Chapter

Programmable Logic Controllers

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Abstract

This chapter presents an introduction to the programmable logic controller, its general function, hardware forms, and internal architecture. A programmable logic controller (PLC) is a special form of microprocessor-based controller that uses a programmable memory to store instructions and to implement functions such as logic, sequencing, timing, counting, and arithmetic to control machines and processes. It is designed to be operated by engineers with perhaps a limited knowledge of computers and computing languages. Input devices and output devices in a system being controlled are connected to the PLC. The operator enters a sequence of instructions, that is, a program, into the memory of the PLC. The controller then monitors the inputs and outputs according to this program and carries out the control rules for which it has been programmed. PLCs are now widely used and extend from small self-contained units for use with perhaps 20 digital inputs/outputs to modular systems, which can be used for large numbers of inputs/outputs, handle digital or analogue inputs/outputs, and also carry out proportional-integral-derivative control modes. A PLC system has the basic functional components of a processor unit, memory, power supply unit, input/output interface section, communications interface, and programming device. It consists of a central processing unit (CPU) containing the system microprocessor, memory, and input/output circuitry. The CPU controls and processes all the operations within the PLC.

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... At the heart of the system, the master station and its sub-masters collate data from various RTUs and often furnish an operator interface for data visualization and remote control of the distributed sites. In larger telemetry systems, sub-master sites undertake the role of gathering information from remote sites and function as relays back to the central control master station, enhancing the scalability of the SCADA system [6,9]. SCADA technology has a rich history, with its origins tracing back to the early 1960s. ...
... Over time, it has coexisted with two competing paradigms: the Distributed Control System (DCS) and the Programmable Logic Controller (PLC). The DCS represents a variant of SCADA in which data acquisition and control functions are executed by numerous distributed microprocessor-based units situated in proximity to the devices under control or the instruments from which data is sourced [8][9][10]. DCS systems have evolved to offer advanced analog control capabilities, including loop control, while also featuring tightly integrated operator interfaces for effortless system configuration and operator control. ...
... PLCs have supplanted traditional hardwired relays with a combination of ladder logic software and solid-state electronic input and output modules. They find extensive use in implementing SCADA RTUs due to their cost-effective and standardized hardware solutions, making them a popular choice for SCADA system deployments [8][9][10][11]. A remote terminal unit (RTU) is an electronically controlled microprocessor device that links physical objects to a distributed control system or SCADA (supervisory control and data acquisition) system. It achieves this by sending telemetry data to a central master system and receiving instructions from the master supervisory system to manage connected objects. ...
Article
In various industrial settings, Supervisory Control and Data Acquisition (SCADA) and Programmable Logic Control (PLC) systems are commonly employed for control purposes, such as in water treatment facilities, electric power stations, and irrigation systems. However, the oil and gas refinery sector typically relies on Distributed Control Systems (DCS) to manage a wide array of process and equipment control functions. This project departs from the conventional reliance on DCS and explores the utilization of a SCADA system, both with and without Arduino integration, to oversee and regulate oil levels within a tank that serves as a representation of a refinery. The project introduces the design and detailed implementation of a real-world SCADA system developed in LABVIEW. Effective solutions encompass automation and monitoring architectures that encompass several components, including a real-time supervision and control system, programmable logic controllers equipped with fundamental libraries, communication systems, standard or custom interfaces interfacing with sensors, electrical drive components, measuring instruments, and more. Leveraging informatics systems offers the potential to proactively prevent various phenomena through data analysis and processing, ultimately leading to optimized operations and significant cost savings. Consequently, this project introduces a SCADA system tailored for the monitoring and control of water distribution stations. This system is designed to ensure the efficient operation of pumping systems, enhance equipment and infrastructure safety and resilience, optimize energy consumption, and efficiently manage the distribution of potable water resources. The project relies on LabVIEW, a graphical programming language utilizing a dataflow model, for programming, control, and monitoring of a simulated water system. Additionally, rain sensors are employed to detect water levels within predefined minimum and maximum thresholds. Moreover, LabVIEW is utilized for programming the Arduino UNO microcontroller board, which serves as an interface between the software and other circuit components. The results of this project demonstrate high-performance levels and the attainment of precise measurements.
... Elementary variables (EVs) are those variables that belong to the data types such as INT (16 bit), DINT (32 bit), REAL (32 bit), LREAL (64 bit), BOOL (1 bit) and so on [17][18][19][20][21][22][23][24]. To store NN parameters depending on the precision needed and the data types supported by the CPU, REAL or LREAL are the recommended options. ...
... Each task has its own watchdog parameter [17][18][19][21][22][23][24]. A watchdog is a safety mechanism in PLCs that monitors system operations and can trigger a transition from the RUN state of the CPU to the STOP state, causing the program to cease execution and thereby halting system control. ...
Article
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The proposed article discusses the principles of implementing artificial intelligence (AI) methods in industrial control systems focusing on the deployment of neural networks (NNs) within programmable logic controllers (PLCs). Recent advancements in AI have led to significant improvements in modeling, control, quality control and predictive maintenance. This progress is further supported by the development of newer CPU architectures in PLCs, which offer enhanced processing speeds and capabilities. These advanced CPUs facilitate the implementation of more complex AI algorithms enabling systems to perform real-time data analysis. By leveraging the power of AI and improved hardware, industries can achieve higher levels of automation and better decision-making.
... The basic parameters of industrial controllers are: processing time of one thousand instructions (Scan Time), access time to internal and external resources, and transition time, which are closely related [1,11]. When developing the optimal design of central units designed for operation in control systems using PLC controllers, all these parameters should be taken into account. ...
... A Programmable Logic Controller (PLC) is an industrial digital computer, adapted for the control of manufacturing processes, such as robotic devices or assembly lines. The main advantage of PLCs over the classical methods of implementing control systems is the possibility to change the operating algorithm without the need to reconstruct the entire control system [1]. ...
... Automating vision systems also provides cost savings to industries. Inspection by humans is estimated to be only 10% of the workforce which is only around 400,000 jobs, meaning an estimated $8 billion is dedicated to industrial inspection [7], [8]. Investing in vision systems will improve the quality of the products offered to the consumer while reducing costs. ...
... Human operators perform most inspections. This method is not one of the most accurate due that human operators may face fatigue while performing inspections all day long [8]. An inaccurate inspection can bring consequences in the industry such as delays, rework, and waste of time, money, and resources. ...
Article
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Companies have developed various systems to improve their processes. These processes’ focus has been to produce more quantity in less time. To accomplish this task, it is important to also consider defects. Defective products can cause delays in the production line, rework, and the loss of money, time, and resources. This project focused on developing an integrated inspection system. Previous research has been done regarding types of vision systems, in-line inspections, and feedback data collection. A programmable logic controller (PLC) was used to control when the conveyor belt starts and stops. When the object has reached a certain position, the camera detects if the object passed or failed the process. If the object fails, the robot will pick up the bottle and take it out of the line. Human-machine interface (HMI) was also integrated, which shows how many bottles have passed and failed with a light that will indicate if a certain object has passed or failed. Feedback from the inspection process can help solve potential issues from different machines and processes. The testbed was designed, integrated, and tested in the paper to perform a feedback analysis for the production line. The setup consisted of MicroLogix PLC, Fanuc robot LR Mate 200iD and Cognex camera.
... To design a monitoring system for juice extraction that measures the real-time input/output weight and controls the screw speed with wireless storage of data, two main components were employed: a load cell and a programmable logic controller (PLC) [27]. Two beam load cells, each with dimensions of 530 mm × 390 mm (width × length) and a maximum load capacity of 100 kg (SB-100K, A&D KOREA Ltd., Seoul, Republic of Korea) were used to measure the amount of input (raw material) and output (juice). ...
Article
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According to the concept of smart postharvest management, an information and communication technology sensor–based monitoring system is required in the juicing process to reduce losses and improve process efficiency. Such technologies are considered economically burdensome and technically challenging for small-scale enterprises to adopt. From this perspective, this study aimed to develop a smart monitoring system for the juicing processes in small-scale enterprises and to identify the optimal operating conditions based on the monitoring data. The system developed is equipped with two weight sensors attached to the twin-screw juice extractor, allowing for the automatic measurement of the weight of the raw material and the resulting juice product. The measured data are automatically transmitted and stored on a computer. Additionally, the system was designed to remotely control the speeds of the juicing and feeding screws, which are the primary controlling factors of the twin-screw juicer. Juice yield and processing time were optimized using carrots and pears. The optimal juicing and feeding speeds for pear yield were found to be 167.4 rpm and 1557 rpm, respectively; carrots achieved an optimal yield at a juicing speed of 502.2 rpm and feeding speed of 1211 rpm. In contrast, the processing time was minimized at juicing–feeding speeds of 6–6 and 7–5 for pears and carrots, respectively. Consequently, it was challenging to determine the optimal conditions for simultaneously optimizing the yield and processing time. This also suggests that the juicing process is affected by the properties of the fruits and vegetables being processed. By developing a system capable of accumulating the data necessary for the digitization of postharvest management and food processing, this research offers a valuable platform for the smart monitoring and optimization of the juicing process.
... PLCs execute predetermined control logic to process real-time input signals from sensors (temperature, pressure, flow, etc.) and correspondingly control the actions of actuators (pumps, motors, valves, etc.). The complexity of this logic ranges from simple Boolean operations to sophisticated optimization algorithms [7]. ST (Structured Text), as a mainstream PLC programming language, shares syntactic similarities with Pascal and C. It supports advanced programming structures including IF-THEN-ELSE, FOR loops, and can be extended to object-oriented programming paradigms, supporting features like classes and inheritance [62]. ...
Preprint
Programmable Logic Controllers (PLCs) are microcomputers essential for automating factory operations. Structured Text (ST), a high-level language adhering to the IEC 61131-3 standard, is pivotal for PLCs due to its ability to express logic succinctly and to seamlessly integrate with other languages within the same standard. However, vendors develop their own customized versions of ST, and the lack of comprehensive and standardized documentation for the full semantics of ST has contributed to inconsistencies in how the language is implemented. Consequently, the steep learning curve associated with ST, combined with ever-evolving industrial requirements, presents significant challenges for developers. In response to these issues, we present AutoPLC, an LLM-based approach designed to automate the generation of vendor-specific ST code. To facilitate effective code generation, we first built a comprehensive knowledge base, including Rq2ST Case Library (requirements and corresponding implementations) and Instruction libraries. Then we developed a retrieval module to incorporate the domain-specific knowledge by identifying pertinent cases and instructions, guiding the LLM to generate code that meets the requirements. In order to verify and improve the quality of the generated code, we designed an adaptable code checker. If errors are detected, we initiate an iterative self-improvement process to instruct the LLM to revise the generated code. We evaluate AutoPLC's performance against seven state-of-the-art baselines using three benchmarks, one for open-source basic ST and two for commercial Structured Control Language (SCL) from Siemens. The results show that our approach consistently achieves superior performance across all benchmarks. Ablation study emphasizes the significance of our modules. Further manual analysis confirm the practical utility of the ST code generated by AutoPLC.
... Digital logic circuits are also widely used in various electronic devices including programmable logic controllers (PLC). Logic gates, relational circuits, counters and shift registers are also significant components both in the PLC programming environment and digital logic design circuits [6]. From these samples of applications, one can sense the importance of developing a re-configurable plat-form that can be used to develop and test ladder-logic and/or digital logic circuits based applications. ...
Article
Full-text available
A Programmable logic controller (PLC) uses the digital logic circuits and their operating concepts in its hardware structure and its programming instructions and algorithms. Therefore, the deep understanding of these two items is staple for the development of control applications using the PLC. This target is only possible through the practical sensing of the various components or instructions of these two items and their applications. In this work, a user-friendly and re-configurable ladder, digital logic learning and application development design and testing platform has been designed and implemented using a Programmable Logic Controller (PLC), Human Machine Interface panel (HMI), four magnetic contactors, one Single-phase power line controller and one Variable Frequency Drive (VFD) unit. The PLC role is to implement the ladder and digital logic functions. The HMI role is to establish the virtual circuit wiring and also to drive and monitor the developed application in real time mode of application. The magnetic contactors are to play the role of industrial field actuators or to link the developed application control circuit to another field actuator like three phase induction motor. The Single -phase power line controller is to support an application like that of the soft starter. The VFD is to support induction motor driven applications like that of cut-to-length process in which steel coils are uncoiled and passed through cutting blade to be cut into required lengths. The proposed platform has been tested through the development of 14 application examples. The test results proved the validity of the proposed platform.
... Generally, increasing the operating voltage of the logic control unit can indeed provide a wider input signal range, thus enhancing the flexibility and applicability of the system [23]. Moreover, the increased voltage can enhance the driving capability of the unit, allowing it to drive more loads or more complex circuits, enabling the system to achieve more intricate functions or improve its operating speed [24][25][26]. Additionally, the increase in operating voltage can positively impact aspects such as response time, power consumption, and performance in special application scenarios [27][28][29]. ...
Article
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For the past few decades, metal–oxide–semiconductor field-effect transistors (MOSFETs) have been the most important application in IC circuits. In certain circuit applications, the breakdown voltage and specific on-resistance serve as key electrical parameters. This article introduces a readily accessible approach to enhance the source–drain breakdown voltage (BVDS) of MOSFETs based on the Bipolar-CMOS-DMOS (BCD) platform without extra costs. By attentively refining the process steps and intricacies of the doping procedures, the breakdown voltages of NMOS and PMOS experienced increments of 3.4 V and 4.6 V, translating to enhancements of 31.5% and 50.3%. Parallel simulations offer insightful mechanistic explanations through simulation tools, facilitating superior outcomes. This initiative lays significant groundwork for the advancement of a comprehensive BCD process development framework.
... To address shortcomings in PLC (Programmable Logic Controller) programming [1] we propose a novel architecture for a machine controller. A PLC (Programmable Logic Controller) is a specialized form of a microprocessor-based controller that utilizes programmable memory to store instructions and implement functions such as logic, sequencing, time control, counting, and arithmetic to control machines and processes [2]. It operates by cyclically executing three steps: read inputs from sensors, calculate control variables, and write outputs to actuators. ...
Conference Paper
A machine control is essential for every production machine. Traditional machine controllers are housed in a single box with numerous connectors or a bus for attaching sensors and actuators. Programming is carried out using one of the IEC 61131-3 languages (usually adapted by the vendor). Switching to a different vendor becomes difficult. In this paper, we introduce a novel architecture to mitigate complexity and portability issues and address other programming challenges for machine control systems commonly used in mechanical engineering.
... 1) Programmable Logic Interface (PLC): A programmable logic controller (PLC) is a computer used to control machines and processes. They are based on microprocessors and use programmable memory to store instructions and implement userdefined control logic [14]. Unlike general-purpose computers, PLCs are designed to withstand industrial environments. ...
Conference Paper
Industrial control systems (ICS) are essential in industrial applications and critical infrastructure. These systems can be composed of various components involving different communication methods. Conducting tests in an ICS can be dangerous and costly. Therefore, having simulation tools is of high value for research and development teams. This work aims to develop an open-source industrial control systems simulator capable of simulating arbitrary process behavior and capturing communication traffic. The NS-3 network simulator was used to simulate communication between the industrial components, and Modbus was developed as the application-level industrial protocol. Abstractions were developed for commonly used industrial devices, as well as the controlled physical process, where end users can define the behavior of these components. Python bindings were developed for the simulator to reduce the learning curve and target system experts. Finally, the proposed simulator is used to model and evaluate an industrial application scenario.
... A PLC is a specialized digital computer designed to control industrial processes by monitoring inputs and executing programmed logic to control outputs, thereby automating machinery and processes [2]. The reliability and efficiency of PLC systems directly influence the productivity and safety of industrial operations. ...
Article
Full-text available
The integration of Deep Learning (DL), MATLAB, and Advanced Computer-Aided Design (CAD) in the root cause analysis of prognostic errors in Programmable Logic Controller (PLC) systems represents a significant advancement in industrial automation and reliability. This research explores the synergistic application of these technologies to diagnose, predict, and mitigate failures in PLC systems, which are critical for controlling automated processes in various industries. By employing DL algorithms, the study enhances predictive maintenance capabilities, allowing for early detection of anomalies and reducing downtime. MATLAB is utilized as the central platform for data processing, algorithm development, and simulation, providing a versatile environment for integrating DL models with real-time data from PLCs. Advanced CAD tools are employed to model and visualize the physical systems controlled by the PLCs, offering a comprehensive view that bridges the gap between digital analysis and physical implementation. The research methodology includes data collection from PLC systems, DL model training and validation, MATLAB-based simulations, and CAD modelling. The findings demonstrate improved accuracy in identifying the root causes of PLC prognostic errors, leading to more efficient maintenance strategies and enhanced system reliability. This paper concludes that the integration of DL, MATLAB, and CAD provides a powerful approach for advancing predictive maintenance in industrial settings, ultimately contributing to greater operational efficiency and cost savings.
... The advent of numerical control (NC) in the mid-20th century laid the foundation for more advanced automation systems [2]. The evolution continued with the integration of electronics and computer systems, leading to innovations such as programmable logic controllers (PLCs), supervisory control and data acquisition (SCADA) systems, and distributed control systems (DCS) [3]. ...
Article
Full-text available
Given the changing landscape of industrial operations, automation technologies help enhance productivity, achieve better operational efficiency and minimize downtime. This Article looks into the importance of standard automation systems like Programmable Logic Controllers (PLC), Supervisory Control and Data Acquisition (SCADA), Human Machine Interface, Batch control system and Distributed Control System in today industrial control projects. These systems are analysed in regards to their architecture, capabilities and relative contribution towards resilience with the operational interruption. Downtime, whether planned or unplanned, can have significant financial and operational impacts on industries, leading to production delays, decreased output, and increased costs. The article addresses how integrating automation technologies provides robust solutions for downtime mitigation, including predictive maintenance, real-time monitoring, and fault tolerance. Through detailed analysis and case studies, the article highlights real-world applications where companies have leveraged these systems to achieve greater reliability, optimize processes, and reduce downtime-related losses. Additionally, the article discusses best practices for implementing automation systems, challenges in system integration, and future trends such as the impact of artificial intelligence, machine learning, and IoT in further enhancing automation and predictive capabilities. The findings present valuable insights for engineers, decision-makers, and organizations striving to improve their automation strategies, achieve operational excellence, and realize long-term cost savings. By employing these advanced control systems, industries can better navigate challenges, increase productivity, and ensure a resilient and future-proof manufacturing environment.
... A PLC is a specialized digital computer designed to control industrial processes by monitoring inputs and executing programmed logic to control outputs, thereby automating machinery and processes [2]. The reliability and efficiency of PLC systems directly influence the productivity and safety of industrial operations. ...
Article
Full-text available
The integration of Deep Learning (DL), MATLAB, and Advanced Computer-Aided Design (CAD) in the root cause analysis of prognostic errors in Programmable Logic Controller (PLC) systems represents a significant advancement in industrial automation and reliability. This research explores the synergistic application of these technologies to diagnose, predict, and mitigate failures in PLC systems, which are critical for controlling automated processes in various industries. By employing DL algorithms, the study enhances predictive maintenance capabilities, allowing for early detection of anomalies and reducing downtime. MATLAB is utilized as the central platform for data processing, algorithm development, and simulation, providing a versatile environment for integrating DL models with real-time data from PLCs. Advanced CAD tools are employed to model and visualize the physical systems controlled by the PLCs, offering a comprehensive view that bridges the gap between digital analysis and physical implementation. The research methodology includes data collection from PLC systems, DL model training and validation, MATLAB-based simulations, and CAD modelling. The findings demonstrate improved accuracy in identifying the root causes of PLC prognostic errors, leading to more efficient maintenance strategies and enhanced system reliability. This paper concludes that the integration of DL, MATLAB, and CAD provides a powerful approach for advancing predictive maintenance in industrial settings, ultimately contributing to greater operational efficiency and cost savings.
... We consider implementations that are reactive: these are programs that alternate between reading an input valuation and writing an output valuation. This setting is interesting for modeling synchronous systems, e.g., controllers for manufacturing systems [Bol15]. The considered requirements are given as automata recognizing sequences of valuations of input and output variables. ...
Preprint
We consider the automatic online synthesis of black-box test cases from functional requirements specified as automata for reactive implementations. The goal of the tester is to reach some given state, so as to satisfy a coverage criterion, while monitoring the violation of the requirements. We develop an approach based on Monte Carlo Tree Search, which is a classical technique in reinforcement learning for efficiently selecting promising inputs. Seeing the automata requirements as a game between the implementation and the tester, we develop a heuristic by biasing the search towards inputs that are promising in this game. We experimentally show that our heuristic accelerates the convergence of the Monte Carlo Tree Search algorithm, thus improving the performance of testing.
... The PLC contains many relays, counters, timers, registers (memory) and function blocks, all virtualized on the CPU. Some manufacturers already provide artificial intelligence (AI) in their CPUs, separate data storage units, and internet connection [13]. (Figures 8a and 8b). ...
Article
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This work was developed with the aim of improving the current sample exchange system of the BH-3 irradiation channel of the IEA-R1 reactor at IPEN. The instrument's operating concept will provide a better use of the irradiation space as well as greater safety and confidence to the operator. The development of the system involved 3D modeling, sizing, construction and non-destructive testing of the various parts, and analysis of neutron-induced activation of the materials most exposed to the beam. A programmable logic controller (PLC) was implemented for the system’s control inside a dedicated electrical panel that was built with materials compatible with the location. The system was designed to support samples weighing up to 15 kg. Bench tests were carried out and showed that the system performs the necessary functions to accurately position samples in three locations: outside the biological shield, at the irradiation channel and at the decay waiting station. The implementation of this instrument will contribute to the application of the ALARA principle in the operator activities at the BH-3 irradiation channel.
... (S Vandana et al., 2021) (Khaing et al., 2018) (Fathahillah, 2020) There are many advantages by implementing PLC in the industries such as remote monitoring, reducing human error, faster operation, reprogrammable, need less maintenance, financing and its flexibility compared to the hardwired control. (Bolton, 2015) (Eriyadi et al., 2020) Most of PLC come with the software to design a desired control system. There are two types PLC such as compact and modular. ...
Article
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The sorting system is usually used as a load handling system in the industrial applications in order to increase the production rate, reduce human error, and increase the efficiency. There are two types of sorting system applied in the industrial applications such as manual sorting system and automatic sorting system. This project presents the design and implementation of PLC based automatic sorting system in mini scale size. The system consists of a conveyor, limit switch, double acting cylinder, and Programmable Logic Controller. Omron PLC CPM2A was used to control the system based on the height of the box. The resulting box sorting system was capable to separate the height of 4 cm block and the height of 1 cm block into their respective location.
... The proposed coconut harvesting robot prototype will utilize the use of a Programmable Logic Controller (PLC) as the main control unit since compared to other microprocessors and computers, a PLC is designed to withstand environment conditions that can withstand vibrations/shocks, temperature, humidity, and noise [14]. This kind of control unit will be suitable in a coconut harvesting robot considering the environment the robot will be used. ...
Conference Paper
Coconut farming plays a big role in the Philippines’ economy yet has faced persistent challenges due to the dangers of the manual harvesting process. This study presents the initial development of a Coconut Harvesting Robot Prototype, seeking to improve the country’s coconut industry. The prototype comprises a climbing module, main body frame, and harvesting module, all designed to improve efficiency, safety, and address labor shortages. Through material selection, fabrication, and innovative control strategies, the robot offers a viable alternative to human tree climbing. A Programmable Logic Controller (PLC) serves as the central processing unit, enabling precise motor control and safety mechanisms. The evaluation phase involved assessing the robot’s ascending and descending capabilities on a real coconut tree. The average climbing rate of 27.5 seconds and descending rate of 17.67 seconds demonstrate the robot’s potential to enhance productivity. While this research is still in its initial stages, it lays the foundation for further development. Recommendations include refining attachment mechanisms, enhancing the robot’s durability, and conducting comprehensive field trials. Although challenges persist, the potential this technology holds the promise of a safer and more efficient coconut harvesting, which is vital to the county’s agricultural sector.
... The insights generated shall be applied in subsequent commercial projects and as part of the mechanical engineering curriculum at the ZHAW. The universal approach, meaning vendor-neutral or readily adaptable to other vendors, and real-time communication are the two outstanding requirements for communication with standard industrial PLC systems [5], [6], such as Siemens, Rockwell Automation, and B&R [7]. ...
Conference Paper
The paper presents a solution for establishing a universal, bi-directional real-time communication between the Digital and Real Twins in mechanical engineering. The exemplary set-up consists of a three-axis XYZ cross table, which was developed together with the Digital Twin Framework in a Model-Based Systems Engineering (MBSE) environment, applying the RFLP V-model method and using Dassault Systèmes’ 3DExperience platform. The Real Twin is controlled by a standard industrial programmable logic controller (PLC). The communication is implemented using Modelica, Named Pipes, and the OPC UA protocol. The paper describes the design and implementation of the communication interface, the connections, and the communication modes. It also describes the performance, precisely the expected turnaround time (expectation value) for one axis value, which is 10 ms for the chosen reference communication loop. Furthermore, the paper describes the potential applications of the solution in industry and education and discusses future challenges and opportunities. The scientific project constitutes the evidence that it is feasible to establish a complete Digital Twin Framework in a complex MBSE environment and yet achieve high performance. It bridges the gap between the Real and Digital Twin in mechanical engineering.
... Komunikasi serial adalah komunikasi di mana data dikirimkan bit per bit (satu persatu) secara berturut-turut melalui sebuah kabel dan akan disusun kembali menjadi data yang sama pada saat diterima [8]. Terdapat dua mode komunikasi serial yaitu mode sinkron dan asinkron. ...
Article
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Proses pemungutan suara saat ini masih dilakukan secara manual yang dalam pelaksanaannya masih terdapat beberapa kekurangan sepertisistem pendukung yang tidak berjalan dengan baik dan kesalahan yang disebabkan oleh manusia. Penerapan e-KTP sebagai tanda keanggotaan yang digunakan untukmemverifikasi data pemilih merupakanhal yang penting dalam pemungutan suara. Oleh karena itu, penelitian ini ditujukan untuk membangun sebuah prototype sistem real time pemungutan suara dengan menggunakan e-KTP. Sistem dibuat dengan menggabungkan antara perangkat keras yang digunakan sebagai perangkat identifikasi RFID dalam membaca kode unik di e-KTP dan perangkat lunak yang digunakan untuk membuat aplikasi antarmuka pemungutan suara yang berjalan secara real time pada saat verifikasi dan validasi data pemilih sebelum pemilihan. Perangkat identifikasi RFID dibangun menggunakan Raspberry Pi model B dan modul RFID RC522, sedangkan aplikasi antarmuka dibangun dengan bahasa pemrograman berbasis web. Hasil dari penelitian adalah sebuah sistem yang dapat digunakan untuk mengolah dan mengelola data dari pemungutan suara, dimulai dari tahap pendaftaran peserta, tahap pemilihan, dan tahap menampilkan hasil pemilihan. Kata kunci: Pemungutan Suara, E-KTP, RFID, Aplikasi Real Time
... Seiring dengan berkembangnya teknologi, banyak industri yang menuntut sistem pengoperasian motor yang murah dan mudah, khususnya untuk motor induksi tiga fasa. Pengoperasian yang mudah dan murah yaitu menggunakan metode control seperti PLC (Programmable Logic Control) dan HMI (Human Machine Interface) [5] [6]. Juga, sistem pengawatan pada metode pengasutan motor induksi lebih sedikit dan kalau ada kesalahan fungsi dapat diketahui secara cepat serta dapat dipantau fungsi kerja masing-masing peralatan. ...
Article
Motor induksi merupakan jenis motor yang paling banyak digunakan secara luas baik dalam industri besar maupun kecil dibandingkan motor jenis lain.Namun dalam kenyataannya, motor induksi paling banyak menimbulkan arus awal (starting) yang besar yaitu (5–7 kali dari arus nominal). Salah satu alternatif untuk mengatasi hal tersebut adalah dengan menggunakan metode pengasutan bintang (Y)-segitiga (Δ). Penelitian ini, dibuat suatu sistem pengoprasian pengasutan motor induksi tiga fasa dengan menggunakan metode pegasutan bintang (Y)-segitiga (∆) yang dikontrol dengan Programmable Logic Control (PLC) dan Human Machine Interface (HMI) sebagai pengontrol motornya. Dari penelitian ini bahwa telah berhasil dibuat rangkaian untuk pengasutan motor induksi tiga fasa dengan metode bintang (Y) segitiga (D) yang berbasis kontrol PLC-HMI dan arduino uno dengan pembacaan secara real time tegangan, arus dan kecepatan motor, diperoleh hasil pengukuran semua sensor memiliki kesalahan pengukuran yang relatif kecil, yaitu untuk pengukuran sensor tegangan memiliki error sebesar 0.86%, untuk sensor arus sebesar 2.697%, dan sensor kecepatan memiliki rata-rata error sebesar 0.27%. dan saat pengujian dilakukan pada motor tanpa beban dan berbeban didapatkan saat kondisi terhubung bintang (Y) tegangan mencapai 220 volt, dan saat perpindahan kehubung segitiga (D) teganganya turun menjadi 216 volt, untuk nilai arus pada hubung(Y) dan hubung (D) cukup kecil dari arus nominal motor yaitu sebesar 4,2 ampere, dan kecepatan motor pada saat berbeban dan tanpa beban saat distart sampai dengan distop relatif sama dengan kecepatan nominal motor yang terdapat pada nameplate yaitu 1400 rpm.
... Figure 1 System in PLC Usually, a PLC system has basic functional components, namely a CPU (processor unit), memory, power supply unit, input/output interface, communication interface, and programming devices. Figure 1 shows the basic arrangement (Bolton, 2015) and (Setiawan, 2006). CP1E N30DTD is a compact type PLC made by OMRON which is designed for easy application. ...
Article
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Proper control design will reduce energy losses and production costs for the industry. Control system design also reduces the role of humans in production. An automatic cable-cutting control system can reduce cable manufacturing time so that a company's human resources do not need to carry out the cable-cutting process manually. This cable cutter uses a PLC for its central control, which will convert the length value into the number of pulses and calculate the number of cables to be cut. The HMI inputs the length of the cable to be cut and the number of cables to be missed. The stepper motor is used to run the cable-pulling mechanic, which will pull according to the size stated on the HMI. This system can cut AWG20 and AWG16 cables in various lengths from 50 mm to 3000 mm with the number or number of wires that can be set from 1 cut to 10 cuts for each size.
... 4. Programación del PLC Para desarrollar la lógica de programación, en primera instancia se realizó un diagrama de flujo en donde de forma lógica se analiza el funcionamiento que se desea tener para la planta piloto. En el cual se describe paso a paso el proceso a ejecutar por el autómata, (Bolton, 1996). ...
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Este trabajo se enfoca en el diseño de un sistema de control y monitoreo para una planta de tratamiento de aguas residuales a nivel piloto. Se desarrolló la programación en lenguaje escalera, y se utilizó el PLC S7-200 Siemens. El diseño de las interfaces gráficas de usuario (Graphical User Interface, GUI), se llevaron a cabo con el software de Siemens WinCC Flexible 2008, las cuales permitirán la interacción con el usuario. El HMI utilizado es un Panel MP277 Siemens, el cual se interconecta con el PLC permitiendo el monitoreo en tiempo real de las etapas de control. Se implementaron las reglas básicas de control para asegurar la protección del proceso. Se comprobó el funcionamiento del sistema de control y monitoreo mediante simulación, posteriormente se realizaron pruebas físicamente para observar el comportamiento del controlador al realizar un ciclo de trabajo empleando un agua sintética.
... Changing the control logic of a certain process was a difficult task to achieve, as it required extensive reconfiguration of electrical schemes and automation panels structures [1]. On the other hand, the tens or hundreds of coils in relays, contactors or actuators get warm during operation and, being in a relatively small space, raised serious problems regarding ventilation in order to ensure operating temperatures within permissible limits. ...
... Kelebihan sistem yang menggunakan Pneumatik adalah pekerjaan dapat lebih bersih dan efisien dikarenakan pada pneumatik memiliki sumber yang tidak terbatas, mudah tersalurkan, fleksibilitas, dapat disimpan dan mudah dimanfaatkan [2]. Sedangkan sistem PLC memiliki keuntungan dikarenakan PLC memiliki sistem yang kuat dan compact, sistem operasi yang handal, waktu eksekusi prosesor yang cepat, mudah dikembangkan sistemnya, konsumsi daya yang rendah, dapat menangani sejumlah input dan output digital [3]. Festo Fluidsim 3.6 adalah perangkat lunak yang dapat mensimulasikan PLC dan Pneumatik dengan menggunakan symbol yang telah mengikuti standar internasional [4]. ...
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This study aims to carry out pneumatic trainer motion simulations using Festo Fluidsim 3.6 software programming simulation. The trainer design has three main parts, namely a frame made of iron, a programmable automatic control device in the form of a PLC, and the third is a mechanical movement device in the form of a pneumatic circuit. This tool will be integrated into a circuit system, which is then tested with three experiments based on circuit simulations made in the Festo Fluidsim 3.6 software. The test results from 3 simulation experiments show that the PLC control system can send signals to the mechanical motion of a single-acting cylinder. The PLC control system can also send signals to the mechanical motion of a double-acting cylinder with non-simultaneous motion. Other than that, the PLC control system can send signals on the mechanical motion of a double-acting cylinder with simultaneous motion. The three experimental tests found that the number of strokes for a single-acting cylinder was more than that for a double-acting cylinder. The three tests showed that they could move the cylinder well with variations in flow control, namely the flow control openings of 25, 50, 75 and 100%.
... 7. It will also permit production data to be acquired in real time, which is necessary for production improvement A production system that is automated with PLC-IoT is capable of improved production because the production data is stored on a computer and other devices, and can be retrieved when it is needed. The IoT can also be used to monitor the environmental conditions in a production area; through IoT, the different variables that are happening in the organisation can be monitored [13]. ...
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The problem that necessitated this study was that some furnaces that were responsible for the further processing of steel pipes at Company X were not connected to a programmable logic control (PLC)–Internet of Things (IoT) system. This slowed down the product flow. To address this problem, PLC-IoT systems were integrated so that the production system could be more effective. This study therefore models and simulates the integrated PLC-IoT control system, using the system dynamics modelling approach to investigate the performance of the automated gas furnaces. The PLC-IoT consists of an internal module that is used to process the data stream. After the implementation of the proposed control system, primary data was acquired by continuously evaluating the performance of the system. The research methodology used involved quantitative analysis and a simulation model using the Anylogic software. The result of the delivery and inventory of ingots from an automated system showed an upward trend with delivery and an inventory of an ingot at about 90 minutes; while a system that was not automated with PLC-IoT showed a downward trend of ingots. This shows that the introduction of the PLC-IoT for control makes the system more effective. The findings of this work could assist the manufacturers in achieving manufacturing or production efficiency, significant time savings, and better monitoring of the manufacturing process. Keywords: Automation, Control system, Gas furnace, PLC-IoT, Simulation
... One is fastened to a support, and the other is circle-cut and fastened to a handcrafted wooden pulley. A drive belt mechanically connects the pulley to a potentiometer with many turns (a rubber band) [24]. A potentiometer may be calibrated to measure the polarizer angle. ...
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Malus' law asserts that the square of the cosine of the angle formed between two polarizers is directly proportional to the light intensity after passing through them. In this study, we demonstrate this law using a straightforward configuration. Our method of measuring the polarizer's rotational angle while keeping the other polarizer stationary is innovative. It involves manually attaching a multi-turn potentiometer to one of the polarizers. The Arduino board is connected to the potentiometer and light sensor used to detect the intensity of transmitted light, allowing for the measurement of light intensity as a function of rotational angle. Additionally, we think that the configuration as it is now can be helpful in physics laboratory classes. It can also be demonstrated by using it during lectures.
... The present paper addresses the problem of execution times in microprocessors for PLCs (Programmable Logic Controllers), which have resulted in a revolution of control engineering, being used for a range of automation tasks [1][2][3] in areas such as industrial processes in manufacturing [4]. Thus, there are some innovations and improvements in microprocessor technology and software programming techniques that have added more features and capabilities to the PLC, enabling it to perform more complex control applications with greater speed [5]. ...
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This work presents the design of a microprocessor synthesized in FPGA based on the IEC 61131-3 standard. We report the architecture, and the operation of the internal hardware which allows the execution of Instruction List (IL). One of the most important components is the operands_selector block which allows memory elements, inputs, or outputs of the microprocessor to be treated as operands. Two ALUs are available to perform a bit, integer, and floating-point operations. The implementation of this microprocessor allows concluding that our designed microprocessor implemented in xc7a100tcsg324 (Xilinx) or EP4CE10E22C8 (Intel) FPGAs is superior in their execution times compared to the microprocessor evaluated in early studies and to one of the S7-1500 family processor.
... Technology based on fog computing demands storing and managing large and complex data structures, while Programmable Logic Controllers, known as PLCs [13], or micro-controllers are not powerful enough to meet such requirements. The latter also offers limited user interface capabilities. ...
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Biogas and hydrogen (H2) are breaking through as alternative energy sources in road transport, specifically for heavy-duty vehicles. Until a public network of service stations is deployed for such vehicles, the owners of large fleets will need to build and manage their own refueling facilities. Fleet refueling management and remote monitoring at these sites will become key business needs. This article describes the construction of a prototype system capable of solving those needs. During the design and development process of the prototype, the standard industry protocols involved in these installations have been considered, and the latest expertise in information technology systems has been applied. This prototype has been essential to determine the Strengths, Challenges, Opportunities and Risks (SCOR) of such a system, which is the first step of a more ambitious project. A second stage will involve setting up a pilot study and developing a commercial system that can be widely installed to provide a real solution for the industry.
... These advancements, in combination with industry demands, have created a need for more powerful instructions that facilitate more compact, function-oriented PLC programs. [2] In the following, five different programming languages specific to PLCs are mentioned, all aimed at achieving the result of the process with the lowest cost, safely and quickly. ...
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This thesis focuses on the development and optimization of hybrid power systems that incorporate renewable energy sources, efficient control and monitoring systems, and advanced automation technologies. The research explores various aspects of these systems, including hydrogen production, photovoltaic (PV) panels, programmable logic controllers (PLCs), and supervision platforms. In the PV-based electrolysis system for hydrogen production, spongy nickel is utilized as an electrode material to enhance the efficiency and sustainability of the electrolysis process. PV panels convert sunlight into electricity, reducing reliance on conventional energy sources. PLCs play a crucial role in controlling and monitoring the hybrid power system, optimizing energy usage and improving overall performance. Supervision platforms like WinCC Flexible software enable real-time monitoring and management of system components. The findings of this research contribute to the global shift towards sustainable energy sources and address the importance of clean energy, efficient control systems, and environmental preservation. By implementing these technologies and optimizing hybrid power systems, we can achieve a greener and more sustainable energy future. Keywords: hybrid power systems, renewable energy, hydrogen production, photovoltaic panels, spongy nickel, programmable logic controllers, WinCC Flexible.
... Berbagai upaya dapat dilakukan untuk keberadaan suatu sistem tertanam (embedded system) [1] berdasarkan kepada sejumlah gagasan melalui pabrikasi rangkaian elektronika dan perakitan berbagai komponen untuk keterbentukan sistem minimum (minimum system) berbasis chip atau Integrated Circuit (IC) mikrokontroler [2-3] dan dilakukan pabrikasi dalam bentuk modul perangkat elektronika [4][5][6][7][8][9][10][11][12][13][14][15][16][17][18][19][20], atau pemanfaatan secara langsung Arduino board [21][22][23][24][25][26][27][28][29][30][31][32][33][34][35][36][37][38][39], atau penggunaan komputer personal (personal computer, PC) [40], maupun pemakaian pengontrol logika terprogram (programmable logic controller, PLC) [41][42][43][44][45] telah menjadi suatu keniscayaan. Salah satu implementasi dari keberadaan sistem minimum berbasis mikrokontroler dapat digunakan untuk sistem penguncian yang bersifat bertingkat (redundancy) yang ditempatkan pada setiap tahapan sebuah tempat penyimpanan barangbarang berharga [46]. ...
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Keberadaan sistem minimum berbasis mikrokontroler dapat digunakan untuk sistem penguncian bertingkat melalui pabrikasi dan perakitan untuk keterwujudan sebuah purwarupa perangkat tertanam berbasis chip mikrokontroler AVR ATmega2560 dan modul Radio Frequency Identification (RFID). Penetapan sasaran penelitian dilakukan setelah tahapan perancangan dan pembuatan perangkat tertanam, yaitu membuat motherboard mini dan mengintegrasikan sejumlah perangkat elektronika dan memrogram sistem mikrokontroler. Sasaran penelitian, yaitu melaksanakan uji verifikasi berupa simulasi dan melakukan uji validasi berupa pengukuran kinerja terhadap purwarupa perangkat tertanam. Metode penelitian dilaksanakan dengan pentahapan, yaitu simulasi dilaksanakan dengan bantuan aplikasi Proteus dan pengukuran kinerja dilaksanakan dengan tahapan sesuai urutan pada simulasi. Hasil penelitian berupa simulasi dalam bentuk pemberian 4 (empat) kondisi buatan dan pengukuran kinerja dilakukan juga dalam bentuk pemberian 4 (empat), tetapi dengan kondisi sesungguhnya. Kesimpulan utama penelitian ini berkaitan dengan saat uji verifikasi dan validasi. Pemaksimalan terhadap uji verifikasi wajib ditindaklanjuti dengan uji validasi. Pertama, ketika kartu tidak terdeteksi modul RFID, ketika kartu terdeteksi modul RFID, ketika sistem penguncian dibuka secara paksa dan buzzer “ON”. Kedua, ketika kartu tidak terdeteksi saat di tag pada antena dan ketika sistem penguncian dibuka secara paksa dan buzzer “ON”, dan kartu terdeteksi saat di tag pada antena.
... This research is motivated by a special reference to previous studies related to simulators for the analogy of regulating highway traffic at ship lane crossings [1]. The essence of this research relates to the redesign for the acquisition of a simulator based on an embedded system [2][3][4][5] in general and specifically to the utilization of a set of programmable logic controllers (PLCs) [6][7][8][9]. The PLC system still functions as the center of control for a simulator, while the sensor-transducer and actuator systems are changed, because the analogy of the bridge body has also changed, from one become two. ...
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The essence of this research relates to the redesign for the acquisition of a simulator based on an embedded system in general and specifically to the utilization of a set of programmable logic controllers (PLCs). The research was chosen on the use of instrumentation systems and controlled automation mechanisms by a PLC which functioned as a simulator to operate the double bridge bodies analogy for road traffic lanes, i.e., highways on crossings with dual water canals as the ship-path system or ship crossings. Some results are (i) the operating principle of the simulator, it is observed for the sensors installed on the simulator, whether they are functioning as programmed into the PLC; (ii) when the auto mode of lifting the bridge body, both on bridge bodies #1 and #2, is longer than the process of lowering the bridge bodies, it is more emphasized on the existence of a gravitational force; and (iii) there is no significant time difference compared between the auto and manual mode selection. Concluding based on the four main research objectives and topics carried out that the stages for performing the simulator assisted by PLC and driven by GX Work of Mitsubishi can be realized according to the initials of idea and design for selecting and determining the hardware and software.
... CPU sebagai pusat kontrol akan mengeksekusi (scan) program yang telah dimasukkan ke dalam CPU melalui piranti pemrograman. Proses scan dilakukan dengan membaca input, kemudian memecahkan logika pemrograman, dan memperbaharui output (Bolton, 2009). ...
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This study aims to develop learning media Virtual Distributing Station for PLC programming. The development model adopts the water-fall procedure from Presman. The waterfall procedure includes 1) communication, 2) planning, 3) modeling, 4) construction, and 5) system delivery. Product validation is carried out by material experts, media experts, and early adopters. The research instrument used a questionnaire with a 4-point Likert scale. The results showed that the performance of the virtual distributing station was included in the Very Eligible category, the feasibility of the virtual distributing station was included in the Very Appropriate category according to material experts, media experts, and early user responses. Thus, the virtual distributing station is very feasible to be used as a PLC programming medium because (1) it has met the eligibility test criteria, (2) it is flexible, it can be installed on a large number of computers, (3) it can be operated based on PLC programming, (4) more economical, limited to PLC programming to operate distributing station.ABSTRAKPenelitian ini bertujuan untuk mengembangkan media pembelajaran Virtual Distributing Station untuk pemrograman PLC. Model pengembangan mengadopsi dari prosedur water-fall dari Presman. Prosedur water-fall meliputi 1) komunikasi, 2) perencanaan, 3) pemodelan, 4) konstruksi, dan 5) penyerahan sistem. Validasi produk dilakukan oleh ahli materi, ahli media, dan pengguna awal. Instrumen penelitian menggunakan angket dengan skala likert 4 poin. Hasil penelitian diketahui bahwa unjuk kerja virtual distributing station termasuk dalam kategori Sangat Layak, kelayakan virtual distributing station termasuk dalam kategori Sangat Layak menurut ahli materi, ahli media, dan respon pengguna awal. Dengan demikian virtual distributing station Sangat Layak untuk digunakan sebagai sarana media pemrograman PLC karena (1) telah memenuhi kriteria uji kelayakan, (2) fleksibel, bisa dipasang pada komputer dalam jumlah banyak, (3) dapat dioperasikan berbasis pemrograman PLC, (4) lebih ekonomis, sebatas pada pemrograman PLC untuk mengoperasikan distributing station.
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Area terbatas di lingkungan Istana Kepresidenan Republik Indonesia di Kota Bogor, masih berupa penghalang (barrier) yang dioperasikan secara manual melalui pengaktifan kontaktor magnetik sebagai pengendali sistem hidrolik silinder untuk penggerakan penghalang. Upgrading terhadap sistem tersebut menjadi suatu keniscayaan sehingga perlu keberadaan sistem berbasis programmable logic controller (PLC) dengan kemampuan operasi secara cepat dan akurat agar diperoleh peningkatan hasil secara kuantitas maupun kualitas. Pembuatan sistem berbasis PLC yang diintegrasikan ke sistem sensor-transduser dan sistem penggerak aktuator difungsikan sebagai penggerak miniatur road blocker secara otomatis pada keamanan area terbatas. Data diperoleh dari setiap tahapan, yaitu (i) pembuatan struktur miniatur road blocker, penempatan sensor-transduser, pemasangan motor dc untuk sistem hidrolik, (ii) pembuatan papan operasi, pengawatan, dan pemasangan sistem PLC, (ii) pemrograman sistem PLC berbasis pada ladder diagram, dan (iii) pengukuran kinerja sistem kendali. Hasil diperoleh berupa purwarupa sistem, struktur program, dan kinerja sistem. Berdasarkan hasil penelitian dapat disimpulkan bahwa perolehan bentuk fisis sistem elektronis berbasis PLC telah terintegrasi secara perangkat keras (hardware) dan perangkat lunak (software), sehingga dapat digunakan sebagai model sistem keamanan untuk area terbatas melalui pengoperasian secara otomatis miniatur road blocker.
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This research was done to meet the needs of the Laboratory of PLC in Politeknik Kampar will be a creative learning media and innovative. With a learning media in the form of a robot arm, the students are expected to be easier to understand and apply a control system using a Programmable Logic Controller (PLC). The research begins by making the design of the robot arm and then assembled into a coherent whole by adding stepper motors on each of the degrees of freedom. Once the tool is assembled, then testing by using PLC. Tests such as the degree rotation (DOF) of each of the robot arm to grab an object. The end result of this research is a tool in the form of a robotic arm that is ready for learning PLC in Politeknik Kampar.
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The present dissertation contributes to facilitating the transformation of industrial composting plants towards standards of Industry 4.0. Optimization potentials are analyzed, and systematic-methodical approaches to solutions are developed. The focus is on the investigation within a technical-logistic context. Thus, the dissertation addresses two key research objectives: the development of an autonomous, intelligent compost turner, and a comprehensive hyperconnected platform for heavy-duty machinery sharing.
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The current study investigates speed control of a single-phase induction motor using the P.L.C (Programmable Logic Controller). There are several methods to control the speed of a single-phase induction motor. However, this method is one of the most recent methods with its rapid response control, flexibility, adjustment making, etc. Most engines in modern industrial facilities and laboratories are equipped with this technology. Here we have designed an electrical circuit that controls the voltage supplied to the motor and is controlled by a PLC unit to control the motor speed and thus we will benefit from all the possibilities, privileges and special benefits provided by the PLC unit to control the motor speed.
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