2020 International Conference on Computer Science and Software Engineering (CSASE), Duhok, Kurdistan Region – Iraq

IoT Based Water Tank Level Control System Using

PLC
Methaq A. Ali Abbas Hussein Miry Tariq M. Salman
Electrical Engineering Department Electrical Engineering Department Electrical Engineering Department
Mustansiriyah University Mustansiriyah University Mustansiriyah University
Basra, Iraq Baghdad, Iraq Baghdad, Iraq
Methaq.ali2006@gmail.com abbasmiry83@uomustansiriyah.edu.iq tariq.salman@uomustansiriyah.edu.iq

Abstract—Internet of Things (IoT) has been widely used in link the physical objects to the gateway, as shown in Fig. 1
various applications such as health and safety, smart homes, Moreover, the use of wireless communication systems leads
greenhouses, and industrial application. It has been increasingly to eliminate a large number of cables and subsequently will
utilized in the industry owing to its benefits in terms of reduce the probability of faults, especially in large industrial
enhancing the overall performance of a given system. There is a
systems. It can be created by using many communication
need to engage the IoT technology to meet the requirements in
many local industries, especially in developing countries. This techniques like NodeMCU (Node Microcontroller) Unit,
can be formulated as having an effective automation system that ZigBee, WAN (Wide Area Network), Nano station,
monitors all essential parts of the system and responds to it in Bluetooth. Controllers are an essential part in IoT since they
the real-time of all sensitive physical variables on the system. used in two issues first one is with physical objects to convert
This is called the Industrial Internet of Things (IIoT). In this it from inactive to active objects (intelligent devices have
paper, a prototype system has been implemented for artificial unique identification) in other words it works as an embedded
control and monitoring using IoT. The article includes two system. The second issue to work as the main controller to
control systems executed: classical PID (Proportional Integral make the computational and processing of a given process
Derivative) and fuzzy logic with a comparison between them.
and gathering the object's signals in some IoT systems.
Fuzzy control is first simulated using MATLAB-R2018b then
developing a fuzzy algorithm based on Sugeno method inside Where in other IoT systems, the signals of objects connected
PLC (Programmable Logic Controller). The connection of PLC directly to the internet and processing operations carried out
with OPC (Object Process Control) server and sensors is used in the cloud. Involve the things directly to the cloud or
by the Modbus protocol. The IoT system is designed to utilize transient through the local main controller depends on the
the OPC and MQTT (Message Queuing Telemetry Transport), importance and complexity of the process and availability
and the obtained data will be uploaded to the cloud. ESP8266 is and stability of internet services in the region of application.
used to connect the sensors to the router through wireless The water level has been used as a case study to prove the
communication. work of the system whereas it is possible to work with any
other process such as temperature or pressure by making
Keywords— IoT, OPC Server, MQTT, PLC, Ubidots.
some changes to the settings [3].
I. INTRODUCTION The rest of the paper is structured as follows. Section II
The IoT is an intelligent technology to provide large
applications in health, environment, transport systems
monitoring, and other commercial areas. The main sections
of IoT are internet, semantics, and objects-oriented vision that
improve communication networks significantly. The IoT is a
network that comprises sensors, physical devices, software,
sharing storage and connectivity of the internet that empower
these things to a collection, recording, manage and exchange
data [1]. Many approaches are useful to monitor and control
industrial processes such as PLC, SCADA, wireless sensor
network (WSN), and the IoT, etc. PLC used by many
automation processes in industries to increase quality and
reliability and reduce the production cost. In the present, IoT
is the more convenient approach for monitoring industrial
process. It is consist of embedded systems and
communication systems in such a way industrial equipment’s
with the assistance of wireless sensor network and devices are
connected to the internet, or industrial applications can be Fig. 1. General Layout of Communication in an IoT System
monitored and controlled through laptops and mobiles [2].
The IoT facilities the connection of physical objects such as presents the most relevant studies related to this study.
sensor's actuators to the Internet. The use of wireless Section III explains our proposed system and section IV
communication in the IoT system, increased the simplicity to describes the design and implementation of the prototype

978-1-7281-5249-3/20/$31.00 ©2020 IEEE 7

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 2020 International Conference on Computer Science and Software Engineering (CSASE), Duhok, Kurdistan Region – Iraq
system. Section V concludes the test results and validation of
this system. Finally, some conclusions and future works are
given in section VI.
II. LITERATURE SURVEY
The authors in [4], designed an IoT system to respond for
temperature sensor via Arduino. They used the Xively
platform to visualize the uploaded data, and then the data
downloaded by using the formalism of Petri nets from the
cloud to PLC through the OPC server and Lab View. In [2],
the authors implemented an IoT network to monitor several
industrial parameters like energy, D.C-motor speeds
controlling, PLC based liquid level, and PLC-based colour
mixer by IoT. In [5], used IoT to monitoring ICRH DAC
system. They use Experimental Physical Industrial Control
System (EPICS) as an interface between PLC and computer
for the design of web page, they used HTML5 & CSS, and
for Graphical User Interface (GUI) they used CSS BOY OPI.
The authors in [6] introduced IoT to control and to
monitor the factory of a stack of pucks. They used PLC and
Node-red and MQTT protocol to connect with tow platforms
(Ubidots & IBM) and then made a comparison for their
latency. The authors in [7], developed a prototype for a smart
home system to monitoring and control some of the home
appliances by IoT. They used Arduino and ESP8266 for Wi-
Fi connection. The authors in [8] introduced the IoT system
with real-time monitoring of the water level of the river. They
made an alarm message to the cloud server in addition to
social media. The used Arduino with ultrasonic water level
sensor in their proposed system.
The Authors in [9], were introduced digital PLC system
remote access based on android for remote access and control
and supervise on the temperature process managed by PID
controller. The researchers in [10] designed and implemented
a sensor system to be used in IoT for environment condition
and home power management monitoring. The system
proposed an approach for safety and comfort when residence
away from home for a long time. In [11], a prototype of IoT
based system for monitoring and control water level system
for the smart village was proposed. The proposed system
comprises from the water level analogue sensor and Arduino
Uno controller along with Arduino shield. The authors in
[12], submitted a water quality monitoring system in real-
time. They implemented prototype low cost, smart water
monitoring with less complex for measuring essential water
parameters such as pH, turbidity, and conductivity and
measured the water level of the sample. The proposed system
used TI CC3200 as the main controller connected to the
Internet through hotspot Wi-Fi. The literary survey
concluded the importance of the use of IoT technology.
However, this paper combined the IoT and artificial
intelligence (Fuzzy) along with the use of an industrial
controller represented by PLC. As a result, this combination
led to an efficient control system in addition to the benefit of
power saving.
III. RESEARCH METHOD
The proposed system layers framework consists of five
layers, as shown below:
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A. Sensors Layer
The first layer in this system is the sensor's layer, which
represents the things, or population of IoT, and it is
considered the base level of IoT. There are a lot of sensors
and actuators, which interrelate with the machinery, in an
industrial IoT setup. Each machine in the industry usually has
multiple sensors to tracking its healthy state and monitors the
key parameters associated with the production. The sensor
and actuator are responsible for obtaining the data or
controlling switches via a pre-defined configuration; each is
combined with a microcontroller. The sensor node is a
microcontroller attached with sensors, powered with a radio.
They are a self-contained, deploying unit, which releases the
data generated from sensors. The sensor node has not
processed the data locally since it does not have enough
processing ability and memory. A low-energy wireless
communication network is utilized that is represented by the
ESP8266 to send the sensors data to a central controller [13].
Three types of sensors have been employed in the project
application; these sensors are essential for simulating the
system. The DC motor is the core of the project so, it has been
to add sensors to control and monitoring it to ensure the
persisting of system operation. The selected physical
variables for the application where are a reservoir water level,
river level, and motor current.
Liquid level control system using PLC has been employed in
managing and monitoring the water level for the tank. It
returns the real-time reading of water level inside the tank.
Two types of water level sensors were used in this project:
VL53LOX (time of flight-micro-lidar distance sensor) and
HC-SR04 (ultrasonic distance sensor). This is because it has
to use two pails of water: one used to simulate the river and
the other to simulate the receiving storage tank.
River's water level is required for DC motor operation
interlock, in the absence of this sensor may lead to DC motor
will be staying in continuous operating. However, the river
level is low or very low. The very low of the river's water
level lead to severe operation since it will reduce the cooling
of the impeller of DC motor. The sensor is used to simulate
switches, and it can be adjusting HC-SR04-(ultrasonic)
sitting easily from its controller ESP8266 to isolate the engine
and prevent mix of air bubbles with water from the entrance
to motor pump as a result to river water low level. This may
lead to overheating the pump and consequently, vibration in
the mechanical system. The sensitivity of HC-SR04 is 1 cm;
then, it does not need exact accuracy for these measurements.
Other benefits of using HC-SRO4 are the monitoring of river
water level and utilize the accumulated data for the year,
which can help us to define the period of very low water level
and make the necessary precautions. The other pail is
(receiving storage tank) the sensor selecting for this position
requires more precision because it reads value used for Fuzzy
Logic system process. Where error and change of error are
depended on their readings, this is why we selected
VL53LOX. The sensitivity of T.O.F VL53LOX Laser is
about 3mm.
DC sensor is so important in this project since it enables
operator monitoring of the motor current. It is as well could
be monitored by cloud and make alarm or trip as the value
 2020 International Conference on Computer Science and Software Engineering (CSASE), Duhok, Kurdistan Region – Iraq
exceeding the threshold and protect a DC motor coil from
damage produced from the exceeded current that causes
rising for coil temperature. To resolve this problem, INA219
has been used; it is compatible with the Arduino controller
and can provide voltage and power in addition to current. The
use of the current sensor has another benefit in fault analytic
issue where the history of the motor current is significant to
define the causes of failures and take the precautions to
prevent defects in the future.
B. Network Layer
The network layer is essential for the project of the IoT
system since it is the layer responsible for connecting
physical sensors utilizing MODBUS TCP/IP that is the most
critical IoT protocol [14].
The MODBUS protocol describes a simple protocol data
unit (PDU) independently of the basic communication layers.
The mapping of MODBUS protocol on definite buses or
networks can return some additional fields on the application
data unit (ADU) [15]. The connecting between different
devices using MODBUS protocol requires well knowledge in
this protocol, and the memory specified address of each
device and how to convert its address to MODBUS address.
The structure or the topology of the proposed IoT system
is a star topology. In a star topology, each IoT device is
directly connected to a central hub (gateway) that
communicates the data from the connected devices upstream.
Wi-Fi is standard wireless networks based on IEEE
802.11a/b/g/n specifications. The communication method
used for proposed IoT system devices is 802.11g, and for
power consumption reasons, the chip ESP8266 has been
used.
C. Processing Layer
There are two parts of the processing; one inside the local
controller, or in Programmable logic control (PLC) which
considered the complex processing represented by fuzzy
logic control. The other processing is in the cloud platform
which represents the data collection, monitoring, and control
for the entire system, including store the alarms and events
and builds up of cloud computing and settings by using the
logical computing in Ubidot's platform. Fuzzy logic control
fashion has been adapted for controlling the given process.
The classical control systems such as P, PI, PD, PID has
lesser efficient than Fuzzy system for many reasons like
existing of overshot, raising the settling time, and have a more
significant steady-state error as will explained in the next
section. The use of classical controllers leads to less energy
saving [16].
There are two places for store the alarms and events, one
in OPCServer (KEPServerEX) by utilizing the alarm and
events facility existed in the OPC Server this kind store in the
hard disk of the local computer.
The other place is remotely in the cloud utilizing the
platform of Ubidots. Alarm and events play a vital role in
analytic, so the maintenance engineers can use it as a history
database for diagnosis the faults occur in the operating
system.
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D. Gateway Layer
It represents a physical device or software program that
serves as the connection point between the cloud and
controllers, sensors and intelligent devices. Another benefit
of an IoT gateway is that it can provide additional security for
the IoT network and the data it transports.
Making the networking relied on current devices is in this
case big challenge since machines from different
corporations and at distinct technological levels generally,
do not communicate with similar data language. An
intelligent gateway that harmonizes communication between
altered data sources is analyzed and transfers data to suitable
recipients. The Gateway of IoT that can accept and process
the data from a PLC, and after that used to store the
processing data from the PLC to the Cloud platform and then,
it controls real devices remotely through the web
applications.
As a standard used for interoperability between industrial
machine's software, OPC specifications describe the
communication of objects and interfaces of OPC servers. The
standard for access to data issued earlier by OPC foundation,
define costume interfaces for automation and other details,
the vital matter is an attempt to access real-time data for local
devices. As long as the service's interfaces and clients access
to the interfaces are accurately agreed with the specifications,
it can guarantee data transfer with high efficiency [4].
MQTT is a straightforward and lightweight's protocol for
messaging. It's published/subscribed for construction is
intended to be open and straightforward to achieve, with up
to Hundreds of distant clients capable of being propped by an
individual server. [17].
E. Cloud Layer
It is a Facility for managing, storing accessing the data via
the Internet. Cloud in this context meaning a large number of
devices connecter through the network that depends primarily
on the virtual computing in submitting its services where each
of these computers is connected has tasks of multiple virtual
devices for achieving cost minimizing.
Cloud computing addresses the issues with remote data
storage; for example, the cost and capacity required to store
big data sets. In addition, cloud providers are deploying and
making available analytic tools that can process massive
amounts of information. These technologies are maturing and
becoming more widely attainable, and this appears to be a key
point [18].
IV. DESIGN AND IMPLEMENTATION
The water intake system regarded as an industrial system, so it is
required more care in providing suitable devices that serve for this
task. The most important things that should be available in selected
devices are durability and reliability. The chosen main controller for
this system is PLC from LSIS Company with 16 digital inputs and
12 digital outputs and two analogue inputs and two analogue outputs
in addition to the communication module. The analogue module,
whether for input or output, can use for voltage or current. As this
work will be applying in reality, an appropriate work configuration
is done for the industry environment, such as including the devices
in suitable PVC panel, to protect them against the dust and humidity.
Local controlling was implemented by adding control push buttons
and a selector switch for change over between Auto and Manual
operation, as shown in Fig. 2. For this control, four digital input and
 2020 International Conference on Computer Science and Software Engineering (CSASE), Duhok, Kurdistan Region – Iraq
three digital outputs and one analogue output have been used. The
selector position on Auto means the IoT control level, whereas the
IoT has been used for remote control, in addition to monitoring and
computing.
The panel also contained two 24V power supply, one for
Fig. 2. Implemented Prototype Panel
PLC and the other for providing 24V for DC motor.
The designed process in the controller is fuzzy logic
control, which aimed to control the DC motor using DC to
DC converter; Fig. 3 depicts the flow chart of the water level
control algorithm. The Arduino and MOSFET circuit
integration are used to build up the DC to DC converter,
where Arduino controller used to receive the PLC analogue
output which ranges from 0 to 5 V and converts it to PWM
(Pulse Width Modulation) signal. This was done by using the
mapping statement:
Fig. 3. Fuzzy Process Flowchart
10
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Motor Value:= map (PLC_OUT, 0, 1023, 0, 255)
The PWM signal drives directly to MOSFET circuit
which has a maximum capacity up to 4A and obtains DC
output voltage over a range from 0 to 24V. The Node MCU
ESP8266 chip is used to secure the wireless communication
between PLC and sensors. In the side of the panel, a router
device is installed for securing Ethernet connection with PLC
and providing the internet for the devices. The MODBUS
protocol has been used to connect PLC with a router and with
all the local devices.
To design PID controller, a PID auto-tuning and PID
function blocks have been created in the PLC ladder diagram
according to the following setting that obtained by using
auto-tuning facility available in the PLC:
Set point=20cm, Cyclic time= 100mSec
The PID parameters are; Kp=187, Ti= 1183, Td=295.
For creating the process of fuzzy logic inside the PLC, a
fuzzy logic algorithm based on Sugeno rules has been
developed. Seven memberships have been selected for both
Error and Change f Error to have an accurate and high-quality
fuzzy system. Raise, and fall edges of a timer have been used
to take the sample of water level and to produce the E and CE
as a result. The creation of Error signal from real-time
ultrasonic water level sensor reading values was done by:
E: = Set_Value - Water Level
Figure 4 explains the labelling of memberships, Error
memberships and Change of Error (CE) respectively:
ENB[1]: = -10.8; ENB[0]: = -7.2;
ENM[0]: = -10.8; ENM[1]: = -7.2; ENM[2]: = -3.6;
Fig. 4. Error (E) and Change of Error (CE) Set of Memberships
The above two statements are an example of defining two
membership (NB&NM) of Error. The fuzzy rules used in this
algorithm are based on the Sugeno method. Sugeno used the
singleton, as the membership functions of the rule
consequential. A singleton, or precisely a fuzzy singleton, it
is a fuzzy set as a membership function which is zero
everywhere except at a particularly unique point in the
universe of discourse will be unity[19]. The output of fuzzy
logic consists of “11” single spikes from (-1) to (1) increment
by 0.2.
An example to Sugeno rule simulation in ST (Structured
Text) language is the following statements;
W(0,0):=-1; W(0,1):=-1; W(0,2):=-0.8;
W(0,3):=-0.6; W(0,4):=-0.4; W(0,5):=-0.2;
 2020 International Conference on Computer Science and Software Engineering (CSASE), Duhok, Kurdistan Region – Iraq

Table II shows that the performance of Fuzzy is better

TABLE II. COMPARISON BETWEEN PID AND FUZZY AT ET VALUE 20CM
than classical PID controller. This is because transient time,
Tr Ts
settling time and Integral Time Absolute Error (ITAE) of
Controller OS IAE ITAE Fuzzy is leaser than PID regardless small difference in
(Sec) (Sec)
PID 630 5% 830 3957 645782 Integral Absolute Error (IAE) that not have a significant
no effect on performance. Hence, the selection of the Fuzzy
Fuzzy 485 475 4340.5 596500
overshot
TABLE I. SUGENO RULES
E NB(0) NM(1) NS(2) Z(3) PS(4) PM(5) PB(6)
CE
NB(0) -1 -1 -0.8 -0.6 -0.4 -0.2 0
NM(1) -1 -0.8 -0.6 -0.4 -0.2 0 0.2
NS(2) -0.8 -0.6 -0.4 -0.2 0 0.2 0.4
Z(3) -0.6 -0.4 -0.2 0 0.2 0.4 0.6
PS(4) -0.4 -0.2 0 0.2 0.4 0.6 0.8
PM(5) -0.2 0 0.2 0.4 0.6 0.8 1
PB(6) 0 0.2 0.4 0.6 0.8 1 1 Fig. 5. MATLAB Fuzzy 3D plot for output with E and CE
controller is the right decision.
W(0,6):=0; ‘W’ is an array vector abbreviation called
(WEIGHT matrix) for the stage of inference to the two- The test of the system was done; it gives real-time results.
dimensional matrix WEIGHT has been assigned. Table I Moreover, it is seen from the comparison between the PLC
contains 49 rules that reflect the fact that it required to write real-time and MATLAB results, that the results of the
49 statements to cover all rules. While Error signal varies implemented fuzzy system are precisely similar to MATLAB
with time, it is expected for “E” to lay at any one of Error results, which means that the proposed algorithm working is
memberships, so it is needed to check the presence of error correct. Fig. 6 shows the comparison curves between PID and
signal at each membership, and accurate value inside the Fuzzy controllers.
membership. Consequently, a similar thing is correct for CE
may be changed; it is position at any time “t”, to achieve that 24
in programming it should by utilize the triangular similarity. 22
20
18
water level cm

EE[0]:=ABS(MAX((MIN((E-ENB[0])/(ENB[1]-
16
ENB[0]),1)),0)); 14 PID controller
CEE[1]:=MAX(0,MIN((CE-CENM[0])/(CENM[1]- 12
10 Set value
CENM[0]),(CENM[2]-CE)/(CENM[2]-CENM[1]))); 8
6 Fuzzy controller
The above two statements are used in the algorithm to find 4
the value of Error (NB) and change of Error (NM). Since 2
there are seven memberships of error and seven memberships 0
0 200 400 600 800 1000
of change of failure, so fourteen statements are needed. Time Sec
There is one problem in particular needs to be in Fig. 6. Comparison between PID and Fuzzy
treatment before operating the system in the real world.
The pump was operated within 24VDC, and if starting the
Control and monitoring were done successfully from the
applied voltage from zero, then the delivered current value
cloud with some delay in reading from PLC to cloud. These
will increase. The problem appears when the voltage applied
delays because Ubidots platform setting the refresh rate of
to the driver is less than 6 V; this cannot derive the pump
data update about 5 Sec and with some delay in the server of
correctly. To solve this problem should design the fuzzy
that platform. A simple dashboard has been implemented to
controller in a way that gives less than 6V only when the
visualize the monitoring of application devices. Besides, this
setpoint has been satisfied. And should check the Error value
dashboard can be used to control the D.C motor, as shown in
if the fuzzy output less than 6V (fuzzy scaled output 1250mV
Fig. 7.
sent as input to D/A converter), then consider the output equal
to zero and the system reach to the desired set point. This The trends of device's values have been monitored if some
action has been done to protect the pump from any damage. value below a specified threshold or exceeded the specified
threshold alarm signal will be initiated and send to E-mail or
V. RESULTS AND ANALYSIS mobile as SMS message, this, in effect, represents the cloud
This system is simulated by MATLAB fuzzy tool and computational. When moving data to the cloud platform of
produces the result shown in Fig. 5. This Figure shows that Ubidots, it can be achieving the back up of data. Anyway,
the output takes a maximum value when the error is 10.8 cm, from the security viewpoint is better to use a commercial
and the CE is 1. The setpoint of the process variable fixed to platform, also to avoid the delay latency of processing data—
20 cm. finally, the project working well and perform all required
functions in the design.

11

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 2020 International Conference on Computer Science and Software Engineering (CSASE), Duhok, Kurdistan Region – Iraq
Fig. 7. Ubidots designed dashboard
VI. CONCLUSION
This paper presented a prototype of the industrial process
for R.O water intake controlled by PLC, that could also be
monitoring and managed to employ IoT. The wireless
communication has been applied in the industry with many
advantages. Namely, such as minimize the number of wire
scheme, and decrease the probability of faults and easily to
make the maintenance. IoT can work as a complement for the
traditional automation systems towards the ideality in
industrial systems. It has a significant role in monitoring the
operating systems remotely from anywhere in the world and
at any time. This will enhance the reliability of the systems.
The performance of Fuzzy is better than classical PID
controller. Also, Fuzzy provides a more efficient, precise and
reliable control system and led to power-saving. Alarms and
event history has been back up using Ubidots platform, SMS
and Emails are done by using cloud computing where SMS
and Email messages have been practically received by mobile
and Email when an alarm signal occurs. IoT is essential in
maintenance where NOC engineers could see the alarms and
events and tracking the data trends remotely by using the
cloud services to utilize them in faults analytics and give
proper solutions. This work has the novelty by integrating
three crucial issues; the use of IoT technology with PLC, by
using wireless technology in transmitting sensor data to the
PLC, and the development of an algorithm to operate the
fuzzy logic within the PLC environment. For future work, the
proposed system can be used as a single node in a more
extensive network of many nodes. This improvement can be
used to cover a larger size grid of plants such as water
purification plants in large cities, utilizing IoT facilities,
cloud, and Fuzzy control and monitoring.
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