PROBLEM DEFINITION & POSSIBLE SOLUTIONS

PROBLEM DEFINITION
In the modern era of revolutionized Industrial Automation and distributed control system, every industry want to automate and centralize all of their projects and operating plants that can be monitored and controlled within a single room and decreasing man power. Programmable Logic Controllers, which serves as an enabling technology by providing such an interface between utility and load that could follow a communication protocol. In an operating industry a problem of interfacing and networking different brands (vendor) of PLCs with a single HMI PG/PC device has vital significance and for that purpose it needs solutions like Communication processors and other communicating devices. So covering these issues we have to find the solution.

PROBLEM DESCRIPTION
To monitor and control four plants, each on an individual PLC & one field device, through a communication protocol. The task is to design a cost effective system for the implementation with following elements:  Physical Field Model  Remote Terminal Unit (PLC)  Communication Equipment  Human Machine Interface Physical field model (Plant), in the project we decided to integrate four plants, two with digital I/Os and others with analog I/Os.
Plant#01 (Digital I/Os)

Four Story Elevator Station (12 digital inputs & 05 digital outputs).
Plant#02 (Digital I/Os)

Industrial Height wise Sorting Conveyor Station(03 digital inputs & 5 digital outputs).
Plant#03 (Digital & Analog I/Os)

Water Flow & Level Control Industrial Monitoring Station(02 Analog Inputs & 03 digital outputs).
Plant#04 (Digital & Analog I/Os)

Variable Frequency AC Motor Industrial Control Station (Via LG VFD as a field device)

POSSIBLE SOLUTIONS
The task is to communicate number of PLCs implemented via communication protocol, in that three PLCs & a field device gather data from remote filed devices and communicate with a central control room computer, equipped with HMI software. This task actually involves the selection of communication protocol equipment and HMI software. We are using one ABB PLC and one Fatek PLC and one Delta PLCs and LG VFD as a field device in the project. Let us look at the probable solution for achieving the task.

Available communication Protocols
To establish communication between PLCs to PLC and with field devices device, following communication standers are available[1]:  MODBUS  PROFIBUS  FOUNDATION FIELDBUS  HART(Highway Addressable Remote Transducer)  INTERBUS Below the figure represents the worth wide utilization of communication protocols widely used Figure 1.1.3(a): Comparison of Worldwide utilization of in the field of industrial automation. communication
protocols for PLC’s Communication

Programming Each PLC For RespectivePlant 10. It is 1979 when PLC manufacturer Modicon—now a brand of Schneider Electric's Telemecanique— published the Modbus communication interface for a multi drop network based on master/client architecture. Plant Descriptions 7. While HART (Highway Addressable Remote Transducer) is the first most according to its implementation & sustainable with very harsh environments usage & good performance. Modbus Communication Description 3. In a short time hundreds of vendors implemented the Modbus messaging system in their devices and Modbus became the de facto standard for industrial communication networks[3].Modbus and Profibus are the second most significant communication protocols widely used in the industries for the implementation & communication. Foundation Field bus also has significant demand in the industry &Interbus also used in some industries. which serves as an enabling technology by providing such an interface between utility and load that could follow a communication protocol. The original Modbus interface ran on RS232. The featured following characteristics:  Completely Automated Communication of different Vendor PLCs & Field devices. Different plants and setup of PLCs are used to implement automation techniques which are comprised of three different PLCs and a field device as the key component by which four plants are controlled and monitor through HMI application. So these can be the possible solutions for the implementation & communication of different vendors PLC’s[1]. Different vendor PLC’s communication is a big deal in industrial automation & the assigned project will lead us to understand the queries & solutions for the communication of different vendor PLC’s via Modbus communication. Modbus is the second most significant communication protocols widely used in the industries for the implementation & communication. Hardware Description For Implementation 5. Selection Of Communication Protocol For Solution 2. 9.  Modbus Communication implementation via RS-485(half duplex). but later Modbus implementations used RS-485 because it allowed longer distances.  User Friendly & Monitoring and Controlling through single HMI. Modbus Addressing Of Slave Devices 6. ASSIGNED TASK To solve the stated problem following important and significant tasks are assigned and listed below: 1. The physical layer of the Modbus interface was free to choose. Human machine Interface (HMI) development & interfacing with Master PLC using OPC server SELECTION OF COMMUNICATION PROTOCOL FOR SOLUTION The major driving force for the present day Industrial and Information Technology revolution is the development in Electronics Engineering. higher speeds and the possibility of a true multi-drop network. it is widely used in several industries to generate valuable solutions to the complex industrial issues. Master Programming ForCommunication Of Three Salves. . Communication between the Modbus nodes was achieved with messages. It was an open standard that described the messaging structure. Slave Programming For Communication 8. MODBUS COMMUNICATION DESCRIPTION Modbus has its roots in the late seventies of the previous century. Block Diagram Of System 4. particularly Programmable Logic Controllers. For this.

although RS422/RS485 interfaces are also used. which is received by the slaves. Figure 2.the address of the responding slave . The master can address individual slaves or can transmit a message to be received by all slaves through a broadcast message. known as an exception response.the action it was requested to carry out . The sequence begins with the master issuing a request or command on the bus (a 'query'). Modbus slaves will only transmit on the network when required to do so by the master. in which only one device (the master) can initiate a communication sequence. The type of interface used defines the connector pin-outs. this will be returned as part of the response. This error message. Transmission rates and parity checking are not defined either and will depend on the serial interface used and the options made available by the manufacturer of each individual Modbus device. address 0 is reserved for broadcast messages. supplying requested data to the master or informing the master that the required action could not be carried out. The format of these Modbus messages is independent of the type of physical interface used. Modbus message structure Field Function code Data Description Code defining message type Data block with additional information Device address Address of the receiver Error check Numeric check value to test for communication errors Table3. Modbus supports up to 247 slaves from addresses 1 to 247 (JBUS 1 to 255).2. For example RS485 is limited to a total of 31 slaves[3]. Messages broadcasted to all slaves do not require responses. On simple interfaces like RS485 the Modbus messages are sent in plain form over the network.2. If the slave cannot carry out the requested action. The slaves respond by taking appropriate action. Modbus ports frequently employ RS232-C compatible serial interfaces. or it informs the master that the action required could not be carried out. indicates to the master: .2(c): Modbus Message Structure . understood and acted upon. the cabling and the signal levels. then it will respond with an error message. the number of slaves that can be used is determined by the physical communication link that is chosen. Slaves never transmit unsolicited messages. This is decided by the equipment manufacturer and a wide range of options are available.an indication of why the action could not be completed Modbus does not specify how numerical data shall be encoded within a message. Modbus Message Structure The Modbus communication interface is built around messages. these are not defined in Modbus.Modbus Master-Slave Communication Modbus controllers communicate using a master-slave technique. In practice. RS-485 compatible serial interface Modbus slaves will only transmit on the network when required to do so by the master. .2(a): Modbus Master-Slave Communication If the query requests data from the slave. Slaves never transmit unsolicited messages. The response confirms that the message was received.

In Modbus/ASCII it is coded with two hexadecimal characters. characters are used to start and end a frame.. remote terminal unit.F are used for coding. the messages are in a readable ASCII format.5 chars silence 3.. A device configured to use Modbus/ASCIIcannot understand messages in Modbus/RTU and vice versa... Messages sent to the latter address will be accepted by all slaves.. With Modbus/RTU the data is exchanged in a binary format.Each Modbus message has the same structure.. where each byte of information is coded in one communication-byte. but reduces the size of each message which allows for more data exchange in the same time span.9 and A. represented with readable ASCII characters. In this way the master can see that the device is actually responding to the request.2(e) Modbus Addressing The first information in each Modbus message is the address of the receiver. because every communication-byte can only define 4 bits in the hexadecimal system. in Modbus/RTU one byte is used. Four basic elements are present in each message..When using Modbus/ASCII. two communication-bytes are needed. With Modbus/ASCII. all messages are coded in hexadecimal values..255 LRC Longitudinal CRC Cyclic Redundancy Check Redundancy Check character ':' characters CR/LF 1 sec 1 7 even/odd 1 none 2 3. ASCII or RTU.F Modbus/RTU Binary 0. The transmission mode in serial communications defines the way the Modbus messages are coded. 1. Properties of Modbus/ASCII and Modbus/RTU Modbus/ASCII Characters Error check Frame start Frame end Gaps in message Start bit Data bits Parity Stop bits ASCII 0. Only the characters 0.5 chars silence 1. Each message must be preceded by a time gap with a minimum length of 3. This parameter contains one byte of information.2.247 are assigned to individual Modbus devices and 0 is used as a broadcast address.. When responding it uses the same address as the master in the request.2. A conversation is always started by a master in the Modbus network.. to make it easy to parse the content of the Modbus message.. The values 1. All nodes on one Modbus network segment must use the same serial transmission mode.2(d): Modbus serial transmission modes Modbus messages on serial connections are not sent in a plain format.. The Modbus/RTU format uses binary coding which makes the message unreadable when monitoring. Addressing in the message header is used to define which device should respond to a message[4]. The sequence of these elements is the same for all messages. For every byte of information. Modbus/RTUon the other hand uses time gaps of silence on the communication line for the framing. When using Modbus/ASCII. Valid addresses are in the range 0.5 characters. Modbus Serial Transmission Modes (Modbus ASCII & Modbus RTU) Serial Modbus connections can use two basic transmission modes. The colon ':' is used to flag the start of a message and each message is ended with a CR/LF combination.247. A slave always responds to a Modbus message. They are framed to give receivers an easy way to detect the beginning and end of a message.9 and A.5 times char length 1 8 even/odd 1 none 2 Table4. ..

However.. In that way the master can see the difference between success and failure responses[4].Device and Modbus address ranges Device address 1.. When a Modbus slave answers a response. BLOCK DIAGRAM OF SYSTEM Industrial Grade System Integration using Modbus Communication consists of three different brands of PLC’s and a field device.. Master is controlling the whole process and communicated with the entire slave by single shielded twisted pair cable following RS-485(half duplex). inputs and outputs are assigned a number between 1 and 10000. Modbus Function Codes The second parameter in each Modbus message is the function code. the highest bit of the function code is turned on.. This defines the message type and the type of action required by the slave. when an error is detected.20000* 40001.10001 address . In the Modbus messages addresses are used with a value between 0 and 9999[4]. . Human Machine Interface (HMI) connected with the master via RS-232 as shown the block diagram below..1 address .. it uses the same function code as in the request.10000 * Modbus address address . The same addresses are used in the Modbus messages to read or set values.2. the holding registers.2(e): Modbus addressing Within a Modbus device. Every device & every standard utilized in the project is of industrial grade.50000 * Table 5. Unfortunately this is not the case.40001 Description Coils (outputs) Inputs Holding registers 10001.

PLC HARDWARE DESCRIPTION FOR IMPLEMENTATION Industrial Grade System Integration using Modbus Communication consists of three different brands of PLC’s and a field device as described in the table below. Reply delay time. Forward. Parity. third slave is a field device which is Modbus supported that’s why its directly connected with the master & controlling AC motor station. the master PLC is also controlling a plant according to the programmed subroutines. b. Transmission delay time.Each PLC as a slave is controlling different plants according to the programming and controlled by the master (HMI).g. Stop bit. Every Fatek PLC has its Communication Parameter setting at port2 having Baud Rate.e. Following figure below shows the Modbus addresses of all the three slaves PLCs and field device. Four Story Elevator Control Station (Control via Master) Industrial Height wise Sorting Conveyor Station (Control via SlaveI) Water Flow & Level Control Industrial Monitoring Station(Control via SlaveII) Variable Frequency AC Motor Industrial Control Station (Control via SlaveIII) . LG Field device variable frequency drive (VFD) reference operations are also highlighted in the above figure for different operations e.2. Master ABB PLC (AC500) Analog Inputs = 08 Analog Outputs = 08 Digital Inputs = 08 Digital Output = 08 Digital Inputs = 08 Digital Output = 06 Analog Inputs = 04 Analog Outputs = 02 Digital Inputs = 08 Digital Output = 06 ---- Slave-I Slave-II FATEK PLC (FBs-14MAR) DELTA PLC (DVP20EX2) Slave-III LG VFD (SV-iG5) Industrial ABB PLC has chosen as a master & FATEK & DELTA PLC’s are acting as slaves while a LG field device is also used as third slave as it’s a field device so it has no any I/O. c. SIEMENS (WinCC Flexible 2008) is used as the front end HMI software. receive timeout interval time & Protocol setting for the communication with the master. Start & emergency Stop.4(a): Different bands of PLC & their I/O descriptions. The list of the Software’s utilized for the Master & slave programming are listed in the table below. PLANT HARDWARE DESCRIPTIONS Following are the four hardware plants controlled by master & each slave: a. Hmi Software ABB PLC (AC500) FATEK PLC (FBS-14MAR) DELTA PLC (DVP20EX2) Simulation Softwares SIEMENS(Wincc Flexible 2008) Codesys_V2. d. Reverse.1 Wplsoft_V2. MODBUS ADDRESSES OF SLAVE DEVICES Every Modbus supported device has Modbus slave addresses for the protocol communication configuration. The last slave i.3 Winproladder_3. Data Bit.20 Modscan_32&Modsim_32 Table6. However.

These actuators are commonly made by the simple DC Motors. The plant is controlled via Delta PLC Slave-II having total 14 digital I/O’s including 06 analog I/O’s. of sensors and actuators for different defined height objects (boxes)  Three sensors of OMRON which are Photoelectric (IF) sensors used[9]. Industrial Height wise Sorting Conveyor Station Sorting is any process of arranging items in some sequence and/or in different sets. These actuators are made in a less U-shaped mechanism to actuate objects easily to their respective destination. in some ordered sequence. it has two common. Total 17 digital I/O’s are required for the operation of the plant including 12 digital inputs & 05 digital outputs. The physical parameters will be sensed by appropriate sensors the ten turn pot generate analog signals which will be conditioned by the use of signal conditioners after thatthe analog signals are fed to the PLC analog inputs[2]. In our project we use no. fault free and proper operation of process industries. The four story elevator prototype contains the limit switches as the gate & Floor sensors & inner & outer call buttons and a heavy geared DC motors& four seven segment displays used to display the floor position of the elevator box. Today.  Categorizing is grouping and labeling items with similar properties together (by sorts). All DC motors are of 24 DC volts. and accordingly. The exercise carefully and wisely divided into different task to cover the practical implementation as well as the theoretical aspects of the project [2]. The achievement of this plant is that it has provided process industry with an easy access alternate which is cost efficient and equally reliable. Three photo sensors are used of Omron brand in which they are located in different. The exercise aims for the accurate controlling of the elevator bucket’s height digitally with a PLC. etc. The system primarily designed to explicitly illustrate the essential components of the Roped Elevator System. “Liquid flow and level control” is one of them that ensure safe. Total 08 digital I/O’s are required for the operation of the plant including 03 digital inputs & 05 digital outputs. nature. The plant is controlled via ABB master PLC having total 32 digital I/O’s including 16 digital inputs & 16 digital outputs. electronics apart from other applications is committed to designing and developing of broad range of electronic systems used in automated processes serving in an industrial environment. Total 03 digital outputs & two analog inputs are required for the operation of the plant. In this system the important parameters of any process industry is monitored and controlled. The pots are calibrated such that the motorize valve & level can be input from HMI & achieve at the graduated scale. PLC can be used to control liquid flow and level control. Water Flow & Level Control Industrial Monitoring Station Industries require a source to acquire the plants data and their monitoring on computers. . yet distinct meanings:  Ordering is arranging items of the same kind. The plant is controlled via Fatek PLC Slave-I having total 14 digital I/O’s including 08 digital inputs & 06 digital outputs. Two 10 turn pots are used for the flow & level feedback in the control tank while a solenoidal valve is also present to drain the water from tank. class. This sort of an exercise is extremely helpful in understanding the concept s of a complete Control system and has been designed in a simple yet realistic manner. Three actuators are used to actuate three different types of objects in which they all are situated to their respective sensor position (at bottom of their respective sensors).Four Story Elevator Control Station Four Story Elevator Control Station plant is a prototype of an elevator having 4 floors.  Three actuators are used to sort different height objects to their respective destination  One Conveyer belt is used for taking object in forward direction A sensor (also called detector) is a device that measures a physical quantity andconverts it into a signal which can be read by an observer or by an instrument.

The master ABB PLC program contains a Modbus_RTU_AC500 block for the purpose of interfacing with other slaves. For complete program please see appendix A. We used 750 watts induction motor in this project because it is easily available in our PLC Lab. The master ABB PLC program contains a Modbus_RTU_AC500 block for the purpose of interfacing with other slaves. SLAVES PROGRAMMING FOR COMMUNICATION On Modbus communication there is verity of settings of master addressing to the slave depends upon the vendor & settings of the device.Variable Frequency AC Motor Industrial Control Station LG Variable Frequency Drive (VFD) is used to control the parameters of AC Motor and vice versa. JOB_END_RTU. . In the figure below the left most one shows the setting of fatek PLC as slave-I including Baurd Rate. And the total capacity of VFD to drive Induction Motor is 1HP (horse power). Data Bits & stop bit. Fatek PLC can be set as slave or master by configuring internal software settings as slave or master. Master PLC utilized a block named Modbus_RTU_AC500 for the addressing of each slave & data sending & receiving JOB_STAR_RTU. MASTER PROGRAMMING FOR COMMUNICATION WITH THREE SALVES Codesys Software is utilized for the programming of master Programming with the three slaves. The program contains D1120 special purpose register for Baud rate & Parity Settings & K2 is the slave id which is assigned (moved) to the special purpose register D1121. Parity. The diagram below shows the starting few networks of the program. The right lowest most section of the figure is Delta PLC slave program. Reply delay time. For example. The diagram above shows the starting few networks of the program. The block contains Job to assign different operations. ADR blocks are the pointers which points the coming data from the slave to the defined arrays of different data types for specified operatons. is SV008IG5. . Some devices only required software settings to become as a slave or as a master. The block contains Job to assign different operations. TIMEOUT_RTU. For complete program please see appendix A. Transmission delay time. The basic available operating functions in VFD are[11]:  DC Braking  Frequency Limit  Frequency Jump  Second Jump  Second Function  Slip  Compensation  Reverse Rotation Prevention  Auto Restart  PID Control But we used only three parameters of it to drive Induction Motor:  On-Off Controlling  Forward-Reverse Direction Controlling  Speed Controlling LG Variable Frequency Drive (VFD) is a field devicedirectly connected to the master via Modbus (RTU) communication as LG VFD is Modbus supported and utilized for the controlling of AC Motor and vice versa. JOB_RTU & DATA_RTU are essentially used for the Modbus communication. The motor we used to control its parameters is Induction Motor in delta connection. The motor we used to control its parameters is Induction Motor. VFD used in our project is LG brand and its serial no. receive timeout interval time & Protocol setting for the communication with the master.Induction Motor is actually the AC Motor in which power is supplied to it by means of electromagnetic induction process. In similar pattern as mentioned above some of the slave required a program to respond with the Master.

.....= EA..4) The torque on the conveyor belt motor is given by..3. ANALYSIS (MATHEMATICAL MODELLING) This section contains the possible mathematical modeling of Plants.....3.. F =W …………………………………………………………………………………………(1... K = mechanical constantent Ø = induced flux IA = armature curr τ = KϕI A.......= P mech... The only possible mathematical modeling in our project plant is:  Industrial Height wise Sorting Conveyor Station Industrial Height wise Sorting Conveyor Station The mathematical modeling for a conveyer belt can be best described bydrawing the conveyer belt diagram..3. moving on the conveyor belt: The total force on the belt is......(1.......3) F =W τ = rW…………………………………………………………………..1) W = mg………………………………………………………………………………….... Winproladder&WPLSoft are the softwares utilized for the programming of Level & Sorting plants controlled via Fatek& Delta PLC respectively..3. The Figure show the steps of OPC tags taking from codesys to the WinCC Flexible software...(1.... The figure below contain the programs of plants controlling via ABB PLC & Delta &Fatek PLC as well[6]. So that the HMI software WinCC take all the tags for its proper operation. The HMI software communicates with the master PLC via RS-232 on OPC server.. P elec.......3.....PROGRAMMING EACH PLC FOR RESPECTIVE PLANT Each plant program must be inserted in the respective controlling slave or master PLC in their respective programming languages &softwares....3.. The figure 5..…………………. ………………………………………………………………. HUMAN MACHINE INTERFACE (HMI) DEVELOPMENT OFSYSTEM&INTERFACING WITH MASTER PLC USING OPC SERVER The HMI software used as the front end of the Master PLC is SIEMENS SIMATIC WinCC Flexible 2008. …………………………………………………………………... EA = induced EMF P mech....... Where....…(1.. IA..... ABB Master controlling Four Story Elevator station so its programming is done in its codesys software..6) Since.. …... Consider an object of mass “m”.....The diagram above shows the starting few networks of the program.....3. = τ ω .......(1......……………..7) Where.. Pelec.. Similary........1 shows a conveyer belt structure that has a object of mass “m” moving on it.(1......5) The relation between mechanical & electrical power is given by.. For OPC server setting its necessary to set communication parameters of the master PLC software (Codesys)..……(1.. τ = rF……………………………………………………………………........2) The mechanical torque on the conveyor belt is given by: Since So.

14) we get τ= (V T− I A R A) / ωA * −IA.………………….(1.3.3.10) τ = KϕI A………………………………………………………………………. (1.3.9) τω = KϕωI A…………………………………………………………………………….… (1. τ = 0.3.2 meterss m = 0.8) in equation (1.4) we have.3. Sensor Modeling This section describes some of the basic and useful characteristics of the sensor.3.………………………………………………. we get rω = E I………………………………………………………………………………………..16) .3.8) Since. we get Kϕ = (VT− IA RA)/ω .………………………………………. Using the distance time relationship we have. The torque due to electrical excitation must be than the torque due to the load.3.3.15) We have. Torque could be calculated using equation (1.3 shows a general block of an object that passes on the conveyer belt and it also shows the width “S” of the object.3.3.7) and (1.45 newton-meter The two values of torques clearly indicate that the electrical torque is quite larger than the mechanical one. Geared motor (which are listed as under).6).45 newton Calculating the torque using equation (1. Consider an object moving with velocity “V” and covering a distance “S” in front of the sensor.11) The terminal voltage is related to induced EMF as VT= EA+ I ARA……………………………………………………….………………….3. VT = 24 volts RT = 3. which is equal to its width.C..554 newton-meter For calculating the torque using equation (1.3.3...25kg W = 2.12)we get V T = Kϕω + I A R A .9) in equation (1.(1.………….4) the parameter r = 0.(1.……….………………….3.4) & (1. s = vt………………………………………………………………………………………(1. One equation represents torque due to load and other due to electrical excitation. Use the typical values of electrical parameters for the D.3.3.5 Ω ω = 70 rpm τ = 0.3.3. (1.. So the conveyor belt motor can bear its load and efficiently run the belt. Figure 1.11) represent the torque.13) Solving for K ø.……………………………………………….Substituting equation (1..3. in order to move the is more than the conveyor efficiency.14) Substituting the value of KΨ in equation (1.3.15) Analysis Equation (1.12) Substituting equation (1. (1. E A= Kϕω…………………………………………………………………………………… (1. The sensor is photovoltaic switch in our system to detect height of the object.

The system primarily designed to explicitly illustrate the essential components of the Roped Elevator System.If the objects used have maximum width of 10cm.1m v = 0. The plant is controlled via Fatek PLC Slave-I having total 14 digital I/O’s including 08 digital inputs & 06 digital outputs. 1. and the velocity of conveyor is not exceeding 0. nature.3. class.16) DESIGNING (Schematics & Circuits) It is important to design the driver schematic& circuit for the three plants. Figure 5.Four Story Elevator Control Station plant is a prototype of an elevator having 4 floors. and the face of the shifter is 10cm long.3 shows the design of the actuator that we have chosen for our project.(1. The four story elevator prototype contains the limit switches as the gate & Floor sensors & inner & outer call buttons and a heavy geared DC motors & four seven segment displays used to display the floor position of the elevator box. and accordingly. we require a sensor that can give response in less than 200msec.5m/sec. Driver Circuit of Four Story Elevator Control Station 2. In our project we use no. The plant is controlled via ABB master PLC having total 32 digital I/O’s including 16 digital inputs & 16 digital outputs. etc. Since the maximum speed of the conveyor belt could be 0. in order to sort out the object.…………………. The parameter that is of significant importance in our project is the time response of the shifter. Total 17 digital I/O’s are required for the operation of the plant including 12 digital inputs & 05 digital outputs. Driver Circuit of Water Flow & Level Control Industrial Monitoring Station Driver Circuit of Four Story Elevator Control Station(Modbus Master) This shows the driver circuit of four story elevator control station. . in some orderedsequence. Driver Circuit of Industrial Height wise Sorting Conveyor Station (Modbus Slave-I) Sorting is any process of arranging items in some sequence and/or in different sets. Driver Circuit of Industrial Height wise Sorting Conveyor Station 3. then the minimum response time can be calculated using these two values t = 200msec So. of sensors and actuators for different defined height objects (boxes)  Three sensors of OMRON which are Photoelectric (IF) sensors used Total 08 digital I/O’s are required for the operation of the plant including 03 digital inputs & 05 digital outputs.. The actuator in our system is designed using DC motor as actuating mechanism. Actuator Modeling Actuators are basically devices that converts electrical signal into mechanicalactions. This result shows that the shifter should give response in 200msec. it has two common.5m/ sec So. we have . yet distinct meanings:  Ordering is arranging items of the same kind.5m/sec. Here s = 0. s = vt ……………………………………………………………………. so the response time of the shifter can be evaluating using the basic relation.

5. A D/A converter (staircase reconstructor). Default: 2. A lowpass analog anti-image postfilter to complete the job of the staircase reconstructor and further remove the spectral images introduced by the sampling process. A digital signal processor. 2. The plant is controlled via Delta PLC Slave-II having total 14 digital I/O’s including 06 analog I/O’s. please fix the scan time. possibly preceded by an equalizing digital filter.(1 scan time + 1ms) ~ + (1 scan time)………………………………………………. We used 750 watts induction motor in this project because it is easily available in our PLC Lab. An A/D converter (sampler and quantizer).Induction Motor is actually the AC Motor in which power is supplied to it by means of electromagnetic induction process. A lowpass analog antialiasing prefilter that bandlimits the signal to be sampled to within the Nyquist interval. Unit: 1ms.[7] Every PLC controlling Analog inputs & outputs have almost all the DSP components stated above. The motor we used to control its parameters is Induction Motor. VFD used in our project is LG brand and its serial no. In this system the important parameters of any process industry is monitored and controlled. “Liquid flow and level control” is one of them that ensure safe. Where D1118 is the special purpose register.(1. fault free and proper operation of process industries. EX2/SX2 sampling time of analog/digital conversation. TS = .1) . 4. Two 10 turn pots are used for the flow & level feedback in the control tank while a solenoidal valve is also present to drain the water from tank. Sampling time will be regarded as 2ms if D1118≦2. electronics apart from other applications is committed to designing and developing of broad range of electronic systems used in automated processes serving in an industrial environment. Whentheerror affects the output. The basic available operating functions in VFD are: But we used only three parameters of it to drive Induction Motor:  On-Off Controlling  Forward-Reverse Direction Controlling  Speed Controlling LG Variable Frequency Drive (VFD) is a field devicedirectly connected to the master via Modbus (RTU) communication as LG VFD is Modbus supported[11]. The achievement of this plant is that it has provided process industry with an easy access alternate which is cost efficient and equally reliable. SimulationFor Modbus Address checking & verification of LG Variable Frequency Drive(VFD) Using ModScan32 LG Variable Frequency Drive (VFD) is used to control the parameters of AC Motor and vice versa. is SV008IG5. Total 03 digital outputs & two analog inputs are required for the operation of the plant. The pots are calibrated such that the motorize valve & level can be input from HMI & achieve at the graduated scale. PLC can be used to control liquid flow and level control.As in Industrial grade system integration using Modbus communication DELTA PLC slave-II is controlling Water Flow & Level Control Industrial Monitoring Station (02 Analog Inputs & 03 digital outputs). The maximum error of sampling time. Today. DSP COMPONENTS (DELTA PLC SLAVE-II Controlling) The minimum number of necessary components in a typical digital signal processing system must be: 1.5. 3.Driver Circuit of Water Flow & Level Control Industrial Monitoring Station (Modbus Slave-II) Industries require a source to acquire the plants data and their monitoring on computers. And the total capacity of VFD to drive Induction Motor is 1HP (horse power)[8].

4. Sorting is any process of arranging items in some sequence and/or in different sets. electronics apart from other applications is committed to designing and developing of broad range of electronic systems used in automated processes serving in an industrial environment. of sensors and actuators for different defined height objects (boxes)  Three sensors of OMRON which are Photoelectric (IF) sensors used. Antialiasing Pre-filter & Post filter are builten at the input & output of the PLC for bandlimits the signal to be sampled to within the Nyquist interval &possibly preceded by an equalizing digital filter. 3. The instruction sets the value specified in n to D1020 (X0 ~ X7 input filter time) directly. Modbus Master(Subsystem-I) Modbus Slave-I(Subsystem-II) Modbus Slave-II (Subsystem-III) Modbus Slave-III(Subsystem-IV) Final Solution Modbus Master (Subsystem-I) The Subsystem-I is controlling Four Story Elevator Control Station plant which is a prototype of an elevator having 4 floors. “Liquid flow and level control” is one of them that ensure safe.Industries require a source to acquire the plants data and their monitoring on computers.PLC provides digital input filters to avoid interference. and accordingly. it has two common. The internal processor of the Delta PLC is the digital signal processor which processes the information & produce its outputs according to the programming. Modbus Slave-I (Subsystem-II) The Subsystem-II is controlling Sorting Plant. Total 08 digital I/O’s are required for the operation of the plant including 03 digital inputs & 05 digital outputs. In our project we use no. . The exercise carefully and wisely divided into different task to cover the practical implementation as well as the theoretical aspects of the project. fault free and proper operation of process industries. PLC can be used to control liquid flow and level control. Three photo sensors are used of Omron brand in which they are located in different. The plant is controlled via Fatek PLC Slave-I having total 14 digital I/O’s including 08 digital inputs & 06 digital outputs. yet distinct meanings. The system primarily designed to explicitly illustrate the essential components of the Roped Elevator System. Today.  Three actuators are used to sort different height objects to their respective destination  One Conveyer belt is used for taking object in forward direction A sensor (also called detector) is a device that measures a physical quantity and converts it into a signal which can be read by an observer or by an instrument. This sort of an exercise is extremely helpful in understanding the concept s of a complete Control system and has been designed in a simple yet realistic manner. Modbus Slave-II (Subsystem-III) The Subsystem-II iscontrolling Flow & Level Control Plant. The response time (n) of X0 ~ X7 inputfilters can be adjusted by REFF instruction. 2. 5. SOLUTION REALIZED (DEVELOPED) There are four subsystems and final solution is the combination of all these four subsystems as follows: 1. The exercise aim for the accurate controlling of the elevator bucket’s height digitally with a PLC.

the master PLC is also controlling a plant according to the programmed subroutines. Each PLC as a slave is controlling different plants according to the programming and controlled by the master (HMI). The plant is controlled via Delta PLC Slave-II having total 14 digital I/O’s including 06 analog I/O’s. Total 03 digital outputs & two analog inputs are required for the operation of the plant. But we used only three parameters of it to drive Induction Motor:  On-Off Controlling  Forward-Reverse Direction Controlling  Speed Controlling LG Variable Frequency Drive (VFD) is a field devicedirectly connected to the master via Modbus (RTU) communication as LG VFD is Modbus supported and utilized for the controlling of AC Motor and vice versa. The motor we used to control its parameters is Induction Motor in delta connection. Master is controlling the whole process and communicated with the entire slave by single shielded twisted pair cable following RS-485(half duplex). And the total capacity of VFD to drive Induction Motor is 1HP (horse power). Final Solution All the above four substations are collectively providing the complete solution for the industrial grade system integration using Modbus Communication. The last slave i. Four Story Elevator Control Station (Control via Master) Industrial Height wise Sorting Conveyor Station (Control via SlaveI) Water Flow & Level Control Industrial Monitoring Station(Control via SlaveII) Variable Frequency AC Motor Industrial Control Station (Control via SlaveIII) . Modbus Slave-III (Subsystem-IV) Subsystem-IV is LG Variable Frequency Drive (VFD) is used to control the parameters of AC Motor and vice versa. The pots are calibrated such that the motorize valve & level can be input from HMI & achieve at the graduated scale. is SV008IG5[10]. However. Every device & every standard utilized in the project is of industrial grade. Each PLC as a slave is controlling different plants according to the programming and controlled by the master (HMI). We used 750 watts induction motor in this project because it is easily available in our PLC Lab. Industrial Grade System Integration using Modbus Communication consists of three different brands of PLC’s and a field device. b. d. However.e. third slave is a field device which is Modbus supported that’s why its directly connected with the master & controlling AC motor station. the master PLC is also controlling a plant according to the programmed subroutines. The figure below shows the master subsystem and all the three slave subsystems which comprises the final communication solution of the problem of communication of different vendors of PLCs using MODBUS communication.Following are the four hardware plants controlled by master & each slave successfully: a. PRACTICAL RESULTS Hence Practical results of every subsystem shows the successful implementation of Industrial Grade System Integration using Modbus Communication which consists of three different brands of PLC’s and a field device. The motor we used to control its parameters is Induction Motor. third slave is a field device which is Modbus supported that’s why its directly connected with the master & controlling AC motor station. c. Induction Motor is actually the AC Motor in which power is supplied to it by means of electromagnetic induction process. VFD used in our project is LG brand and its serial no. The last slave i.Two 10 turn pots are used for the flow & level feedback in the control tank while a solenoidal valve is also present to drain the water from tank. Every device & every standard utilized in the project is of industrial grade.e.

User Friendly & Monitoring and Controlling through single HMI. sech PLC as a slave is controlling different plants according to the programming and controlled by the master (HMI) successfully and can be controlled by using single HMI frontend of Siemens (SIMATIC winCC Flexible 2008). So covering these issues we have to find the solution. The motor we used to control its parameters is Induction Motor in delta connection. Modbus controllers communicate using a master-slave technique. Thus. Modbus Communication implementation via RS-485(half duplex).In an operating industry a problem of interfacing and networking different brands (vendor) of PLCs with a single HMI PG/PC device has vital significance and for that purpose it needs solutions like Communication processors and other communicating devices. Hence the result of each subsystem confirms the successful working & implementation of the solution. Since the simulation using Modscan32 &Modsim 32 softwares are for the confirmation & satisfactory response of the slave & master PLC’s. Our project meets the specified needs and provides a complete solution with the human friendly and complete HMI for Industrial automation and Networking using MODBUS communication protocol . Programmable Logic Controllers. positioned at level 7 of the OSI model that provides client/server communication between devices connected on different types of buses or networks. every industry want to automate and centralize all of their projects and operating plants that can be monitored and controlled within a single room and decreasing man power. which serves as an enabling technology by providing such an interface between utility and load that could follow a communication protocol. supplying requested data to the master or informing the master that the required action could not be carried out. which is received by the slaves. So the Simulation & Practical results of the whole system are nearly same. Different plants and setup of PLCs are used to implement automation techniqueswhich are comprised of three different PLCs and a field device as the key component by which four plants are controlled and monitor through HMI application. The sequence begins with the master issuing a request or command on the bus (a 'query'). in which only one device (the master) can initiate a communication sequence. The featured following characteristics:    Completely Automated Communication of different Vendor PLCs& Field devices. The slaves respond by taking appropriate action. MODBUS is an application layer messaging protocol.DISCUSSION OF RESULTS Hence Practical results of every subsystem show the successful implementation. LG Variable Frequency Drive (VFD) is a field devicedirectly connected to the master via Modbus (RTU) communication as LG VFD is Modbus supported and utilized for the controlling of AC Motor and vice versa. CONCLUSION In the modern era of revolutionized Industrial Automation and distributed controlsystem. The project contains three PLC’s& a field device of different vendors controlling different plants & each PLC is communicated with one master via MODBUS communication Protocol.

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