETo. Methods: The Kp coefficients estimated by the models were multiplied with the daily Epan values, and the daily average ETo values were estimated on the basis of the model. The daily Epan values were measured using an ultrasonic sensor sensitive to the water surface placed on the class-A pan evaporimeter. The ultrasonic sensor was managed by a programmable logic controller (PLC). To enable the sensor to be managed by PLC, a software was prepared using the CODESYS programming language and uploaded to the PLC. The daily average ETo values determined by the FAO-56 Penman–Monteith equation were accepted as actual values. The ETo values estimated by the Kp models were compared with the actual ETo values using the mean absolute error (MAE), mean absolute percentage error (MAPE), root mean square error (RMSE) and determination coefficient (R2) statistical approaches. Results: The Wahed & Snyder outperformed the other models in estimating daily (MAE = 0.78 mm day−1, MAPE = 14.40%, RMSE = 0.97 mm day−1, R2 = 0.82) and monthly (MAE = 0.32 mm day−1, MAPE = 5.88%, RMSE = 0.32 mm day−1, R2 = 0.99) average ETo. FAO-56 showed the nearest performance to Wahed & Snyder. The Snyder model presented the worst performance in estimating daily (MAE = 2.09 mm day−1, MAPE = 37.53%, RMSE = 2.36 mm day−1, R2 = 0.82) and monthly (MAE = 1.83 mm day−1, MAPE = 31.82%, RMSE = 1.87 mm day−1, R2 = 0.99) average ETo. It has been concluded that none of the six Kp models can be used to estimate the daily ETo in Kahramanmaraş located in the Mediterranean–Southeastern Anatolian transitional zone, and only Wahed & Snyder and FAO-56 can be used to estimate the monthly ETo without calibration. [ABSTRACT FROM AUTHOR]

To improve the uniformity of microwave heating and enhance the quality of continuous microwave drying for raspberry pulp, a self-developed programmable logic controller (PLC) control system with pulsed microwave output was implemented. The central composite experimental design method was employed to analyze the effects of four experimental factors, namely microwave duty cycle, pulse period, air velocity and drying time on the average temperature, temperature dispersion value, moisture content, moisture content dispersion value, anthocyanin retention rate, and anthocyanin retention rate dispersion value of raspberry pulp. The optimal process for pulsed microwave drying of raspberry pulp was obtained. Compared with dried pulp quality and uniformity indexes from pulsed microwave drying, commonly used feedback temperature control microwave drying, intermittent microwave drying, and continuous microwave drying processes to develop a continuous microwave drying quality optimization control system for raspberry pulp. The results showed that the magnetron from pulsed microwave drying in the form of pulse output rectangular wave form power through the PLC control system. Turning on the magnetron intermittently was more effective than continuous microwave heating. Pulsed microwave drying of raspberry pulp has better product quality and heating efficiency, lower cost and better reliability than feedback temperature control systems. The optimal process parameters for pulsed microwave drying were microwave duty cycle of 0.6, pulse period of 17 seconds, air velocity of 1.9 m/s, and drying time of 12.5 minutes. Compared with continuous microwave drying, pulsed microwave drying resulted in the highest quality of dried pulp as a 35.31%±0.55% increase in anthocyanin retention, a 33.59%±0.23% increase under feedback temperature control, a 16.42%±0.18% increase under intermittent microwave drying. Pulsed microwave drying can control the power to reduce the dried fruit pulp temperature, improve the uniformity of post-drying quality and provide a basis for the industrial production of dried raspberry products.

Water quality is essential for a healthy life, so it is necessary to look for technologies to measure its parameters in real time and automatically. The purpose of this study was to implement and determine the reliability of an automated system to evaluate the Organoleptic Water Quality intended for human consumption, in the urban distribution network of the district of Daniel Hernandez - Peru, using a Programmable Logic Controller (PLC) and Simulink. The study was carried out from January to March 2024, corresponding to the rainfall season. In the process of the research, a data acquisition and processing algorithm was implemented in a Simatic S7 1500 PLC with analog input module; using the National Sanitation Foundation Water Quality Index (NSF-WQI) methodology. The work focused on five key water parameters: potential hydrogen (pH), electrical conductivity (EC), turbidity, free chlorine (FCL) and temperature. The methodology included programming in contact language (KOP) of the algorithm for calculating subscripts for each parameter, according to the functions established by NSF-WQI. Measurements were performed with 4-wire sensing devices with 4-20 mA current signals, ensuring data accuracy. The interface to visualize the parameters and the water quality index was implemented in Simulink, communicating via OPC UA with the PLC server, facilitating the graphical representation of the Organoleptic Water Quality index. The overall equipment efficiency (OEE) or automated system implemented was 90.56%, indicating its acceptable reliability for evaluating water quality. By performing the measurements, with the sensors of the five parameters immersed in tap water, at each of the three established sampling points (Dwelling_1, Dwelling_2 and Dwelling_3) along the water distribution network, the system facilitated the automated and real-time evaluation of the quality, resulting in an average NSF-WQI of 83.08%, classifying the water as good for human consumption. This information is important for water quality management and can guide future treatments to achieve better quality.

Water quality is essential for a healthy life, so it is necessary to look for technologies to measure its parameters in real time and automatically. The purpose of this study was to implement and determine the reliability of an automated system to evaluate the organoleptic water quality intended for human consumption, in the urban distribution network of the district of Daniel Hernandez (Peru), using a programmable logic controller (PLC) and Simulink. The study was carried out from January to March 2024, corresponding to the rainfall season. In the process of the research, a data acquisition and processing algorithm was implemented in a Simatic S7 1500 PLC with analog input module; using the national sanitation foundation water quality index (NSF-WQI) methodology. The work focused on five key water parameters: potential hydrogen (pH), electrical conductivity (EC), turbidity, free chlorine (FCL) and temperature. The methodology included programming in contact language (KOP) of the algorithm for calculating subscripts for each parameter, according to the functions established by NSF-WQI. Measurements were performed with 4-wire sensing devices with 4–20 mA current signals, ensuring data accuracy. The interface to visualize the parameters and the water quality index was implemented in Simulink, communicating via OPC UA with the PLC server, facilitating the graphical representation of the organoleptic water quality index. The overall equipment efficiency (OEE) or automated system implemented was 90.56%, indicating its acceptable reliability for evaluating water quality. By performing the measurements, with the sensors of the five parameters immersed in tap water, at each of the three established sampling points (Dwelling_1, Dwelling_2 and Dwelling_3) along the water distribution network, the system facilitated the automated and real-time evaluation of the quality, resulting in an average NSF-WQI of 83.08%, classifying the water as good for human consumption. This information is important for water quality management and can guide future treatments to achieve better quality. [ABSTRACT FROM AUTHOR]

This paper presents simplest fuzzy logic controller (SFLC) PLC's based implementation applied to the cascade control strategy. Level and flow control loops are important and widely used in the oil and manufacturing industries to ensure a quality product. The control is used to maintain the level of the liquid in the tank at the desired value by manipulating the liquid in the reservoir. Two fuzzy sets on each input variable, five fuzzy sets on the output variable, five linear control rules, algebraic product bounded AND/OR operator, Larsen product inference and Centre of Sums (CoS) defuzzification are the components of this simplest nonlinear fuzzy controller to be implemented. The proposed work deals with the real implementation of a simplest fuzzy logic cascade control strategy designed on SIMATIC S7-300 Plc based on ladder diagram (LD) programming. In this paper, we have presented the results of the experimental tests of the conventional PI control strategy as well as the simplest fuzzy PI implementation applied to a PUL-2/EV cascade control device. Experimental results using this simplest fuzzy PI controller with the setpoint error shown that the setpoint tracking rise time can be reduced by 30% and the disturbance rejection time is decreased at 7sec compared to the conventional PID-PLC based controller, and concluded by stressing the importance of this new controller implementation. [ABSTRACT FROM AUTHOR]

Obtaining mathematical models of nonlinear cyber–physical systems for use in controller design is both difficult and time consuming. In this paper, an ANN-based method is proposed to design a controller for a nonlinear system that does not require a mathematical model. The developed ANN-based control algorithm is implemented directly on a real-time field controller, and its performance is evaluated without the use of auxiliary devices, such as PCs or workstations. By executing machine learning algorithms on local devices or embedded systems, edge artificial intelligence (Edge AI) with transfer learning gives priority to processing data at the source, minimizing the necessity for continuous connectivity to remote servers. The control algorithm was developed using the Matlab Simulink environment. The first and second ANNs were cascaded, wherein the first ANN computes the appropriate pressure signal for the given displacement, while the second predicts the force based on the pressure value from the first ANN. Subsequently, the ANN-based control algorithm was converted to SCL code using the Simulink PLC Coder and deployed on the PLC for operation. The algorithm was tested using two different scenarios. The conducted tests demonstrated the successful prediction of pressure signals corresponding to the targeted displacement values and accurate estimation of force values. Experimental work was carried out on PAM manipulators as a nonlinear model application, and the obtained results were discussed. [ABSTRACT FROM AUTHOR]

A wireless electronic pulse fish interceptor based on LoRa was developed to address the limited interception area and low intelligence level of traditional fish interceptors. The fish interceptor uses the Modbus RTU protocol to enable high-speed,long-distance wireless communication between a master and multiple slaves. Users can flexibly select the number of units, pulse frequency, pulse width, and other parameters according to different aquaculture areas to adapt to the ability of different fish to produce evasive responses in different water qualities. The host sends timing commands to control the slave to generate two inverted PWM square waves with deadband control, which, in turn, controls the IGBT for rapid commutation. This method is highly efficient, safe, and reliable, and it has low energy consumption and noise,which aligns with the current concept of green environmental protection. Additionally, the fish interceptor is equipped with conductivity, dissolved oxygen, pH, and temperature sensors on PLC. This allows for real-time monitoring of the water quality information of each slave point and the user's aquaculture area. This information plays a crucial role in supporting the user's aquaculture. An intelligent aquaculture platform based on the Internet of Things (IoT) has been developed using a C# environment. This platform can monitor the working status of the fish interceptor and the water quality information of each measurement point in real time. It can also carry out early warning of failures. The electronic pulse fish interceptor,with a pulse frequency of 3-12 Hz and pulse width of 0. 6-1. 2 ms,saves 60% electricity compared to SCR. It has implanted the new concept of " Internet of Things + Fisheries", which enables remote control by cell phone or computer. The practice has shown that the electronic pulse fish interceptor has the characteristics of automation,intelligence,and network. It can be applied to all kinds of aquaculture fish interceptor operations. [ABSTRACT FROM AUTHOR]

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In the solid-state fermentation of soybean meal, in order to provide suitable conditions for the growth and reproduction of microorganisms to achieve good fermentation effect, the real-time temperature was monitored and controlled in the complex fermentation environment. The temperature of the fermenter was controlled by PID closed loop with PLC and the experiments with the target value of 37 °C were designed. The results show that, the peptides content and ACE inhibitory activity of fermented soybean meal reach 4.45 g/kg and 53.2% respectively at the end point, which are 5.7% and 9.92% higher than that under natural fermentation state. The temperature control system can effectively improve the quality of soybean meal fermentation products and the method is feasible. This work provides a theoretical basis for the production-oriented solid-state fermentation of soybean meal industry. [ABSTRACT FROM AUTHOR]

Background Reference evapotranspiration (ETo), which is used as the basic data in many studies within the scope of hydrology, meteorology, irrigation and soil sciences, can be estimated by using the evaporation (Epan) measured from the class-A pan evaporimeter. However, this method requires reliable pan coefficients (Kp). Many empirical models are used to estimate Kp coefficients. The reliability of these models varies depending on climatic and environmental conditions. Therefore, they need to be tested in the local conditions where they will be used. In this study, conducted in Kahramanmaraş, which has a semi-arid Mediterranean climate in Turkey during the July–October periods of 2020 and 2021, aimed to determine the usability levels of six Kp models in estimating daily and monthly average ETo. Methods The Kp coefficients estimated by the models were multiplied with the daily Epan values, and the daily average ETo values were estimated on the basis of the model. The daily Epan values were measured using an ultrasonic sensor sensitive to the water surface placed on the class-A pan evaporimeter. The ultrasonic sensor was managed by a programmable logic controller (PLC). To enable the sensor to be managed by PLC, a software was prepared using the CODESYS programming language and uploaded to the PLC. The daily average ETo values determined by the FAO-56 Penman–Monteith equation were accepted as actual values. The ETo values estimated by the Kp models were compared with the actual ETo values using the mean absolute error (MAE), mean absolute percentage error (MAPE), root mean square error (RMSE) and determination coefficient (R2) statistical approaches. Results The Wahed & Snyder outperformed the other models in estimating daily (MAE = 0.78 mm day−1, MAPE = 14.40%, RMSE = 0.97 mm day−1, R2 = 0.82) and monthly (MAE = 0.32 mm day−1, MAPE = 5.88%, RMSE = 0.32 mm day−1, R2 = 0.99) average ETo. FAO-56 showed the nearest performance to Wahed & Snyder. The Snyder model presented the worst performance in estimating daily (MAE = 2.09 mm day−1, MAPE = 37.53%, RMSE = 2.36 mm day−1, R2 = 0.82) and monthly (MAE = 1.83 mm day−1, MAPE = 31.82%, RMSE = 1.87 mm day−1, R2 = 0.99) average ETo. It has been concluded that none of the six Kp models can be used to estimate the daily ETo in Kahramanmaraş located in the Mediterranean–Southeastern Anatolian transitional zone, and only Wahed & Snyder and FAO-56 can be used to estimate the monthly ETo without calibration.

This research aims to (1) examine the differences in learning outcomes of programmable logic controllers between cadets who use problem-based learning strategies assisted by mockup media and problem-based learning strategies, (2) examine the differences in learning outcomes of programmable logic controllers between cadets who have high and low initial abilities, and (3) examine the interaction effect between learning strategies and initial abilities on learning outcomes of programmable logic controllers. This research uses a 2 x 2 factorial design with the object of research being the 3rd-semester airport electrical engineering study program students at Aviation Polytechnic Surabaya. The sample of this research includes 47 students of the TLB 11 AB class as the experimental group of problem-based learning strategy assisted by mockup media and 46 students of the TLB 12AB class as the control group of problem-based learning strategy. A learning outcomes test collected the data on learning outcomes in the form of multiple choice. Learning outcomes data were analyzed using two-tailed ANOVA (analysis of variance). The results showed that there is a significant difference in learning outcomes of the programmable logic controller between cadets who learn using problem-based learning assisted by mockup media and problem-based learning, there is a significant difference in learning outcomes of the programmable logic controller between cadets who have high and low initial abilities, there is no interaction effect between learning strategies and cadets' initial abilities on learning outcomes of the programmable logic controller. This research can contribute to improving students' understanding and skills in the field of PLC. Through practical experience and relevant projects, students can develop a deeper understanding of PLC concepts and improve their technical skills in designing, implementing, and solving problems related to PLC systems.

To develop a cost-efficient robot arm for a typical pick and place application that can applied in industry, this paper deployed a programmable logic controller (PLC) to control the rotation motion of the robot joints. The main tasks of the PLC controller are to calculate the kinematics, create high-speed pulse outputs for stepper motors, and implement sequence operations for a certain application. Functions are written into subprogram segments. When needed, the main program only turns on the corresponding flag for executing the subprogram. Using the pre-written subprograms, a logical sequence to implement the Pick and Place application is easily implemented and described in this paper. The PLC program is developed to control a SCARA robot with three rotation joins. Stepper motors drive the robot joints. The Delta DVPSV2 PLC is utilized to design the robot controller. This PLC series has four high-speed pulse output pins, which is suitable for this project. Synchronous motion of stepper motors is easily performed using high-speed pulse output commands built into the PLC program. Experimental results of robot arm control have demonstrated the efficiency and accuracy of the developed program. The robot arm's forward and inverse kinematics problems are verified using the simulator on the software. The robot's joints move synchronously as required to perform pick-and-place applications.

The object of research is an automated system for controlling the bending mechanisms of the folding-gluing line for cardboard packaging products. In the work, the ways of optimization and the development of an automated control system for the bending mechanisms of the folding and gluing line, which makes it possible to fold various structures and standard sizes of cardboard boxes using modern automation tools based on programmable logic controllers, were carried out in the work. A mathematical model has been proposed to describe operations on the folding-gluing line. Based on the model, a methodology has been developed for calculating the parameters of the automated control system for the box folding production line, depending on the technical parameters of the line and the parameters of the boxes to be bent. This will make it possible to choose optimal technological modes of the production process and obtain high quality parameters of cardboard packaging products. To verify the mathematical model of the production line, software has been developed in the Delphi development environment, which was applied with the developed automated production process control system based on a programmable logic controller (PLC) and an operator panel. This produced a number of results, in particular, controlling the speed of the hook bend in proportion to the speed of the line. And also provided an opportunity to increase line speed and, accordingly, production productivity. It has been possible to change the mutual location of system elements, which made it possible to reduce the distance between workpieces and increase the capacity of the line tape by 30 %. The obtained research results were implemented at the production enterprise of typographic products «Dinas» (Zaporizhzhia, Ukraine), which contributed to the improvement and optimization of production processes. Conducting further research will provide an opportunity to expand the proposed methodology for use on all types of folding and gluing lines. [ABSTRACT FROM AUTHOR]

Induction motors are widely used in industries as well as some home appliances. It is therefore necessary to provide protection from likely sources of faults such as overcurrent, overvoltage, under voltage and high temperature. The continuous and intensive use of squirrel cage induction motors in modern industry has in some cases caused a serious deterioration of the electrical insulation in the windings of the machine, generating internal short-circuit failures. Early detection of the fault is essential due to technical and economic issues. The classical method of protecting induction motors from faults involves the use of timers, contactors, and voltage and current relays. Simulation of fault detection is observed using DVPSS2 series PLC with the ISP Soft and DOP Soft software. The results are validated using the hardware experimental setup including voltage, current relays with contactors and auxiliary relays. The method is highly reliable in protection of motor for various conditions. [ABSTRACT FROM AUTHOR]

Relevance. It is justified by the necessity to confirm the operability of the algorithm of accurate movement of the selected wood sorting to the corresponding storage bunker in the technological process of roundwood sorting at winter warehouses of timber processing companies to solve scientific and engineering problems both at present and in the future. Aim. To investigate the process of moving piece load on the physical model of longitudinal chain or belt conveyor, providing scaled reduction of positioning error. When sorting roundwood on chain longitudinal conveyors of considerable length, there is an error of movement of the selected roundwood sort to the place of discharge into the accumulator, which increases in proportion to the length of the sorting line. At present, conveyors of limited length are used. The accumulators are located on both sides of the conveyor. This reduces the transport error. Sometimes the sorting yard does not allow placing a short conveyor on it or there is a considerable amount of assortments. In this case, it is necessary to use a conveyor of considerable length. The paper proposes a new method of sorting roundwood on longitudinal chain conveyors of considerable length. This reduces the tracking error of the movement of the assortment. Optoelectronic sensors of angular displacements of the leading and driven shafts of the belt conveyor are used as sensors of angular displacements of the shaft. Methods. Physical modelling, information-static processing methods. Results and conclusions. The authors have carried out the analysis of the structure of the physical similarity stand of the longitudinal conveyor; sensors of the technological process, namely, angular frequency of rotation; software and hardware means of processing the obtained information to minimize the error of transporting piece cargo on the conveyor belt. The results of the study confirm the possibility of practical application of the device for operation on longitudinal conveyors.

As the electrical system of mine digging anchor machine always encounters maintaining difficulties and mechanical failure, the mainstream electrical design principles, cable introduction devices, and control methods of current anchor digging machine are studied. At the same time, programmable logic controller is selected as the main controller, and the explosion-proof electric control box is optimized and redesigned. The optimized electrical control box for anchor digging machine is composed of external structure, distribution circuit, intrinsic safety electrical circuit, motor comprehensive protection circuit, and human-machine interface. It also has the characteristics of rich interfaces, simple assembly, and convenient programming and debugging. Practical applications have shown that the use of this electric control box for the anchor digging machine is convenient for maintenance, low in failure rate, and high in excavation efficiency. [ABSTRACT FROM AUTHOR]

Critical infrastructures are making increasing use of digital technology for process control. While there are benefits, such as increased efficiency and new functionality, digitalization also introduces the risk of cyber-attacks to systems that support critical functions. A valuable target in these Industrial Control Systems (ICSs) are the Programmable Logic Controllers (PLCs) controlling the machinery that manages a physical process. PLCs have proven to be vulnerable to a range of cyber-attacks in the past; however, newer technologies such as embedded servers and virtualization have the potential to improve this situation and be used to monitor a PLC's function. In this article, the implementation of a Host-based Intrusion Detection System (HIDS) for a modern PLC is described. This method uniquely makes use of native technologies on the PLC to monitor a dynamic simulated process in real time. Both the PLC's integrity (checksum, file size, etc.) and the process control are monitored to determine whether the PLC has been compromised in a cyber-attack. The proposed solution detects a range of attacks, even when the PLC's control logic is compromised and—unlike previous PLC HIDS methods—requires no modification of the underlying PLC technology. [ABSTRACT FROM AUTHOR]

Cyberattacks targeting industrial control systems (ICS) are becoming more sophisticated and advanced than in the past. Programmable logic controller (PLC), a core component of ICS, controls and monitors sensors and actuators in the field. However, PLC has memory attack threats such as program injection and manipulation, which has long been a major target for attackers, and it is important to detect these attacks for ICS security. To detect PLC memory attacks, a security system is required to acquire and monitor PLC memory directly. In addition, the performance impact of the security system on the PLC makes it difficult to apply to the ICS. To address these challenges, this paper proposes a system to detect PLC memory attacks by continuously acquiring and monitoring PLC memory. The proposed system detects PLC memory attacks by acquiring the program blocks and block information directly from the same layer as the PLC and then comparing them in bytes with previous data. Experiments with Siemens S7-300 and S7-400 PLC were conducted to evaluate the PLC memory detection performance and performance impact on PLC. The experimental results demonstrate that the proposed system detects all malicious organization block (OB) injection and data block (DB)manipulation, and the increment of PLC cycle time, the impact on PLC performance, was less than 1ms. The proposed system detects PLC memory attacks with a simpler detection method than earlier studies. Furthermore, the proposed system can be applied to ICS with a small performance impact on PLC. [ABSTRACT FROM AUTHOR]

Programmable control for automated production is an essential technology for industrial development. In addition, a flexible main control system and scheduling management can significantly improve production efficiency. This study improved a programmable logic controller (PLC) subroutine module and communication methods using the modular production system (MPS) automated workstation developed by Festo to optimize the process of production. First, a simulated production line with feeding, transportation, discrimination, and processing stations was set up in a laboratory. Experiments and tests were performed, and data were collected. Consequently, different program editing and planning methods, such as program modularization, step system, and subroutines of the busbar, were proposed for PLC and automation systems. The design with clearer and more modularized subroutines was used to improve the production line performance and stability and achieve dynamic scheduling to optimize the production line efficiency to meet the demands. [ABSTRACT FROM AUTHOR]

In cable production, it is imperative to control speed and tension. This paper proposes a web tensile force regulation between input and output pulling caterpillar devices. The web tensile force is controlled indirectly using a PI controller based on feedback information about tensile force using a tensile observer. This paper also deals with the regulation speed of the input-pulling caterpillar device and the speed and torque (current) of output pulling caterpillar device and deals with the effect of line speed on the temperature change at the extruder zones. The input and output-pulling caterpillar devices are connected by the web material that is processed on them. The input and output-pulling caterpillar devices are connected by the web material that is processed on them. The task was realized using a programmable logic controller Micrologix 1200 controller and SIMOREG DC drives, which regulate the input caterpillar's speed and output caterpillar's torque. The identification of separately excited DC motors parameters was made. Models for the input, output caterpillars and web zone were simulated in MATLAB and SIMULINK. The controllers of the current loop, velocity loop, and tension loop are all integral isolated PI regulators. Speed signal is obtained by tacho generator. In practical realization, tensile force is observed directly from the Simoreg DC converter, eliminating the tension sensor. The tensile force controller is realized with the PI controller, which was realized with programmable logic controller. Setting optimal parameters is performed using ITAE criteria. The ITAE function is calculated using a complex Simpson's quadrature formula. [ABSTRACT FROM AUTHOR]

Designs of timer function blocks (FBs) are presented in the article. The developed modules are IEC 61131-3. An analysis of IEC 61131-3 in terms of timer functionality and implementation options is presented. Three types are presented, timer-on, timer-off, and timer-pulse, with each type designed to be fully hardware or software-like. Both designs, hardware or software-like, can operate as multi-channel timers. Particularly noteworthy is the software-like design, for which a solution without edge detectors was achieved. Such a feature was obtained by reversing the method of time determination by counting the difference between the start and end times and by using specific features of the D flip-flops, that is, clock-enable inputs. The presented timers were written in Verilog language and implemented in an FPGA chip. Thanks to the universal design of the interface, the proposed FBs can be used for the hardware support of existing programmable logic controllers (PLCs) or as an integral part of newly built PLC CPUs. The idea of a CPU architecture with hardware support is proposed. The paper presents the results of the implementation in an FPGA of the Kintex UltraScale+ family from AMD-Xilinx. [ABSTRACT FROM AUTHOR]

Industrial systems require efficient techniques to observe the stable operation of various industrial processes and to achieve optimal control. Considering the importance of industrial processes, Proportional Integral and Derivative (PID), Adaptive PID, and fuzzy logic are the most utilized control systems. Programmable Logic Controller (PLC) is a low-cost solution for the industrial processes requiring control and having the flexibility of graphical user interface. In this paper, an experimental study on flow rate control system for water flowing in a vessel is realized and implemented using Proportional (P), Proportional Derivative (PD), Proportional Integral (PI), and PID controllers with Programming Logic Controller (PLC). For optimal control, the constants for the PID controller are calculated based on Zeigler-Nichols (ZN) rules. ZN tuning rules can be used to find controller constants where the plant dynamics are not available. The experimental analysis is performed to validate the theoretical concepts. The achieved results and analysis demonstrate that the process variable, which is water inflow rate 4.92L/minute, is equal to the set point without any overshoot and remains controllable at every set point change. [ABSTRACT FROM AUTHOR]

Obtaining mathematical models of nonlinear cyber–physical systems for use in controller design is both difficult and time consuming. In this paper, an ANN-based method is proposed to design a controller for a nonlinear system that does not require a mathematical model. The developed ANN-based control algorithm is implemented directly on a real-time field controller, and its performance is evaluated without the use of auxiliary devices, such as PCs or workstations. By executing machine learning algorithms on local devices or embedded systems, edge artificial intelligence (Edge AI) with transfer learning gives priority to processing data at the source, minimizing the necessity for continuous connectivity to remote servers. The control algorithm was developed using the Matlab Simulink environment. The first and second ANNs were cascaded, wherein the first ANN computes the appropriate pressure signal for the given displacement, while the second predicts the force based on the pressure value from the first ANN. Subsequently, the ANN-based control algorithm was converted to SCL code using the Simulink PLC Coder and deployed on the PLC for operation. The algorithm was tested using two different scenarios. The conducted tests demonstrated the successful prediction of pressure signals corresponding to the targeted displacement values and accurate estimation of force values. Experimental work was carried out on PAM manipulators as a nonlinear model application, and the obtained results were discussed.

SMK Negeri 1 Balige memiliki konsentrasi bidang teknik instalasi tenaga listrik dan perlu ditingkatkan kemampuannya dalam otomasi industri, khususnya Programmable Logic Controller (PLC). Berdasarkan kebutuhan ini, tim pengabdian kepada masyarakat (PkM) tergerak untuk dapat ikut berkontribusi dalam diseminasi pengetahuan dibidang otomasi PLC. Kegiatan pelatihan dilaksanakan dengan mengkombinasikan sesi pelatihan teori secara daring dan praktik menggunakan PLC Trainer KIT OMRON. Selama pelatihan, peserta telah memperoleh pengetahuan dan keterampilan PLC level dasar. Hasil evaluasi menunjukkan terjadinya peningkatan kemampuan PLC sebesar 0,3 (kategori sedang). Pendampingan dan pelatihan PLC ini perlu dilanjutkan guna memberikan wawasan dan ketrampilan tambahan bagi para siswa/i SMK Negeri 1 Balige dalam upaya peningkatan daya saing tenaga kerja di bidang otomasi industri.

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Most of the old machines installed in different industries are managed manually by system operators. This action makes their productivity low and not suitable to cover the needs in other sectors. In addition, these machines are not without risks due to the proximity of the operators to them. The installing a new full system instead of the old one on the same site requires very high costs. So, modernizing the same old system by making its operation automatic has become necessary to reduce the economic cost significantly. In this paper, an automatic control system based on programmable logic controller (PLC) for the cutting steel plate machine that had been managed manually in a factory is designed. The system includes an Encoder that is used to specify the length of the steel plate to be cut by sending a signal to the PLC. The system operation is completed by using human machine interface (HMI) unit to monitor and control the system performance by the system operator. A practical test for the developed system offered more productivity (more than 30%), more safety, reduces human efforts and the total daily production cost (less than one third). [ABSTRACT FROM AUTHOR]

The intelligent production line is generally composed of industrial robot workstations or multiple workstations, with complex process, large equipment investment, and difficult on-site debugging. In order to solve the problem of difficult on-site debugging, virtual simulation debugging technology has been gradually applied to the debugging of industrial robot workstations and intelligent production lines. In order to improve the debugging efficiency and safety of the industrial robot workstation, taking the industrial robot simulation assembly workstation as an example, the authors propose a virtual simulation debugging method based on the simulation software OCTOPUZ for the industrial robot workstation and Siemens programmable logic controller (PLC). We created an OCTOPUZ simulation model for an industrial robot workstation using SolidWorks and completed offline programming and PLC programming of the industrial robot in a personal computer based on the workstation’s task flow. In response to the problem of information exchange between simulation software OCTOPUZ and PLC during the simulation of industrial robot workstations, OLE for process control technology is adopted, with PLC as the server and OCTOPUZ as the client, in order to achieve real-time interaction of control signals between PLC and simulation software OCTOPUZ; thus, the virtual simulation joint debugging of PLC and industrial robot workstation was completed. The effectiveness of the virtual debugging scheme of industrial robot workstation and the correctness of industrial robot program and PLC program are verified. In practice, the simulation debugging before the equipment construction can find and solve the program problems in advance, and improve the efficiency of the workstation design programming and debugging. Through simulation, problems in the design of industrial robot control programs, PLC control programs, and other electromechanical components during workstation assembly can be identified and solved in advance, saving the cost of actual equipment debugging, thus improving the debugging efficiency and safety of actual equipment.