Design and Implementation of Advanced Controller for Flow ......ow loop process is connected to the...
Transcript of Design and Implementation of Advanced Controller for Flow ......ow loop process is connected to the...
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About PlantCommunication
OPCSimulink Models and ResultsRole of MATLAB/Simulink
Design and Implementation of Advanced Controller forFlow Loop Control using OPC
Pritesh ShahProf Sudhir Agashe
Department of Instrumentation & Control Engineering,College of Engineering, Pune
Department of Electronics and Telecommunication,Symbiosis Institute of Technology, Pune
Pritesh Shah,Prof Sudhir Agashe
![Page 2: Design and Implementation of Advanced Controller for Flow ......ow loop process is connected to the PLC and PLC has a Modbus Ethernet port. I A Modbus TCP/IP protocol is con gured](https://reader034.fdocuments.in/reader034/viewer/2022042017/5e755a2492b7c2152427f38a/html5/thumbnails/2.jpg)
About PlantCommunication
OPCSimulink Models and ResultsRole of MATLAB/Simulink
Outline
About Plant
Communication
OPC
Simulink Models and Results
Role of MATLAB/Simulink
Pritesh Shah,Prof Sudhir Agashe
![Page 3: Design and Implementation of Advanced Controller for Flow ......ow loop process is connected to the PLC and PLC has a Modbus Ethernet port. I A Modbus TCP/IP protocol is con gured](https://reader034.fdocuments.in/reader034/viewer/2022042017/5e755a2492b7c2152427f38a/html5/thumbnails/3.jpg)
About PlantCommunication
OPCSimulink Models and ResultsRole of MATLAB/Simulink
Abstract
Title: Design and Implementation of Advanced Controller for Flow LoopControl using OPC
I A flow loop process is connected to the PLC and PLC has a ModbusEthernet port.
I A Modbus TCP/IP protocol is configured in OPC server.
I After this communication, plant is connected to Simulink using OPCclient.
I The OPC communication is simple and easy for real timecommunication in the automation industry.
Pritesh Shah,Prof Sudhir Agashe
![Page 4: Design and Implementation of Advanced Controller for Flow ......ow loop process is connected to the PLC and PLC has a Modbus Ethernet port. I A Modbus TCP/IP protocol is con gured](https://reader034.fdocuments.in/reader034/viewer/2022042017/5e755a2492b7c2152427f38a/html5/thumbnails/4.jpg)
About PlantCommunication
OPCSimulink Models and ResultsRole of MATLAB/Simulink
Flow Loop Plant Specifications
I Range of flow: 0-4000 LPH
I Sensor mounted in flow loop: Ultrasonic, Turbine, Magnetic flowmeter etc.
I Three phase motor with VFD
I Value: equal percentage globe valve
Pritesh Shah,Prof Sudhir Agashe
![Page 5: Design and Implementation of Advanced Controller for Flow ......ow loop process is connected to the PLC and PLC has a Modbus Ethernet port. I A Modbus TCP/IP protocol is con gured](https://reader034.fdocuments.in/reader034/viewer/2022042017/5e755a2492b7c2152427f38a/html5/thumbnails/5.jpg)
COLLEGE OF ENGINEERING, PUNE
FF
F
WT
Tank 1
Tank 2
Flow Loop P&ID
Orifice MeterVenturi Meter
Pitot Tube
Magnetic Flow Meter Turbine Flow Meter Ultrasonic Flow Meter
VFD
VPLC
I P
VPLC
AFR
Control Valve
Drain
Figure: P & I Diagram of Flow Loop Plant
![Page 6: Design and Implementation of Advanced Controller for Flow ......ow loop process is connected to the PLC and PLC has a Modbus Ethernet port. I A Modbus TCP/IP protocol is con gured](https://reader034.fdocuments.in/reader034/viewer/2022042017/5e755a2492b7c2152427f38a/html5/thumbnails/6.jpg)
About PlantCommunication
OPCSimulink Models and ResultsRole of MATLAB/Simulink
Flow Loop Plant
Figure: Flow Loop Plant
Pritesh Shah,Prof Sudhir Agashe
![Page 7: Design and Implementation of Advanced Controller for Flow ......ow loop process is connected to the PLC and PLC has a Modbus Ethernet port. I A Modbus TCP/IP protocol is con gured](https://reader034.fdocuments.in/reader034/viewer/2022042017/5e755a2492b7c2152427f38a/html5/thumbnails/7.jpg)
About PlantCommunication
OPCSimulink Models and ResultsRole of MATLAB/Simulink
OPC
I Open Platform Communications (OPC) is a series of standardsand specifications for industrial telecommunication.
I OPC specifies the communication of real-time plant data betweencontrol devices from different manufacturers.
I The OPC specifications are based on Microsoft Windows technologyusing the COM/DCOM (Distributed Component Object Model) forthe exchange of data between software components.
Pritesh Shah,Prof Sudhir Agashe
![Page 8: Design and Implementation of Advanced Controller for Flow ......ow loop process is connected to the PLC and PLC has a Modbus Ethernet port. I A Modbus TCP/IP protocol is con gured](https://reader034.fdocuments.in/reader034/viewer/2022042017/5e755a2492b7c2152427f38a/html5/thumbnails/8.jpg)
About PlantCommunication
OPCSimulink Models and ResultsRole of MATLAB/Simulink
OPC Features
I Security: OPC is firewall-friendly while addressing security concernsby providing a suite of controls.
I OPC architecture is extensible.
I The OPC information modeling framework turns data intoinformation.
I Platform independence
Pritesh Shah,Prof Sudhir Agashe
![Page 9: Design and Implementation of Advanced Controller for Flow ......ow loop process is connected to the PLC and PLC has a Modbus Ethernet port. I A Modbus TCP/IP protocol is con gured](https://reader034.fdocuments.in/reader034/viewer/2022042017/5e755a2492b7c2152427f38a/html5/thumbnails/9.jpg)
About PlantCommunication
OPCSimulink Models and ResultsRole of MATLAB/Simulink
OPC Toolbox MATLAB
I OPC Toolbox provides a connection to OPC DA and OPC HDAservers, giving you access to live and historical OPC data directlyfrom MATLAB and Simulink.
I It can read, write, and log OPC data from devices, such as distributedcontrol systems, supervisory control and data acquisition systems, andprogrammable logic controllers.
I It can read and analyze data from any data historian that conforms tothe OPC Foundation Historical Data (HDA) access standard.
I Platform independence
Pritesh Shah,Prof Sudhir Agashe
![Page 10: Design and Implementation of Advanced Controller for Flow ......ow loop process is connected to the PLC and PLC has a Modbus Ethernet port. I A Modbus TCP/IP protocol is con gured](https://reader034.fdocuments.in/reader034/viewer/2022042017/5e755a2492b7c2152427f38a/html5/thumbnails/10.jpg)
About PlantCommunication
OPCSimulink Models and ResultsRole of MATLAB/Simulink
Communication with Plant
I Flow loop plant is connected through PLC to OPC server using TCP/IPprotocol.
I In Simulink, inputs can be configured from OPC server and data canbe readout.
I Similar way, outputs can be written from Simulink to plant.
I So, real plant can be controlled using OPC protocol.
Pritesh Shah,Prof Sudhir Agashe
![Page 11: Design and Implementation of Advanced Controller for Flow ......ow loop process is connected to the PLC and PLC has a Modbus Ethernet port. I A Modbus TCP/IP protocol is con gured](https://reader034.fdocuments.in/reader034/viewer/2022042017/5e755a2492b7c2152427f38a/html5/thumbnails/11.jpg)
About PlantCommunication
OPCSimulink Models and ResultsRole of MATLAB/Simulink
OPC Communication Block Diagram
Figure: OPC Communication Setup
Pritesh Shah,Prof Sudhir Agashe
![Page 12: Design and Implementation of Advanced Controller for Flow ......ow loop process is connected to the PLC and PLC has a Modbus Ethernet port. I A Modbus TCP/IP protocol is con gured](https://reader034.fdocuments.in/reader034/viewer/2022042017/5e755a2492b7c2152427f38a/html5/thumbnails/12.jpg)
About PlantCommunication
OPCSimulink Models and ResultsRole of MATLAB/Simulink
OPC Configuration in SimulinkSteps for configuration of OPC in Simulink
I An OPC Configuration block is used to specify the OPC server to beused in the Simulink model.
Figure: OPC Configuration Block in Simulink
Pritesh Shah,Prof Sudhir Agashe
![Page 13: Design and Implementation of Advanced Controller for Flow ......ow loop process is connected to the PLC and PLC has a Modbus Ethernet port. I A Modbus TCP/IP protocol is con gured](https://reader034.fdocuments.in/reader034/viewer/2022042017/5e755a2492b7c2152427f38a/html5/thumbnails/13.jpg)
About PlantCommunication
OPCSimulink Models and ResultsRole of MATLAB/Simulink
OPC Configuration in SimulinkI Need to configure OPC server (from local or remote server)
Figure: OPC Configuration Block in SimulinkPritesh Shah,Prof Sudhir Agashe
![Page 14: Design and Implementation of Advanced Controller for Flow ......ow loop process is connected to the PLC and PLC has a Modbus Ethernet port. I A Modbus TCP/IP protocol is con gured](https://reader034.fdocuments.in/reader034/viewer/2022042017/5e755a2492b7c2152427f38a/html5/thumbnails/14.jpg)
About PlantCommunication
OPCSimulink Models and ResultsRole of MATLAB/Simulink
OPC Configuration in SimulinkI Configure OPC Read Block: we need to add tags (address) which we
want to read and configured in OPC server.
Figure: OPC Configuration Block in Simulink
Pritesh Shah,Prof Sudhir Agashe
![Page 15: Design and Implementation of Advanced Controller for Flow ......ow loop process is connected to the PLC and PLC has a Modbus Ethernet port. I A Modbus TCP/IP protocol is con gured](https://reader034.fdocuments.in/reader034/viewer/2022042017/5e755a2492b7c2152427f38a/html5/thumbnails/15.jpg)
About PlantCommunication
OPCSimulink Models and ResultsRole of MATLAB/Simulink
OPC Configuration in SimulinkI Configure OPC write Block: we need to add tags (address) which we
want to write and configured in OPC server.I Generally, we run the Simulink model for ∞ time.
Figure: OPC Configuration Block in Simulink
Pritesh Shah,Prof Sudhir Agashe
![Page 16: Design and Implementation of Advanced Controller for Flow ......ow loop process is connected to the PLC and PLC has a Modbus Ethernet port. I A Modbus TCP/IP protocol is con gured](https://reader034.fdocuments.in/reader034/viewer/2022042017/5e755a2492b7c2152427f38a/html5/thumbnails/16.jpg)
About PlantCommunication
OPCSimulink Models and ResultsRole of MATLAB/Simulink
Simulink Model for Fractional PID Controller
Figure: Simulink ModelPritesh Shah,Prof Sudhir Agashe
![Page 17: Design and Implementation of Advanced Controller for Flow ......ow loop process is connected to the PLC and PLC has a Modbus Ethernet port. I A Modbus TCP/IP protocol is con gured](https://reader034.fdocuments.in/reader034/viewer/2022042017/5e755a2492b7c2152427f38a/html5/thumbnails/17.jpg)
About PlantCommunication
OPCSimulink Models and ResultsRole of MATLAB/Simulink
Subsystem for Plant
Figure: Simulink Model
Pritesh Shah,Prof Sudhir Agashe
![Page 18: Design and Implementation of Advanced Controller for Flow ......ow loop process is connected to the PLC and PLC has a Modbus Ethernet port. I A Modbus TCP/IP protocol is con gured](https://reader034.fdocuments.in/reader034/viewer/2022042017/5e755a2492b7c2152427f38a/html5/thumbnails/18.jpg)
About PlantCommunication
OPCSimulink Models and ResultsRole of MATLAB/Simulink
Output of Fractional PID Controller
0 50 100 150 200 250 3000
500
1000
1500
2000
2500
3000
3500
Time(Sec)
Out
put (
LPH
)
Figure: Output Response of Flow LoopPritesh Shah,Prof Sudhir Agashe
![Page 19: Design and Implementation of Advanced Controller for Flow ......ow loop process is connected to the PLC and PLC has a Modbus Ethernet port. I A Modbus TCP/IP protocol is con gured](https://reader034.fdocuments.in/reader034/viewer/2022042017/5e755a2492b7c2152427f38a/html5/thumbnails/19.jpg)
About PlantCommunication
OPCSimulink Models and ResultsRole of MATLAB/Simulink
Simulink Model for Fuzzy Controller
Figure: Simulink Model for Fuzzy Controller
Pritesh Shah,Prof Sudhir Agashe
![Page 20: Design and Implementation of Advanced Controller for Flow ......ow loop process is connected to the PLC and PLC has a Modbus Ethernet port. I A Modbus TCP/IP protocol is con gured](https://reader034.fdocuments.in/reader034/viewer/2022042017/5e755a2492b7c2152427f38a/html5/thumbnails/20.jpg)
About PlantCommunication
OPCSimulink Models and ResultsRole of MATLAB/Simulink
FIS for Fuzzy Controller
Figure: Fuzzy FIS
Pritesh Shah,Prof Sudhir Agashe
![Page 21: Design and Implementation of Advanced Controller for Flow ......ow loop process is connected to the PLC and PLC has a Modbus Ethernet port. I A Modbus TCP/IP protocol is con gured](https://reader034.fdocuments.in/reader034/viewer/2022042017/5e755a2492b7c2152427f38a/html5/thumbnails/21.jpg)
About PlantCommunication
OPCSimulink Models and ResultsRole of MATLAB/Simulink
Output for Fuzzy Controller
0 200 400 600 800 1000 1200 14000
500
1000
1500
2000
2500
3000
3500Closed Loop Response
Flo
w in
LP
H
FigurePritesh Shah,Prof Sudhir Agashe
![Page 22: Design and Implementation of Advanced Controller for Flow ......ow loop process is connected to the PLC and PLC has a Modbus Ethernet port. I A Modbus TCP/IP protocol is con gured](https://reader034.fdocuments.in/reader034/viewer/2022042017/5e755a2492b7c2152427f38a/html5/thumbnails/22.jpg)
About PlantCommunication
OPCSimulink Models and ResultsRole of MATLAB/Simulink
Simulink Model for PID Controller
Figure: Simulink Model for PID Controller
Pritesh Shah,Prof Sudhir Agashe
![Page 23: Design and Implementation of Advanced Controller for Flow ......ow loop process is connected to the PLC and PLC has a Modbus Ethernet port. I A Modbus TCP/IP protocol is con gured](https://reader034.fdocuments.in/reader034/viewer/2022042017/5e755a2492b7c2152427f38a/html5/thumbnails/23.jpg)
About PlantCommunication
OPCSimulink Models and ResultsRole of MATLAB/Simulink
Output for PID Controller
0 500 1000 1500 2000 2500 3000 35000
500
1000
1500
2000
2500
Flo
w in
LP
HClosed Loop Response using PID Controller
FigurePritesh Shah,Prof Sudhir Agashe
![Page 24: Design and Implementation of Advanced Controller for Flow ......ow loop process is connected to the PLC and PLC has a Modbus Ethernet port. I A Modbus TCP/IP protocol is con gured](https://reader034.fdocuments.in/reader034/viewer/2022042017/5e755a2492b7c2152427f38a/html5/thumbnails/24.jpg)
About PlantCommunication
OPCSimulink Models and ResultsRole of MATLAB/Simulink
Challenges
I Real time control of pilot plants
I Access of data from multiples PLC manufactures
I Implementation of advance controller
Pritesh Shah,Prof Sudhir Agashe
![Page 25: Design and Implementation of Advanced Controller for Flow ......ow loop process is connected to the PLC and PLC has a Modbus Ethernet port. I A Modbus TCP/IP protocol is con gured](https://reader034.fdocuments.in/reader034/viewer/2022042017/5e755a2492b7c2152427f38a/html5/thumbnails/25.jpg)
About PlantCommunication
OPCSimulink Models and ResultsRole of MATLAB/Simulink
MATHWORK Solution
I Real time control of pilot plants: Support many protocolcommunication (TCP/IP, Serial, USB, OPC etc.)
I Access of data from multiples PLC manufactures OPC Toolbox
I Implementation of advance controller Fuzzy Controller,PIDController, MPC toolbox, Support many third party toolboxes
Pritesh Shah,Prof Sudhir Agashe
![Page 26: Design and Implementation of Advanced Controller for Flow ......ow loop process is connected to the PLC and PLC has a Modbus Ethernet port. I A Modbus TCP/IP protocol is con gured](https://reader034.fdocuments.in/reader034/viewer/2022042017/5e755a2492b7c2152427f38a/html5/thumbnails/26.jpg)
About PlantCommunication
OPCSimulink Models and ResultsRole of MATLAB/Simulink
Applications
I Data can be fetched easily through different PLCS.
I Plant can be controlled through various controllers like fuzzy control,PID, fractional PID controller etc.
I It can be used for modeling of systems.
Pritesh Shah,Prof Sudhir Agashe
![Page 27: Design and Implementation of Advanced Controller for Flow ......ow loop process is connected to the PLC and PLC has a Modbus Ethernet port. I A Modbus TCP/IP protocol is con gured](https://reader034.fdocuments.in/reader034/viewer/2022042017/5e755a2492b7c2152427f38a/html5/thumbnails/27.jpg)
About PlantCommunication
OPCSimulink Models and ResultsRole of MATLAB/Simulink
Tools used
I MATLAB
I Instrument Control Toolbox
I OPC Toolbox
I Control System Design
I Simulink
Pritesh Shah,Prof Sudhir Agashe
![Page 28: Design and Implementation of Advanced Controller for Flow ......ow loop process is connected to the PLC and PLC has a Modbus Ethernet port. I A Modbus TCP/IP protocol is con gured](https://reader034.fdocuments.in/reader034/viewer/2022042017/5e755a2492b7c2152427f38a/html5/thumbnails/28.jpg)
About PlantCommunication
OPCSimulink Models and ResultsRole of MATLAB/Simulink
Thank [email protected]
Pritesh Shah,Prof Sudhir Agashe