Download - 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

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



Outline

About Plant

Communication

OPC

Simulink Models and Results

Role 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.




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


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



Flow Loop Plant

Figure: Flow Loop Plant




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.




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




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




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.




OPC Communication Block Diagram

Figure: OPC Communication Setup




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




OPC Configuration in SimulinkI Need to configure OPC server (from local or remote server)

Figure: OPC Configuration Block in SimulinkPritesh Shah,Prof Sudhir Agashe



OPC Configuration in SimulinkI Configure OPC Read Block: we need to add tags (address) which we

want to read and configured in OPC server.





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.





Simulink Model for Fractional PID Controller

Figure: Simulink ModelPritesh Shah,Prof Sudhir Agashe



Subsystem for Plant

Figure: Simulink Model




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



Simulink Model for Fuzzy Controller

Figure: Simulink Model for Fuzzy Controller




FIS for Fuzzy Controller

Figure: Fuzzy FIS




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



Simulink Model for PID Controller

Figure: Simulink Model for PID Controller




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



Challenges

I Real time control of pilot plants

I Access of data from multiples PLC manufactures

I Implementation of advance controller




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




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.




Tools used

I MATLAB

I Instrument Control Toolbox

I OPC Toolbox

I Control System Design

I Simulink




Thank [email protected]


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