PLC-based Smart Elevator Control System: July 2013

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PLC-based Smart Elevator Control System
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Tanta University
Faculty of Engineering
Electrical Power and Machines Engineering Department
PLC-Based Smart Elevator Control System
Abd-Elmoghney Talaat Shahin

PLC-Based Smart Elevator
Ahmed Magdy Awad

Control System
Ebrahim Mostafa Shokr

Supervised by
Hala Said Mohammed
Dr. Said M.Allam
Islam Mohammed Sarhan
Mohammed Ahmed Almozayen
Samar Mohammed Dabour
Walaa Ahmed Ebrahim
Chapter 1
Introduction
With the overall rapid development taking place in all spheres,
the living standard of human being has tremendously increased as
such the high rise buildings are constructed for malls, and housing
purposes. Thus the installation of elevators in these high rise
buildings becomes an integral part of the infrastructure for the
movement of goods and people. So, the control system is essential
in the smooth and safe operation of the elevator. It guides the
elevator in what order to stop at floors, when to open or close the
door etc.
1.1 Historical Review

Over years, man has developed in somehow an elevator shape
to use in his everyday life to raise water, food and other objects to
higher levels, the first reference to an elevator is in the works of
the Roman architect Vitruvius, who reported that “Archimedes”
built his first elevator probably in 236 BC. In some literary
sources of later historical periods, elevators were mentioned as
cabs on a hemp rope and powered by hand or by animals. It is
supposed that elevators of this type were installed in Sinai, Egypt.
Chapter 1 Introduction
1.2 Types of Elevators

1.2.1 Traction Elevators
These elevators have steel ropes that raise and lower cars from
above. In a machine room above the elevator shaft, a control
system operates a motor that turns a sheave. Cables roll over this
deeply grooved pulley to pull a car up or lower it down. The
cables are also attached to a counterweight that weighs about as
much as the car on the other side of the sheave when it is at 40
percent of capacity purpose of the counterweight is to create a
balance to conserve energy. With a counterweight, the elevator
operates much like a see-saw. The motor can move the car by just
overcoming friction between the ropes and sheave and the
difference in weight between the elevator car and the
counterweight.
1.2.2 Hydraulic Elevators
Use a fluid to lift and lower the car. The car has a piston in a
cylinder beneath it; the elevator lifts when an electric motor
powers a hydraulic pump to push a fluid (typically oil) into the
cylinder, which pushes the piston up. To lower the car, the control
system opens a valve and the fluid flows back into the tank as the
weight of the car pushes down on the piston. Hydraulic machines
can effectively multiply the relatively weak force of the pump to
generate the stronger force needed to lift the car.
2 PLC-Based Smart Elevator Control System
Hydraulic elevators are simple and inexpensive, but they are

comparatively inefficient because they lack the counterweight that
traction elevators have.
1.2.3 Traction-Hydraulic Elevators

The traction-hydraulic elevator has overhead traction cables
and counterweight, but is driven by hydraulic power instead of an
overhead traction motor. The weight of the car and its passengers,
plus an advantageous roping ratio, reduces the demand from the
pump to raise the counterweight, thereby reducing the size of the
required machinery.
The great development in variable speed drives nowadays

made traction elevators the most widely used type, also its
advantage of energy saving managed it to become favorable.
1.2.4 Smart Elevator Choice System

Due to the wide need for more than one elevator car in the big
buildings, a smart choice algorithm has been developed recently to
choose the nearest elevator car to the passenger current location,
for saving time and energy.
In this system, there is one destination panel at every floor for

passengers to specify their desired destination and then the control
system chooses the nearest elevator car and moves it to the
passenger current place.
1.3 Modern Elevators Drive System

Good and reliable drive system is the major component of a
high quality elevator.
The most commonly used motor type in modern elevators is

three phase induction motor as they are simple, has low
maintenance requirements, has relatively high starting torque
especially with the aid of variable speed drives which give a great
aid in the enhancement of three phase induction motor
performance.
Microprocessors are the most commonly used controllers for

operation and speed control of elevators, position sensors
(commonly, magnetic sensors) give a feedback signal of the
elevator’s cabin position to the controller, and then the controller
receives the destination order from user panel to execute the
control algorithm and move the elevator to its destination.
The most commonly used speed control algorithm moves the

elevator under two different speeds, low speed at starting and
before mechanical braking but the most advanced algorithm
named variable voltage variable frequency (VVVF) which moves
the elevator under increasing speed steps at starting and under
decreasing speed steps before mechanical braking which gives
very smooth movement.

1.4 Project Objectives

The main objectives of this project are to:
 Save time and energy in big buildings when more

than one elevator is needed by including smart
control algorithm to choose the nearest elevator to the
passenger leaving other elevators unmoved.
 Use programmable logic controller (PLC) as
controller rather than using microprocessor, as it is
more reliable and easier to maintain.
 Use closed loop speed control method of three phase
induction motor. This enhances dynamic response
and transient operation of the motor.
1.5 Project Outlines

Chapter 1: Introduction
Chapter 2: System description
 Presents an overall description of the
proposed smart elevator system
Chapter 3: PLC-based destination control system

 Presents a detailed description of
implemented PLC programming and choice
algorithm of the smart elevator system

Chapter 4: System modeling and control

 Presents a theoretical study of induction
motor modeling including the application of
both scalar and vector speed control methods
Chapter 5: Experimental system

 Presents a full description of
implemented elevator system

Chapter 2
System Description
The proposed system presents a full smart elevator control
system including driving motors, inverters and control unit which
derives these motors to lead elevators to the desired destination
specified by passengers precisely, also to control motor's speed
during journey up or down to guarantee maximum movement
softness, soft starting and soft stopping which gives the elevator
users the highest service quality.
2.1 System Components
Figure (2.1) system description

Chapter 2 System Description
2.1.1 Driving Motor

The driving motor of the proposed system is a three phase
induction motor, due to its simple construction, low maintenance
requirements and the wide spread and development of using
power electronics in speed control of these motors to give a high
efficient and accurate speed control methods.
2.1.2 Inverter
The most commonly used speed control method of three phase
induction motor in modern systems is varying both the stator
supply voltage and frequency. The variation of supply voltage and
frequency was a very complicated matter until the wide
development in industrial power electronic devices. Inverter is a
power electronic device that can be used to obtain a variable
voltage and variable frequency. It consists of power electronic
switches which can be controlled by driving pulses generated
from the control unit.
2.1.3 Control Unit

A. Destination Control Unit
A programmable logic controller (PLC) is used to control
elevator movement until reaching the desired destination.
The PLC-code which represents the destination control

algorithm must have input data from sensors or buttons to be able

Chapter 2 System Description
to control elevator movement precisely. These data includes

elevator car current location determined by magnetic sensors or
limit switches, passenger current location and passenger desired
destination which determined by push buttons panel at every floor.
B. Speed Control Unit

In modern elevators drive systems, speed control algorithms
are included with the inverter in a compact device called “digital
inverter” or “variable speed drives (VSD)” which have ports to be
connected directly to PLC.

Chapter 3
PLC-Based Destination Control System
3.1 Introduction
Peak-hour traffic in a busy high-rise often means long waits, a
scramble for each arriving elevator, crowded elevator-cars and too
many stops. A Programmable Logic Controller (PLC) is used in a
destination control system for elevator selection to minimize these
inconveniences by instantly assigning each passenger to the
nearest elevator.
3.2 Control System Layout
In conventional-elevators systems, passengers press randomly

an up or down call button and wait. Then they crowd abroad the
first arriving car and after entering this car, the other cars reach
without interest. This is depreciation to these elevators and their
motors and loss of power and time.
On the other hand, in smart-elevators systems, instead of
pressing traditional up or down buttons, passengers enter their
desired destination floors before entering an elevator. The control
system instantly directs each passenger to the nearest car assigned
to the requested floor. The system continuously reviews passenger
destination data and adapts to changing traffic patterns, ensuring
optimal traffic flow throughout the day.
Chapter 3 PLC-Based Destination Control System
Using smart-elevator system leads to the following

advantages:
 Saving a large amount of energy
 Less-crowded cars
 Reducing passenger waiting time
 Reducing number of stops per trip to decrease elevator
travel time
 Eliminating crowding during heavy traffic
 Reducing the maintenance of the elevators and the driving
motors
 Increasing the life span of elevators
3.3 Control System Description
In large buildings, more than one elevator can be used. Firstly,

the passenger enters the desired destination from a control panel
beside the elevators. Limit switches are used to specify elevator
place. Secondly, the control system using a PLC unit compares
elevator place and passenger place to select the nearest elevator-
car to the passenger and display the name of this elevator on
screen. Finally, the nearest elevator-car takes the passenger from
his place to his destination. This can be easily described as shown
in table 3-1.

Table 3-1
Control system
Location of Location of
Passenger location selection
Elevator A Elevator B
Floor (1) Floor (2) Floor (3) Elevator (A)
Floor (4) Floor (1) Floor (3) Elevator (B)
Floor (2) Floor (3) Floor (4) Elevator (A)
3.3.1 Programmable Logic Controller
Programmable Logic Controllers (PLCs), also referred to as

programmable controllers, are in the computer family. They are
used in commercial and industrial applications. A PLC monitors
inputs, makes decisions based on its program, and controls outputs
to automate a process or machine. PLCs consist of input modules
or points, a Central Processing Unit (CPU) and output modules or
points. An input accepts a variety of digital or analog signals from
various field devices (sensors) and converts them into a logic
signal that can be used by the CPU. The CPU makes decisions and
executes control instructions based on program instructions in
memory. Output modules convert control instructions from the
CPU into a digital or analog signal that can be used to control
various field devices (actuators). A programming device is used to
input the desired instructions. These instructions determine what
the PLC will do for a specific input. An operator interface device
allows process information to be displayed and new control
parameters to be entered.

Microprocessors are commonly used as a control unit in

elevators control systems. PLC is used instead of microprocessors
because of the great advantages of PLC against microprocessors.
These advantages can be summarized as follows:
 Visual observation and control: When running a PLC
program a visual operation can be seen on a screen.
 Control board: PLC board is easy to design rather than
microprocessors board.
 Interfacing: PLC is easy to interface with other system.
 Programming: Using ladder diagrams for programming are
very simple and easy to understand.
 Program: PLC program can be tested, validated and
corrected easily that leads to save a large time
 Troubleshooting and fault detection: PLC troubleshooting
and fault detection are really quick, easy and simple.
 Noise effect: PLC is not affected by noise as
microprocessors.
3.3.2 PLC-Unit Specifications
The SIMATIC S7-300 universal controller, shown in figure

(3.1), saves on installation space and features a modular design. A
wide range of modules can be used to expand the system centrally
or to create decentralized structures according to the task at hand,
and facilitates a cost-effective stock of spare parts.

Figure (3.1) SIMATIC S7-300 (S7 313c) PLC
 Features of S7 313C PLC:

 16 digital inputs
 16 digital outputs
 Memory:
o Ram
 Integrated: 32KB for program and data
 Expandable: no
o Load memory
 Upgradable FEPROM : with micro
memory card (MMC)UP TO 4 MB
o Backup
 Without battery: program and data
 Profibus-DP/Device Net
 Execution times
o Pit operation: 0.1 ㎲ to 0.2 ㎲
o Word operation: 0.5 ㎲
3.4 Control System Flow Chart
Figure (3. 2) Flow chart of the PLC program (part 1)

Figure (3. 3) Flow chart of the PLC program (part 2)

3.5 Simulation Results

3.5.1 PLC Inputs and Outputs
Table 3-2: PLC Inputs and Outputs
PLC Inputs
I0.0 Elevator A –limit switch I1.0 Ok switch at floor 1
at floor 1
I0.1 Elevator A -limit switch I1.1 Ok switch at floor 2
at floor 2
I0.2 Elevator A -limit switch I1.2 Ok switch at floor 3
at floor 3
I0.3 Elevator A -limit switch I1.3 Ok switch at floor4
at floor 4
I0.4 Elevator B -limit switch I1.4 Call button 1
at floor 1
at floor 2
at floor 3
at floor 4
PLC outputs
Q0.0 Elevator (A) up Q0.2 Elevator (B) up
Q0.1 Elevator (A) down Q0.3 Elevator (B) down
3.5.2 Case-Study Simulation Results
Firstly, the existing conditions are entered to the simulation

program of S7 313c software. The conditions of the presented
case-study are:
 The location of elevator (A): floor (3)

 The location of elevator (B): floor (4)
 Passenger location: floor (1)

 Passenger desired destination: floor (4)
It can be noted that the elevator A is the nearest one, therefore,

the control system should select elevator A. This smart choice
algorithm can be illustrated as follows:
1. Figure (3.4) shows PLC inputs and outputs.
Figure (3.4)

2. Figure (3.5) shows that the location of elevator (A) is floor

(3) and the location of elevator (B) is floor (4).
Figure (3.5)
3. Figure (3.6) shows that passenger location is floor (1) and
the desired destination is floor (4).
Figure (3.6)

4. Figure (3.7) shows that the control system selection is

elevator (A).
Figure (3.7)
5. Figure (3.8) shows that elevator (A) arrived floor (2).
Figure (3.8)
6. Figure (3.9) shows that elevator (A) arrived floor (1), and
timer (T3) operates for 5 seconds till the passenger entering the
elevator.
Figure (3.9)
7. Figure (3.10) shows that elevator A is moved up after the
passenger entered the elevator.
Figure (3.10)

Figure (3.11)
Figure (3.12)

10.Figure (3.13) shows that elevator (A) arrived floor (4).
Figure (3.13)

Chapter 4
System Modeling and Control
4.1 Dynamic Model of a Three-Phase Induction

Motor
Induction motor, which is the most widely used motor type in

industry, has been favored because of its good self-starting
capability, simple construction, low cost and reliability. Along
with variable frequency ac inverters, induction motors are used in
many adjustable speed applications. Induction motors can be
controlled to achieve dynamic performance as good as that of DC
motors [1].
The dynamic model of the machine subjected to control must

be known in order to understand and design modern speed control
drives. Due to the fact that every good control has to face any
possible change of the plant, it could be said that the dynamic
model of the machine could be just a good approximation of the
real plant. Nevertheless, the model should incorporate all the
important dynamic effects occurring during both steady-state and
transient operations [1].
46 PLC based smart elevator system

Chapter 4 System Modeling and Control
Figure (4.1) shows schematic diagram of a three-phase

induction motor (axes relationship)
Figure (4.1) Schematic diagram of a three-phase induction motor (axis

relationship)
4.1.1 Dynamic d-q axis Model
The dynamic performance of three phase induction motor is

somewhat complex because the three-phase rotor windings move
with respect to the three-phase stator windings. The machine
model can be described by differential equations in natural (abc-
axes) seventh order model with time-varying mutual inductances.
But such a model tends to be very complex[2].
Dynamic d-q model solves the problem of high system order

by solving machine model with respect to two quadrant d-q axes.

Using reference frames, the problem of time varying mutual

inductances can be solved.
Figure (4.2) Schematic diagram of a three-phase induction motor in both abc-

axes and d-q models
Assume that the ds - qs are oriented at angle  .The voltages

vdss and vqss can be resolved into as-bs-cs components and can be
represented in the matrix form as:
1  vqs 
s
vas  cos( ) sin( )
v   cos(  120) sin(  120)  s
 bs   1 vds  (4.1)
vcs  cos(  120) sin(  120)  s 
1 vos
 
The corresponding inverse relation is:
vqss  cos( ) cos(  120) cos(  120)  vas 

 s  2
vds   sin( ) sin(  120) sin(  120)  vbs  (4.2)
 s  3 0.5  vcs 
vos   0.5 0.5

4.1.2 Dynamic model of three-phase induction motor

in arbitrary reference frame
The stator voltage equations are given by:
d
vqs  R si qs  Ψqs  ωΨds (4.3)
dt
d
v ds  R s i ds  Ψ ds  ωΨ qs (4.4)
dt
The rotor voltage equations are given by:
d
vqr  Rr iqr  qr  (  r )dr  0 (4.5)
dt
d
vdr  Rr idr  dr  (  r )qr  0 (4.6)
dt
For synchronous reference frame ω  ωe
For stationary reference frame ω  0
For rotating reference frame ω  ωr
The flux linkage expressions:
qs  Lqsiqs  Lmiqr (4.7)
ds  Ldsids  Lmidr (4.8)
qr  Lqriqr  Lmiqs (4.9)

dr  Ldridr  Lmids (4.10)
The electromechanical developed torque expression in terms

of d-q axis Variables:
dm
Te  Tl  J  Bm (4.11)
dt
4.2 Dc to ac Converter (Inverter)
Inverter is a power electronic device that converts dc to ac

power by switching the dc input voltage (or current) in a pre-
determined sequence so as to generate ac voltage (or current)
output as shown in figure (4.3).
IDC Iac
+ +
VDC Vac


Figure (4.3) General block diagram of the dc-ac converter
The inverter is so named because it performs the opposite

function of a rectifier. A variable output voltage can be obtained
by varying the input dc voltage and maintaining the gain of the
inverter constant. On the other hand if the dc input voltage is fixed
and it is not controllable, a variable output voltage can be obtained
by varying the gain of the inverter, which is normally
4: PLC-Based Smart Elevator Control System
accomplished by Pulse Width Modulation (PWM) control within

the inverter. The inverter gain may be defined as the ratio of the ac
output voltage to dc input voltage[2].
4.2.1 Three-Phase Inverter
Three-phase inverters are used for variable-frequency drive

applications with three phase ac motors and for high power
applications such as HVDC power transmission. A basic three-
phase inverter consists of three single phase inverter switches each
connected to one of the three load terminals as shown in figure
(4.4).
Figure (4.4) Three phase voltage source inverter using power transistor
4; PLC-Based Smart Elevator Control System

Figure (4.5) explains the fabrication of the output voltage

waves in square wave or six step mode of operation.
Figure (4.5) Equivalent circuit indicating voltage vno between the neutral
points
If the three phase load neutral (n) is connected to the center

tap of the dc voltage Vd, then the load phase voltages are Vao, Vbo
and Vco.
From figure (4.5) the following relations can be derived:
2 1 1
van  vao  vbo  vco (4.12)
3 3 3
2 1 1
vbn  vbo  vao  vco (4.13)
3 3 3
2 1 1
vcn  vco  vao  vbo (4.14)
3 3 3

4.2.2 Pulse Width Modulation (PWM) Inverter
The energy that a switching power converter delivers to a

motor is controlled by Pulse Width Modulated (PWM) signals
applied to the gates of the power electronic switches. PWM
signals are pulse trains with fixed frequency and magnitude and
variable pulse width. There is one pulse of fixed magnitude in
every PWM period. However, the width of the pulses changes
from period to period according to a modulating signal. When a
PWM signal is applied to the gate of a power electronic switch, it
causes the turn on and turns off intervals of the power electronic
switch to change from one PWM period to another PWM period
according to the same modulating signal. The frequency of a
PWM signal must be much higher than that of the modulating
signal, the fundamental frequency, such that the energy delivered
to the motor and its load depends mostly on the modulating signal.
In sinusoidal PWM, output signals are constructed by
comparing two signals, a carrier signal and a modulation signal as
shown in figure (4.6). The carrier signal is a high frequency
(switching frequency) triangular waveform. The modulating
signal is a controlled sine wave.[2]

Figure (4.6) PWM operation

4.3 Speed Control of a Three-phase Induction

Motor
Induction motor drives have been and are the workhorses in

the industry for variable speed applications in a wide power range
that covers from fractional horsepower to multi-megawatts. These
applications include pumps and fans, paper and textile mills,
subway and locomotive propulsions, electric and hybrid vehicles,
machine tools and robotics, wind power generation systems, etc.
the control of induction motor drives for variable speed
applications is included in this chapter. The control schemes
available for the induction motor drives are the scalar control,
vector or field oriented control, direct torque and flux control and
adaptive control.
Because of advances in solid state power devices and
microprocessors, variable speed ac Induction motors powered by
power converters are becoming more and more popular.
Switching power converters offer an easy way to regulate both the
frequency and magnitude of the voltage and current applied to the
motor. As a result much higher efficiency and performance can be
achieved by these motor drives with less generated noises. The
most common principle of this kind is the constant V/Hz principle
which requires that the magnitude and frequency of the voltage
applied to the stator of the motor maintain a constant ratio. By

doing this, the magnitude of the magnetic field in the stator is kept
at an approximately constant level throughout the operating range
below base speed.
4.3.1 Scalar Control
Scalar control as the name indicates is due to magnitude

variation of the control variables only, and disregards any
coupling effect in the machine. For example the voltage of the
machine can be controlled to control the flux, and the frequency or
slip can be controlled to control torque. Using scalar control, also
called "volts per hertz" control or v/f control, a drive essentially
acts as a power supply of a selected frequency and proportional
voltage. At a given speed, the motor performs much as it would
when supplied by utility power. For each frequency setting, motor
operation is governed by a torque vs. speed curve.
However, flux and torque are also functions of frequency and

voltage respectively. Scalar controlled drives give somewhat
inferior performance than the other control schemes but they are
the easiest to implement.
A. Open Loop Volts/Hz Control
The open loop volts/Hz control of an induction motor is very

popular because of its simplicity.

In Figure (4.7) the primary control variable is the frequency

er. The commanded phase voltage is generated by a gain
stage based on the speed e to maintain a constant air gap flux.
Figure (4.7) open loop V/F speed control with voltage-fed inverters
Figure (4.8) shows the drive's steady state performance on a

torque speed plane with a fan or pump load (TL=kωr2). As the
frequency is gradually increased, the speed also increases
proportionally as indicated at points 1, 2, 3, 4, etc. The operation
can be continued smoothly in the field weakening region (after
base speed) where the supply voltage Vs saturates.

Suppose the load torque is changed from TL to TL' for the

same frequency command, the speed will drop slightly from r to
r'. This type of speed variation can easily be tolerated by a fan or
pump where precision speed control is not necessary[2].
Figure (4.8) Torque speed curves showing effect of frequency variation, load
torque and supply voltage changes
It can be noted that, in the open-loop control mode, the speed

of the motor cannot be controlled precisely.
B. Closed Loop Volts/Hz Control with Slip Regulation
An improvement over open loop Volts/Hz control is closed

loop Volts/Hz control with slip regulation as shown in Figure
(4.8).However, additional feedback control loops increases
system complexity and potential stability problems but lead to
more smooth variation.
Here, the speed loop error generates a slip command sl* via a
proportional-integral controller (P-I controller) and limiter. This
slip command is added to the feedback speed signal r to get the
frequency command e* which, in turn, generates the voltage
command through a volts/Hz function generator.[2]
Figure (4.9) close loop speed control with V/F control and slip regulation
Since slip is proportional to torque at constant flux, this

approach may be considered as open loop torque control within a
speed control loop.
If a step-up speed command is provided, the motor accelerates

freely until a slip limit (corresponding to the motor’s torque limit)
is achieved and then settles down to the steady state load-limited
torque[2].
If r* is stepped down, the drive behaves as a generator and

decelerates with constant negative slip sl*. However, the value of
sl* must be limited to a safe margin below the slip speed

corresponding to the pull-out torque point.
Since the slip speed is relatively small compared to the rotor

speed, this mode of operation requires precise measurement of the
rotor speed. Also, in negative slip mode of operation, the
regenerated power must either be dissipated in a braking resistor
or fed back to the ac mains.
4.3.2 Vector Control
Scalar control is simple to implement, but the inherent

coupling effect, both the flux and the torque are functions of
voltage or current and frequency, gives sluggish response and the
system is prone to instability because of a high order system
effect. If the torque is increased by incrementing the slip or
frequency the flux tends to decrease and this flux variation is very
slow. The flux decrease is then compensated by the flux control
loop, which has a large time constant. This temporary dipping of
flux reduces the torque sensitivity with slip and lengthens the
response time. The variations in the flux linkages have to be
controlled by the magnitude and frequency of the stator and rotor
phase currents and their instantaneous phases. Normal scalar
control of induction machine aims at controlling the magnitude
and frequency of the currents or voltages but not their phase
angles[2].

There is a close parallel between torque control of a dc motor

and vector control of an ac motor.
In a dc machine, the field flux f (f) produced by field
current If is orthogonal to the armature flux a (a) produced by
the armature current Ia as shown in figure (4.10).
Figure (4.10) separately excited dc motor
The developed torque Te can be written as:
Te  k 't I a I f
(4.15)
Dc motor-like performance can be achieved with an induction

motor if the motor control is considered in the synchronously
rotating reference frame (de-qe) where the sinusoidal variables
appear as dc quantities in steady state.
Two control inputs ids and iqs can be used for a vector
controlled inverter as shown in Figure (4.11).

Figure (4.11) vector controlled induction motor
Thus torque is given by:
Te  k t Ψ r i qs  k 't i ds i qs (4.16)
This dc motor-like performance is only possible if i*qs only

controls iqs and does not affect the flux, i.e. iqs and ids are
orthogonal under all operating conditions of the vector-
controlled drive. Thus, vector control should ensure the correct
orientation and equality of the command and actual currents.
There are essentially two general methods for vector control.

One, called the direct or feed-back method, and the other, known
as the indirect or feed forward method.
A. Direct Vector Control
In direct vector control the field angle is calculated directly by

using terminal voltages and current or Hall sensors or flux sense
windings.

A block diagram of a direct vector control method using a

PWM voltage-fed inverter is shown in figure (4.12).
Figure (4.12) direct vector control block diagram with rotor flux orientation
The principal vector control parameters, i *ds and i*qs, which

are dc values in the synchronously rotating reference frame, are
converted to the stationary reference frame (using the vector
rotation (VR) block) by using the unit vector cose and sine.
These stationary reference frame control parameters idss* and iqss*
are then changed to the phase current command signals, i a*, ib*,
and ic* which are fed to the PWM inverter[2].
A flux control loop is used to precisely control the flux.

Torque control is achieved through the current i*qs which is

generated from the speed control loop (which includes a bipolar

limiter that is not shown). The torque can be negative which will
result in a negative phase orientation for iqs in the phasor diagram
in figure (4.13).
Figure (4.13) stationary and synchronous phasors showing correct rotor flux
orientation
Here the de-qe frame is rotating at synchronous speed e with

respect to the stationary reference frame ds-qs, and at any point in
time, the angular position of the de axis with respect to the ds axis
is (e =et).
From this phasor diagram we can write:
s
Ψ dr  Ψ r cosθ e
(4.17)

s
Ψ qr  Ψ r sinθ e
(4.18)
s s
Ψ dr Ψ qr
where; cosθ e  , sinθ e 
Ψr Ψr
Ψr  (Ψsdr ) 2  (Ψsqr ) 2
(4.19)
These unit vector signals, when used in the vector rotation

block, cause ids to maintain orientation along the de-axis and the
iqs orientation along the qe-axis.
In low speed region the rotor flux component can be

synthesized more easily with the help of speed and current signals.
Representing the flux equations using the currents and speed
results in:
s
dΨ dr Lm s s 1 s
 i ds  w r Ψqr  Ψ dr (4.20)
dt τr τr
s
dΨ qr Lm s s 1 s
 i qs  w r Ψ dr  Ψqr (4.21)
dt τr τr
Where r = Lr / Rr is the rotor circuit time constant.

These two equations are defined as the current model for flux
estimation as shown in figure (4.14).
Figure (4.14) Current model flux estimation
The main advantage of using current model is that the drive

operation can be extended down to zero speed so the current
model estimation can be made at any speed however; note that the
estimation accuracy is affected by the variation of the machine
parameters such as rotor resistance variation due to skin effect and
temperature.

B. Indirect Vector Control
The indirect vector control method is essentially the same as

direct vector control, except the unit vector signals
are generated in feed forward manner. Indirect
vector control is very popular in the industrial applications. Figure
(4.15) explains the fundamental principle of indirect vector
control with the help of a phasor diagram. The axes are
fixed on the stator and the axes are fixed on the rotor.
Synchronously rotating axes are rotating ahead of
axis by positive slip angle corresponding to slip
frequency . Since the rotor flux is directed on the axes
and [2].
θ e   ωe .dt   (ωr  ωsl )dt  θ r  θsl (4.22)
Figure (4.15) phasor diagram explaining indirect vector control

The rotor circuit equations can be written as:
dΨ dr
 R r i dr  (ωe  ω r )Ψ qr  0 (4.23)
dt
dΨ qr
 R r i qr  (ωe  ωr )Ψ dr  0 (4.24)
dt
Ψdr  L r i dr  L mi ds (4.25)
Ψ qr  L r i qr  L mi qs (4.26)
From equations (4.25) and (4.26), the dq-axis rotor current can be
written as:
1 L
i dr  Ψ dr  m i ds (4.27)
Lr Lr
1 L
iqr  Ψqr  m i qs (4.28)
Lr Lr
The rotor current in equation (4.25) and (4.26) which are
inaccessible, can be eliminated with the help of equation (4.27)
and (4.28) as:
dΨ qr Rr L
 Ψ qr  m R r i qs  ωsl Ψ dr  0 (4.29)
dt Lr Lr
dΨ qr Rr L
 Ψ dr  m R r i ds  ωsl Ψ qr  0 (4.30)
dt Lr Lr
Where ω ω ω has been substituted.

For decoupling control, it is desirable that:
dΨ qr
Ψ qr  0 That is, 0
dt
So that the total rotor flux ̂ is directed on the axis
Substituting the above condition in equations (4.29) and (4.30),

we get
L r dΨ r
 Ψ r  L mi ds (4.31)
R r dt
Lm R r
ωsl  i qs (4.32)
Ψ r Lr
̂
Where Ψ Ψ has been substituted
̂
If rotor fluxes Ψ , which is usually the case, then
from equation (4.31):
Ψ r  L mi ds
(4.33)
In other words, the rotor flux is directly proportional to
current in steady state.
C. Implementation of indirect vector control
The indirect vector controller takes only the speed from the
machine while all other parameters are estimated. The
implementation of the indirect vector control is as shown in figure

(4.16). The torque command is generated as a function of the

speed error signal, generally processed through a PI controller.
The flux component of current for the desired rotor flux

r r
is determined from this equation: m ids and
maintained constant here in the open loop manner for simplicity.
The slip frequency is generated from in feed forward
manner, Slip gain KS is given by:
ωsl Lm R r
ks    (4.34)
i qs Lr Ψ r
Slip speed Signal is added with speed signals to

generate frequency signal . The unit vector signals are then
generated from by integration and look up table as indicated in
the figure (4.16).

Figure (4.16) indirect vector control block diagram with open loop flux
control

4.6 Simulation Results
In this chapter, simulation results are presented by solving the

aforementioned models using the MATLAB_R2009a7.8 software,
including three-phase induction motor, three phase voltage source
inverter, scalar control and vector control of three phase induction
motor.
The presented simulation results are taken using a 0.32hp,

220v, 4pole, 50Hz three phase squirrel cage induction motor. The
induction motor parameters are listed in table (4-1).
Table (4-1): Induction motor parameters
Rr 28 ohms Rotor winding resistance
Rs 38 ohms Stator winding resistance
Lm 0.9944 H Mutual inductance
Ls 1.1541 H Stator winding inductance
Lr 1.1541 H Rotor winding inductance
J 7e-4 Kg.m2 Inertia constant
B 0.0 Friction coefficient
In this section a sample of the obtained simulation results of

both scalar control and vector control are presented considering
the following cases:
1. Constant speed reference and constant load torque

2. Step change of speed reference with a constant load torque

3. Step change of load torque with a constant speed reference
4.6.1 Scalar Control Simulation Results:
Case 1: Constant speed and constant load torque
Figure (4.17) shows the run up response, developed torque and

stator phase a current of three phase induction motor for a speed
reference of 1500 rpm under a constant load torque of 0.5 N.m.
Figure (4.17) run-up response of a three-phase induction motor with a load of

0.5 N.m

Case 2: Step change in the speed reference with a constant load

torque

stator phase a current of three phase induction motor under step
change in speed reference from 1500 rpm to 1000 rpm and a
constant load torque of 0.5 N.m.
Figure (4.18) run-up response of a three-phase induction motor with a step

change in speed reference at a constant load of 0.5 N.m

Case 3: Step change in load torque with a constant speed

reference

change in load torque from 1 N.m to 0.5 N.m and a constant speed
reference of 1500 rpm.
Figure (4.19) developed and load torque with a step change in load at a
constant speed reference of 1500 rpm

4.6.2 Vector Control Simulation Results:
In this section, simulation results of both direct and indirect

vector control methods are introduced.
A. Direct vector control
Case 1: Constant speed and constant load torque
Figure (4.20) shows the run up response, developed torque

and stator phase a current of three phase induction motor under
constant speed reference 1500 rpm and a constant load torque of
0.5 N.m.

0.5 N.m
Case 2: Step change of the speed reference with a constant load



Case 3: Step change of load torque with a constant speed

reference

change in load torque from 0.5 N.m to 1 N.m and a constant speed
Figure (4.22) developed and load torque with a step change in load at a

B. Indirect vector control
Case 1: Constant speed reference and constant load torque

stator phase a current of three phase induction motor under a
constant speed reference of 1500 rpm and a constant load torque
of 0.5 N.m.

0.5 N.m

Case 2: Step change in speed reference with a constant load

torque



Case 3: Step change in load torque with a constant speed

reference

change in load torque from 0.5 N.m to 1 N.m and a constant speed
Figure (4.25) developed load torque with a step change in load torque and a

It can be observed from the obtained simulation results that:
 For the same required load torque, motor under vector

control draws lower current compared with current drawn
under scalar control.
 Scalar control suffer from coupling effect which leads to
sluggish response, this problem is solved in vector control
by controlling the value and the direction of motor flux and
torque ,which leads to faster response.
 Due to free of coupling effect, compared to scalar control,
Vector control gives faster and smoother transition from a
speed to another.
Generally, it can be concluded that the overall system

performance using vector control is much better than using scalar
control. Therefore, vector control is suggested to be a more
suitable control method for traction elevator.

4.6.4 Elevator-Movement Mechanism
Control system should provide suitable acceleration/

deceleration time and rate depending on the length of journey
taken by the elevator to reach the desired destination.
Figure (4.26) summarizes the operation mechanism of the

elevator. When a passenger presses the call button, the direction of
the motor is determined by comparing the elevator car current
location and the passenger current location. Then the elevator
moves under increasing speed steps at starting and under
decreasing speed steps before mechanical braking which gives a
very smooth movement.
Figure (4.26) the mechanism of elevator movement

Figure (4.27) shows the elevator-movement mechanism for a

short distance of one floor (i.e. low free speed). It can be observed
that, the control system forces the elevator to track acceleration
pattern of just two different speeds before reaching the relatively
low free speed.
Figure (4.27) elevator-movement mechanism for a distance of one floor


medium distance of two floors (i.e. medium free speed). It can be
observed that, the control system forces the elevator to track
acceleration pattern of three different speeds before reaching the
relatively medium free speed.
Figure (4.28) elevator-movement mechanism for a distance of two floors


long distance of three floors (i.e. high free speed). It can be
observed that, the control system forces the elevator to track
acceleration pattern of four different speeds before reaching the
relatively high free speed.
Figure (4.29) elevator-movement mechanism for a distance of three

floors
It can be concluded that, the passenger desired destination

specifies the overall speed pattern that elevator will track.

Chapter 5
Experimental Set-Up
In order to validate the proposed smart choice algorithm, an

experimental system has been built as shown in figure (5.1). The
proposed system consists of two dc motors driving two elevator-
cars. Dc motors are used due to limited laboratory resources.
Figure (5.1) Elevator Model

Chapter 5 Experimental Set-Up
5.1 Experimental System Components
The overall experimental system components can be described

as follows:
1. PLC-Unit
In this project, the used PLC-unit is s7313c as shown in figure
(5.2) and has the following features:
 16 digital inputs
 16 digital outputs
 Memory:
o Ram
 Integrated: 32KB for program and data
 Expandable: no
o Load memory
 Upgradable FEPROM : with micro
memory card (MMC)UP TO 4 MB
o Backup
 Without battery: program and data
 Profibus-DP/Device Net
 Execution times
o Pit operation: 0.1 ㎲ to 0.2 ㎲
o Word operation: 0.5 ㎲
61 PLC-based Smart Elevator Control System

Figure (5.2) Plc-Unit
2. Limit Switches
In order to indicate the location of the elevator-car, eight limit
switches are used. The employed limit switch and its operating
conditions are shown in figure (5.3).
Figure (5.3) Limit Switch

3. Push Buttons
Generally, Push buttons, shown in figure (5.4) are used to
choose the desired destination. This can be done by pressing the
floor button (green) followed by the confirmation button (red).
These push buttons are normally open and its operation includes
two functions as follows:
 Send signal to the PLC to determine the passenger location.

 Send signal to the PLC to determine the passenger desired
destination.
Figure (5.4) Push Buttons
4. Driving Motors
Two geared dc-motors are used to drive the two elevators-cars
as shown in figure (5.5).

Figure (5.5) Dc-Motors
5. Relays
Four relays, shown in figure (5.6), are used to control the
rotating direction of the driving motors.
Figure (5.6) Relays

6. Dc Power Supply
The dc motors are supplied from a dc power supply as shown
in figure (5.7) consisting of the following components:
 1-phase transformer (220v/12v)

 Bridge rectifier
 Capacitor (400µf) as a filter
Figure (5.7) Dc-Supply
5.2 Case-Study Experimental Results
Firstly, the existing conditions are entered to the proposed

system. The conditions of the presented case-study are:
 Elevator (A) location: floor (3)

 Elevator (B) location: floor (4)
 Passenger location: floor (1)

 Passenger desired destination: floor (4)
It can be noted that the elevator A is the nearest one,

therefore, the control system should select elevator A. This smart
choice algorithm can be illustrated as follows:
1. Figure (5.8) shows that the location of elevator (A) is floor

(3) and the location of elevator (B) is floor (4).
Figure (5.8)

2. Figure (5.9) shows that the desired destination is floor (4).
Figure (5.9)

3. Figure (5.10) shows that passenger location is floor (1).
Figure (5.10)

4. Figure (5.11) shows that the control system selection is the

elevator (A) and elevator (A) moved to arrive to floor (2).
Figure (5.11)

5. Figure (5.12) shows the Elevator (A) arrived to floor (1).
Figure (5.12)

6. Figure (5.13) shows that elevator A is moved up after the

Passenger entered the elevator and then arrived to floor 2.
Figure (5.13)

Figure (5.14)

8. Figure (5.15) shows that elevator (A) arrived floor (4) and
stopped.
Figure (5.15)

References
[1] Dal Y. Ohm, “Dynamic Model of Induction Motor”,

Drivetech, Inc., Blacksburg, Virginia.
[2] Bimal K. Bose, “Modern Power Electronic and Ac Drives”,

Prentice Hall PTR NJ07458, 2001.
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PLC-based Smart Elevator Control System

Thesis · July 2013

Axial Flux Machines View project

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Electrical Power and Machines Engineering Department

PLC-Based Smart Elevator Control System

Abd-Elmoghney Talaat Shahin

Ahmed Magdy Awad

Ebrahim Mostafa Shokr

1.1 Historical Review

1.2 Types of Elevators

1.2.2 Hydraulic Elevators

Hydraulic elevators are simple and inexpensive, but they are

1.2.3 Traction-Hydraulic Elevators

The great development in variable speed drives nowadays

1.2.4 Smart Elevator Choice System

In this system, there is one destination panel at every floor for

1.3 Modern Elevators Drive System

The most commonly used motor type in modern elevators is

Microprocessors are the most commonly used controllers for

The most commonly used speed control algorithm moves the

4 PLC-Based Smart Elevator Control System

1.4 Project Objectives

 Save time and energy in big buildings when more

1.5 Project Outlines

Chapter 3: PLC-based destination control system

5 PLC-Based Smart Elevator Control System

Chapter 4: System modeling and control

Chapter 5: Experimental system

6 PLC-Based Smart Elevator Control System

2.1 System Components

Figure (2.1) system description

2.1.1 Driving Motor

2.1.3 Control Unit

The PLC-code which represents the destination control

8 PLC-Based Smart Elevator Control System

to control elevator movement precisely. These data includes

B. Speed Control Unit

9 PLC-Based Smart Elevator Control System

3.2 Control System Layout

In conventional-elevators systems, passengers press randomly

Using smart-elevator system leads to the following

3.3 Control System Description

In large buildings, more than one elevator can be used. Firstly,

11 PLC-Based Smart Elevator Control System

3.3.1 Programmable Logic Controller

Programmable Logic Controllers (PLCs), also referred to as

12 PLC-Based Smart Elevator Control System

Microprocessors are commonly used as a control unit in

3.3.2 PLC-Unit Specifications

The SIMATIC S7-300 universal controller, shown in figure

13 PLC-Based Smart Elevator Control System

Figure (3.1) SIMATIC S7-300 (S7 313c) PLC

 Features of S7 313C PLC:

3.4 Control System Flow Chart

Figure (3. 2) Flow chart of the PLC program (part 1)

15 PLC-Based Smart Elevator Control System

Figure (3. 3) Flow chart of the PLC program (part 2)

16 PLC-Based Smart Elevator Control System

3.5 Simulation Results

3.5.2 Case-Study Simulation Results

Firstly, the existing conditions are entered to the simulation