International Journal of Advanced Research in Engineering and Technology (IJARET)

Volume 11, Issue 10, October 2020, pp. 1353-1363, Article ID: IJARET_11_10_129
Available online at
http://iaeme.com/Home/issue/IJARET?Volume=11&Issue=10
ISSN Print: 0976-6480 and ISSN Online: 0976-6499
DOI: 10.34218/IJARET.11.10.2020.129

© IAEME Publication Scopus Indexed

INDUSTRIAL AUTOMATION USING PLC, HMI

AND ITS PROTOCOLS BASED ON REAL TIME
DATA FOR ANALYSIS
Mhetraskar S. S.
Department of Electrical Engineering
Bharati Vidyapeeth (Deemed to be University) College of Engineering, Pune, India

Swapnil A. Namekar
Professor, Department of Electrical Engineering
Bharati Vidyapeeth (Deemed to be University) College of Engineering, Pune, India

Dr. Rajesh M Holmukhe

Department of Electrical Engineering
Bharati Vidyapeeth (Deemed to be University) College of Engineering, Pune, India

Santosh M. Tamke
Technical Head, M/S Sensycon Control, India

ABSTRACT
Aim of this study is to resolve the automation and control issues in Indian industry
with low cost control and effective data analysis for industrial automation. The objective
of study is to take the overview of industrial automation need for present Industries
requirement with advance communication facility, record generation for report analysis
as well as visualization of information & utilization of advance VFD function to reduce
the use of mechanical system and optimize the energy for manufacturing & increase the
operation flexibility. In this investigation a new concept is implemented wherein, user
can monitor the data and control the data remotely using web access in mobile or else
from location where user is located. Also data can be analyzed as per date and time of
log in excel format otherwise through email directly.
In this study, the concept of PLC (programmable logic controller), HMI (human
machine interface), energy measurement device, VFD (variable frequency drive),
induction motor, data logging are studied. the interface of PLC, HMI, VFD &
measurement device was done into various protocols like rs-232, rs-485, etc. Here, VFD
is used for controlling the speed of induction motor using analogue output of PLC. The
PLC is used for ladder logic development. HMI is used to monitor a variety of
parameters of energy measurement device, like speed, direction & operations of

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 Industrial Automation Using Plc, Hmi and its Protocols Based on Real Time Data for Analysis

induction motor. Analysis is conducted by data logging of parameters like voltage,

current, power, along with HMI display. The input – output status is also shown in
display for diagnosis purpose. The report is generated in excel format which is stored
in pc drive or USB. This report is useful for future analysis which increases the
productivity of the system. In this study of advance technology the researchers have
done analysis and monitoring of the data using web as well as in mobile application.
Key words: Programmable Logic Controller (PLC), Human Machine Interface (HMI),
Multifunction Meter, Variable Frequency Drive (VFD), Industrial Automation.
Cite this Article: Mhetraskar S. S., Swapnil A. Namekar, Dr. Rajesh M Holmukhe and
Santosh M. Tamke, Industrial Automation Using Plc, Hmi and its Protocols Based on
Real Time Data for Analysis, International Journal of Advanced Research in
Engineering and Technology, 11(10), 2020, pp. 1353-1363.
http://iaeme.com/Home/issue/IJARET?Volume=11&Issue=10

1. INTRODUCTION
The automation industry in India is facing new type of challenges like information security
management. The major part of the challenge comes from the diffusion of new information and
communications technology (ICT) technology into the field. Solutions in the field show a strong
trend of convergence towards common ICT solutions, especially to IP-based communication
and de-facto operating systems.
Today’s requirement of automation has shifted to increase more authenticate records,
reports, visualization and easy to analysis to reduce the cost of the product. This advance
automation system needs unique hardware and software for control and monitor system. In this
field the present market leaders, vendors available are Siemens, Mitsubishi, Allen Bradley, and
Schneider. To get the information from one equipment to other equipment, one process to
another process, energy monitoring is made easy and flexible by using various communication
networks and protocols.

2. BRIEF LITERATURE REVIEW

In this study, the researchers reviewed few subject specific research articles, industrial
engineering studies and research reports. Few company websites in addition to company
manuals were also referred. Few companies were also visited.
In the study of “Industrial Burner Automation Based On PLC HMI & SCADA” the authors
“Rahul Pandey & Nidhi Bhatt” reveal that automation is based on PLC,HMI & SCADA with
remote monitoring and energy conservation. These authors used SCADA software for remote
monitoring, HMI for control & monitoring of the burner, VFD for controlling the speed of
motor using PID logic. These authors explain HMI display for monitoring the setting screen,
mode selection screen, VFD parameters, and input-output status. The data logging is done in
CSV format [1]. In one more study of “process automation of demineralization plant using delta
PLC, wonderware intouch and delta HMI” the authors Jayanthi et.al., used automation using
PLC,HMI & SCADA. In their study of demineralization, the raw water obtained from
underground and lake is treated to meet standard as per usage and parameters monitored are PH
and turbidity. In their authors Jayanthi et.al, project delta PLC is used which is interfaced with
HMI and further HMI is connected through Wi-Fi for remote monitoring and control purpose
and SCADA is also interfaced with PLC and PC. This is used for improving the quality and
quantity of dematerialized water [2].
Industrial automation uses control devices like PLC, PC, HMI etc. While using these
control devices, user can control the industrial processes and machine using less labour making

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 Mhetraskar S. S., Swapnil A. Namekar, Dr. Rajesh M Holmukhe and Santosh M. Tamke

it easy to operate automatically. Control systems is most important part of Industrial automation
[10]. The control and monitoring process using latest technology such as ladder logic &
controls, robotics & industrial software is called automation. Automation reduces the human
work, save the money and gain money [4]. The advantages of Industrial automation includes ,
improvement in product quality, reduction in labour required, reduction in production cost,
reduced routine manual tasks, improved safety and assisted remove monitoring. Industry 4.0
means smart factory. In smart factory different types of digital devices are connected together
and then communicated with robots, raw material flow, machine tools, products and human.
The Industry 4.0 presents a change by digitalization as well automation of every company and
manufacturing process. The manufacturer will communicate with the computers. According to
Kagermann et.al. (2013), Industry 4.0 utilizes the power of communications technology and
innovative inventions to boost the development of the manufacturing industry [5]. The
advantages to Industry 4.0 include, improved productivity, improved efficiency, increased
knowledge sharing & collaborative working, flexibility, increased profitability, reduces costs
and a return on investment.

3. RESEARCH GAPS FOR THE STUDY

During the study, primary data was collected after interaction with this subject specific experts
in industries in Pune city region of Maharashtra state (India).The secondary data is referred
from Engineering journals, industrial component manuals, research and industry websites.
After the literature review and dialogue with industry experts, the authors understand that
there is a need of industrial automation using modern controls for handling the business in the
more cost effective way for meeting the market demands in prompt way. Moreover, to meet
the diversified business demand in the global manufacturing, there is demand of industries to
be setup in the varies geographical locations which require real-time, fast, authenticate data as
well as information is on demand. The authors in this study furthermore found that, there is
need of up-to-the-minute techniques for easy to handling of machines in the factories, for
handling the complexities, remote operations, data logging, monitoring, reporting etc.,. It is
also revealed that for increasing the productivity and thus the profit, the industries also need to
make use of smart instruments, automation, communications etc. Additionally, it is found that,
for the development of the electronics and computer sector, use of modern concepts of
automation are in high demand.

4. AIM OF STUDY
Aim of this study is to resolve the automation and control issues with low cost control and
effective data analysis for industrial automation. This is done with high quality & reliable
control systems by considering latest control devices ( PLC, PC, HMI , VFD, etc.) along with
communication protocols (ETHERNET , RS-232,RS-485,PROFIBUS,PROFINET,ETC.) in
addition to application of industrial software used for monitoring and controlling the devices.

5. OBJECTIVES OF STUDY
In Indian industries there are various automation and control issues. In agreement with this
following are the specific objectives of industrial automation using modern controls PLC, HMI
and its protocols based on real time data monitoring & logging for analysis.
[1] To study the overview of industrial automation need for present Indian industries
requirement by means of advance communication facility, record generation for report &
analysis as well as visualization of information.

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 Industrial Automation Using Plc, Hmi and its Protocols Based on Real Time Data for Analysis

[2] Utilization of advance VFD function to reduce the mechanical system by gear box
elimination , in addition to this , optimize the energy for manufacturing , furthermore
increase the operation flexibility.

6. METHODOLOGY
This study considered Mitsubishi make compact PLC (programmable logic controller) which
is having on board display , digital 8 input and 8 output of 24v dc and 1 expansion module
having 4 channel analogue output 0-10 v . For programming of PLC (programmable logic
controller) CODESYS software is used as a programming platform to develop the logic, testing
and simulation. This study has considered the exor HMI (human machine interface) of 7 inches
touch screen having 1 ethernet port and 2 serial ports, one of rs-232 and another is rs-422/485
for interfacing of the base PLC (programmable logic controller). This is used for information
exchange between the system and the human. This HMI (human machine interface) can be
monitored remotely by providing the internet connection. This can be monitored and controlled
as it is the HMI (human machine interface) application on the web , data logging and report
generation for the analysis. The JMOBILE studio platform is used for development of screen,
reports, visualizations, alarms and data collection. The smart multifunction meter is used of
Schneider make to monitor the load digitally. All the basic parameters like voltage, current,
power, power factor, and frequency can be monitored through using rs -485 communication
protocol to the HMI (human machine interface) or PLC (programmable logic controller). The
data registers of respective parameters can be read directly. This study has used VFD (variable
frequency drive),YASAKWA make VFD (variable frequency drive) to control the speed of
induction motor. we can vary the speed of the induction motor from 0 to 100 % of motor rated
rpm. can change the direction and speed locally or remotely through HMI (human machine
interface) and PLC (programmable logic controller). This study work can provide the accurate
protection to the motor by reading the parameter from multifunction meter.

7. STUDY WORK AND ITS IMPLEMENTATION

7.1 Block diagram

Figure 1 Controlling f Induction Motor by Using PLC and VFD[12]

7.1.1. Programmable logic controller

Figure 1. Consists of input block, base PLC (programmable logic controller), output block, and
analogue expansion output module.
Various types of programmable logic controller's are available in market with brand names
like Siemens, Mitsubishi, Delta, Allen Bradley, Omron, etc. In this investigation Nexgenie 1000

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 Mhetraskar S. S., Swapnil A. Namekar, Dr. Rajesh M Holmukhe and Santosh M. Tamke

series programmable logic controller is experimented. Here NG16DL model is experimented.

This model PLC has 8 input and 8 output. The NG16DL PLC (programmable logic controller)
is compact PLC, therefore it is used for small size machine control applications.
Following features this PLC are used : For this PLC 4 expansions modules are used. We
can expand this further up to maximum 80 Input/output (I/O). Here, 24 volts power supply is
required for of this programmable logic controller. There are 2 ports. one port is used for
programming and another port is used for interfacing the third party devices. Here the
programming software - CODESYS is used. Display of 128 x 64 pixcel graphic LCD helps for
setting the PLC (programmable logic controller) data , faults, machine status , etc.[6] Memory
-marker memory - 4kbtyes, data memory - 24kbtyes, application program memory -128 kbytes
flash, 384 program organization units (POU’s) maximum,Source code memory - 1 mega bytes
flash source code memory is used for project file with symbolic names, comments, visualization
screens, libraries, etc.

7.1.2. Human machine interface

Human Machine Interface specifications are as follows: Make - Exor, Model - Esmart07m,
The 7 Inches Screen, Programming Software - JMOBILE Suite, Serial Port Rs-232, Rs-
485, Rs-422 Software Configurable, Resolution - 800x480, User Memory - 60 Mb Flash, Ram
- 512 Mb Ddr, Screen - 100, Tags – 1000.[7]
In the HMI (human machine interface) for interface between the PLC (programmable logic
controller) and multifunction. All the registers read and displayed on the HMI (human machine
interface) of present load status. In the HMI (human machine interface) shows Di / Do status,
operations, data settings and data logging. Advanced features are: it is having screen rotation,
screen switching functions, scheduling, recipes, graphical representations, alarms status,
scripting, remote monitoring, and client server functions, etc.

7.1.3. Variable frequency drive

The variable frequency drive view. It has specifications as: Make – Schneider, Model - J1000,
Capacity - 1.5 KW,

Figure 2 Control Diagram of VFD

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 Industrial Automation Using Plc, Hmi and its Protocols Based on Real Time Data for Analysis

Variable frequency drive Figure 2. is used for speed controlling of induction motor, Here,
control the motor, start -stop operation and speed variation locally is done from the keypad of
the drive and remotely from the PLC sending commands to the drive on digital and analogue
terminals. The interface terminal details are shown in the figure 10. use of input supply R, Y,
B phases respectively - 440 v, 3 ph to the terminal of r/l1, s/l2, t/l3 respectively is done. The
motor is connected to output terminal u/t1, v/t2, w/t3. From PLC digital outputs are connected
to the s1 terminal - forward run stop command, s2 terminal - reverse run stop command is used
for change the direction of motor.[8]
Analogue output of the expansion module is connected to the a1 and ac terminal of the drive
for speed variations. This is 0 to 10 v corresponding to 0 to 100% speed variation of minimum
and maxmum.

7.1.4. Multifunction meter

The CONZERV make EM6436H series meter is used for the electrical parameter of the load.
It senses the CT. For measurement purpose external CT are used. This series is used for the
demanding needs of energy monitoring and cost management applications. This series is with
class 0.5 and class 1.0 accuracy standards. [9]
This is used in various applications like, metering in custom panels, switch boards & switch-
gear, motor control centres ( MCC), power factor improvement panels.

7.2. Hardware setup

Figure 3 Hardware Setup of Power Panel Figure 4 Hardware Setup of Control Panel
Figure 3. Show all component which are required for the experimental setup. Figure 4.
second mounting plate required for control as well as power panel design. In Figure 3., on one
plate the all CT’s , input and output devices, multifunction meter , SMPs, MCB and connectors
are used. In Figure 4. on one plate, the PLC, HMI,VFD, contactor , SMPS,MCB and
connectors are used.
In the above setup, the 3 phase, 440v input supply is made available through the mains
through the CT’s R, Y, B respectively. CT’s supply is connected to the multifunction meter.
SMPs is used for input- output control supply on one plate and on other plate SMPS is used
for PLC, HMI control supply which is 24 volt dc.
The VFD input supply is coming from MCB and VFD output goes to motor terminal U, V,
W. The contactors are used for induction motor forward and reverse direction.

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 Mhetraskar S. S., Swapnil A. Namekar, Dr. Rajesh M Holmukhe and Santosh M. Tamke

7.2.1. Programmable logic controller ladder logic

What is CoDeSys Software ?
CoDeSys is a complete development environment for your PLC, The CoDeSys stands for
Controlled Development System. CoDeSys puts a simple approach towards the powerful IEC
language for the PLC programmer. It is used the editors and debugging functions is based upon
the proven development program.[6]
In the Figure 5. screen shots are the PLC programme. In that we had done the PLC
programme using codesys software. The language of programme is ladder. In the ladder logic
we did the input-output testing programme. The analogue output programme for speed control
and contactor through induction motor forward-reverse operations.

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 Industrial Automation Using Plc, Hmi and its Protocols Based on Real Time Data for Analysis

Figure 5 Ladder Logic for PLC program Screen Shot

7.2.2 Human machine interface design

JMobile Studio is a software application designed to create graphical HMI pages. JMobile
Studio has a drag-and-drop interface that makes it easy to create complex pages. Many of the
features found in common Windows applications are also available in JMobile Studio. JMobile
Studio is available in multiple languages.
In Figure shows HMI screen design Jmobile studio software used. In this software screen
design for input-output addressing Figure 6 (a). and indication status Figure 6 (b). is executed ,
VFD speed representation, motor start - stop operation and motor forward- reverse operations
is also executed . The Figure 6 (c). last screen is design for multifunction parameters reading
using modbus protocol. Here, following multifunction parameters were measured : phase to
phase voltages, phase to neutral voltages, currents, ac power , frequency and power factor.

Figure 6 (a) Screen design for input-output addressing Figure 6 (b). Indication status

Figure 6 (c) Screen for design of multifunction parameters reading using modbus protocol

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 Mhetraskar S. S., Swapnil A. Namekar, Dr. Rajesh M Holmukhe and Santosh M. Tamke

8. RESULTS

Figure 7 Measurement device data logging screen shot of Energy Meter

The Figure7. Screen shot shows the data logging. In that, the data is logged by using date
and time. The various parameters are read in the report like R, Y, B phase voltages, currents,
ac power, frequency and power factor, etc. The data is logged at every 1 minute Interval.
The advanced technology used for this study is monitoring the HMI screen on web access.
Here Google chrome is used for web access. HMI monitoring is opened using IP address. The
data is analysed using mobile The Fig.18 screen shot shows the web access connectivity through
IP address (192.168.3.40). We can also see in mobile information shown in Figure 8.

Figure 8 Web access in google chrome screen shot

9. CONCLUSIONS
In this study, data is analyzed on the basis of diverse industrial components like PLC, HMI,
VFD, Energy meter. During analysis, the researchers used the software’s like Codesys for
logic development, Jmobile Suite for HMI design, Modbus tester for energy parameter reading
using RS-485 protocol and data logging and reporting in Excel format. Here, data is monitored
in web access.
This exploration implemented the hardware as well as programming. The study dealt in
detail with PLCs and HMI. PLCs and HMI make available advantages like flexibility, easy
implementation of changes, correcting errors, low cost, visual observation, easy programming
method, reliability, maintainability, documentation, reporting and data logging.

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 Industrial Automation Using Plc, Hmi and its Protocols Based on Real Time Data for Analysis

During analysis, all the operations are controlled from the HMI. The operations controlled
were speed control of induction motor using reverse / forward control by using contactors ,
direct on line (DOL) starting of induction motor, speed control using VFD through PLC
analogue output system and start /stop operations done from the HMI through PLC. Energy
meter parameters monitored are voltage, current and power on the HMI.
This study search gives the overview of industrial automations used in the industries.
Subsequent to experimentation and after practicing and implementing the test setup, the
researchers were able to handle and introduce present industrial automation system.
From the results it is observed that the automation can make the engineering more efficient,
less time consuming, flexible, more useful and interactive from the operation point of view.
Also, automation makes system more accurate and can act more safety and protective to the
equipment, machinery and processes. Therefore, it is concluded that automation can be widely
accepted in Indian industries as it endow with economical productivity.
Last but not least, a new concept is implemented wherein; user can monitor the data and
control the data remotely using web access in mobile or from location where ever user is
located. Also data can be analyzed as per date and time log in excel format or through email
directly.

10 FUTURE SCOPES
Future automation engineers will no longer be limited to the field of production. Many
automation projects, for example will be implemented within the so-called smart environment.
In transportation, buildings, and health care, future automation projects will have closer
proximity to people’s everyday lives. The engineers’ expertise in automation will be applied in
many non-traditional fields. These innovations will drastically change people’s lives, adding
convenience. The automation systems will become an important foundation for the future
construction and operation of intellectualized and automated societies.
This autonomic network concept can benefit the productivity of smart applications in smart
environment. This work will also facilitate to investigate the new strategies to improve the
security management in automation field.

11. LIMITATIONS
The only disadvantage in using PLC is that it makes use of fixed programs for applications and
in some cases fail safe operations can be possible only through wired control. Further, while
using JMobile Studio software application designed to create graphical HMI pages, although
all languages are installed by default as part of JMobile Suite, the default language is English.

ACKNOWLEDGMENTS
The authors express thanks to Bharati Vidyapeeth (Deemed to be) University, College of
Engineering, Pune Satara Road, Pune-411043, Maharashtra state. This paper and the research
behind it would not have been possible without the exceptional support of college individuals
and lab facilities made available.

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