Final Report of BE (Industrial Electronics) 2018

PR–IIEE – 26B – 42604 – 2018

Adaptable PID Controller for Industrial Hot and Cold

Chamber

Aizaz Ahmad Malik (14003)

Hunza Muhammad Hanif (14017)

Muhammad Ahmed Siddiqui (14022)

Muhammad Talha Khan (14033)

Project Supervisors
Dr. Farah Haroon
Engr. Agha M. Shakir
Submitted to In-Charge Project Work

Engr. Agha Muhammad Shakir

Assistant Professor, IIEE

Institute of Industrial Electronics Engineering, PCSIR

www.iiee.edu.pk

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 CERTIFICATE
This is to certify that the project report entitled

“Adaptable PID Controller for Industrial Hot and Cold Chamber”

Submitted by

Aizaz Ahmad Malik (14003)

Hunza Muhammad Hanif (14017)

Muhammad Ahmed Siddiqui (14022)

Muhammad Talha Khan (14033)

Is a bonafide work carried out by them under the supervision of Engr. Agha Muhammad Shakir
& Engr. Asif Ahmad and it is approved for the partial fulfilment of the requirement of the
Institute of Industrial Electronics Engineering for the award of the degree of Bachelor of
Engineering in Industrial Electronics Engineering during the academic year 2018.

This project report has not been earlier submitted any other Institute or University for the award
of any degree.

Members FYP-Committee

1. Dr. Farah Haroon 2. Engr. Sajid Hussain 3. Engr. Agha M. Shakir

Associate Professor Assistant Professor Assistant Professor

4. Engr. Asif Ahmad 5. Engr. Nauman Pirzada

Lecturer External Advisor

Engr. Ashab Mirza

Principal, IIE
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The Project Group Detail
Mr. M. Talha Khan (Group Leader) Enrolment Number: IIEE-1108/IE/2014-15
Address: G-7/8 Pak Colony Manghopire Road, Karachi.
Cell: 0348-2482567 Email:talha.26@iiee.edu.pk

Mr. Aizaz Ahmad Malik Enrolment Number: IIEE-1078/IE/2014-15

Address: 2-B/4. Flat # A-101, Blessing Homes, Nazimabad # 2, Karachi.
Cell: 0347-2018994 Email: aizaz.26@iiee.edu.pk

Mr. Muhammad Ahmed Siddiqui Enrolment Number: IIEE-1097/IE/2014-15

Address: R-287 Sector # 9 North Karachi, Karachi.
Cell: 0336-2211123 Email: ahmed.26@iiee.edu.pk

Mr. Hunza M. Hanif Enrolment Number: IIEE-1092/IE/2014-15

Address: Flat-502 Marium Tower, Lawrence Quarter, Nishtar Road, Garden West,
Karachi
Cell: 0324-2137519 Email: hunzahanif.26@iiee.edu.pk

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 ACKNOWLEDGEMENTS

First of all, we are very thankful to ALLAH ALMIGHTY who gives us such power,
knowledge, and ability to accomplish our goals. Without His kind help, we would be unable to
do this.

The primary acknowledgment for this project is directed towards our supervisors
Engr. Agha Muhammad Shakir and Engr. Dr. Farah Haroon who gave us the golden
opportunity to do this wonderful project “Adaptable PID Controller for Industrial Hot and
Cold Chamber” which also helped us in doing a lot of research and we came to know about
so many new things we are really thankful to them. Both these supervisors helped us in
providing an easier solution of our problems during the development of this project. We would
also thankful to our external supervisor which helped us not only in the selection of this project
but also helped a lot in every step of the development of the project.

We also thank our classmates for their useful suggestions. Their technical support and
encouragement helped us to finalize our project. We would also like to express our gratitude
towards the Institute for providing us with the best facilities and proper environment to work
on our project.

“May Allah Almighty bless all the personalities who had directly or indirectly helped us to
achieve our goals.”

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 ABSTRACT

Our aim in this project is to design an Adaptable PID Controller for Industrial Hot and Cold
Chamber. In this project, there is a Chamber in which we have to control the temperature of
the fluid by heating and cooling it. Controlling is done by making PID adaptable by using
analogical gates regarded as fuzzy operation. It doesn’t depend on the changing of PID
controller parameters but it depends on changing the share of each controller term on the total
control action. The purpose of this project is to eliminate Auxiliary controller which are used
as a compensator with PID in industries. The project also comprises the application of OPC
communication protocol for communicating the PC and PLC for HMI used for monitoring and
controlling of parameters.

The adaptable PID controller is favorable for the quick control action when the setpoint changes
throughout the process. It is also feasible to use in different process industries like beverages,
pharmaceutical, cement industries, and Textile industries etc.

Key words: PLC, HMI, Industrial Automation, Adaptable PID, Fuzzy Operation, OPC.

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 TABLE OF CONTENTS

CHAPTER TITLE PAGE

Title Page i
Detail of Supervisors ii
Detail of Group Members iii
Acknowledgments iv
Abstract v
Table of Contents vi
List of Tables viii
List of Figures ix
List of Abbreviations x
List of Symbols xi
1 Introduction 01
1.1 Background 02
1.2 Motivation 02
1.3 Problem and Challenges 02
1.4 Possible Solutions 02
1.5 Proposed Solution 02
1.6 Objectives 03
1.7 Organization of the Report 03
2 Literature Review 04
2.1 Information 04
2.1.1 Methods to calculate the volume of the tank 04
2.1.2 Specifications of Tank 04
2.1.3 Insulation of a tank 05
2.2 Programmable Logic Controller 05
2.2.1 History of PLC 05
2.2.2 Functions and Uses of PLC 06
2.2.3 Advantages of PLC 06
2.2.4 PLC Manufacturers 06
2.3 Delta PLC Overview 07
2.3.1 Delta DVP 20 SX2 07
2.3.2 Specifications of Delta DVP 20 SX2 07
2.3.3 Communication in Delta DVP 20 SX2 07
2.3.4 A/D Conversion in Delta DVP Series PLC 08
2.3.5 D/A Conversion in Delta DVP Series PLC 08
2.4 Communication Between PC & PLC 08
2.4.1 Hardware Protocol of Compunction 09
2.5 OPC 09
2.5.1 What is OPC? 09
2.5.2 History of OPC 09
2.5.3 Uses of OPC 10
2.5.4 Design of OPC 10

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 2.5.5 KEP Server EX 11
2.6 Selection of Sensors 12
2.6.1 RTD-PT100 12
2.7.1 Temperature Transmitter 13
2.7.2 Solid State Relay 14
2.7.3 Solenoid Valve 14
3 Methodology 15
3.1 Concepts 16
3.1.1 Block Diagram of the Project 17
3.1.2 Process Flow Diagram 18
3.2 Temperature Controlling 18
3.2.1 Heater Control Technique 18
3.2.2 Mathematical model of the heater 19
3.3 System Identification By MATLAB 22
3.3.1 Close loop transfer function 23
3.4 Communication Between PC And PLC 23
3.5 Project Hardware 24
3.5.1 Hot and Cold Chamber 25
3.5.2 Cooling Source 26
3.5.3 Heating Source 26
3.6 Optocoupler Circuit 26
3.7 Software 26
3.7.1 WPL Soft 26
3.7.2 OPC KEP Server 27
3.7.3 WinCC Flexible 28
3.7.4 MATLAB 29
3.8 Overall Algorithm 29
4 Results and Discussion 30
4.1 Simulation Results 30
4.2 Experimental Results 31
4.3 Comparison between Simulation and Experimental Results 32
5 Conclusion and Recommendations 33
5.1 Conclusion 33
6 References 34
7 Appendices 35

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 LIST OF FIGURES

FIGURE TITLE PAGE

2.1 Programmable Controller I/O Connection 05

2.2 Delta DVP 20 SX2 PLC 06
2.3 OPC Server as Linking Software 09
2.4 2 Wire Configuration RTD-Connection Diagram 12
2.5 3 Wire Configuration RTD Connection Diagram 13
2.6 Temperature Transmitter 13
2.7 Solid State Relay (SSR) 14
2.8 Solenoid Valve 14
3.1 Block diagram of PID tuning Network 16
3.2 Block diagram showing different section of project 17
3.3 Process flow diagram of project 18
3.4 Phase Angle control Schematic and waveform 20
3.5 PWM output with AC wave 21
3.6 PWM output of PLC 21
3.7 System Identification tool of MATLAB 22
3.8 OPC Architecture 24
3.9 OPC KEP-server Simulation Server Configuration 24
3.10 Complete Hardware view 24
3.11 Stages of fabrication of hot and cold chamber 25
3.12 Cylindrical tank 26
3.13 Glass Wool 26
3.14 Spray Foam 26
3.15 Cooling Source (outer) 26
3.16 Simulation of optocoupler circuit 27
3.17 KEP Server Channel (FYP) 28
3.18 Main Screen Of HMI 29
3.19 Trends in HMI 29
3.20 Process flow in HMI 30
3.21 SAMA diagram of Overall Algorithm 30
4.1 Comparative Simulated Response of PID & Adaptable PID 31
4.2 Comparative Experimental Response of PID & Adaptable PID 32

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 LIST OF TABLES

TABLE TITLE PAGE

2.1 Specification of Delta DVP 20 SX2 07

2.2 Delta DVP 20 SX2 AD and DA Specifications 08
2.3 Specifications of Temperature Transmitter 14
2.4 Specifications of Temperature Transmitter 15
3.1 Specifications WPL Soft 28
4.1 Comparative Simulated Results of PID & Adaptable 31
4.2 Comparative Experimental Results of PID & Adaptable 32
4.3 Comparative Results of Simulation and Experiment of PID & 33
Adaptable PID

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 LIST OF ABBREVIATIONS

ADC Analog to Digital Converter

DAC Digital to Analog Converter
PLC Programmable Logic Control
OPC Open Platform Communications
HMI Human–Machine Interface
MPC Model Predictive Control
SSR Solid State Relay
PEM Prediction-Error Minimization
PWM Pulse width modulation
COM Component Object Model
SCADA Supervisory Control And Data Acquisition
DCS Distributed Control System
HAD Historical Data Access
OLE Object Linking and Embedding
DCOM Distributed Component Object Model
LAN Local Area Network
OSI Open System Interconnection
ISO International Standards Organization
CR Control Registers

x
 LIST OF SYMBOLS
∧ Analogical Invoke
⨁ Analogical OR

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 CHAPTER 1
INTRODUCTION

1.1 Background/Rationale for the project:

Industrial automation is the use of control systems, such as computers, to control industrial
machinery and processes, replacing human operators. Automation greatly reduces the need for
human sensory and mental requirements as well [1]. Although there is still a gap between most
advanced automated systems and human natural capabilities; for example, no device has been
invented which can match the human eye or ear for accuracy and precision in many tasks;
industrial production is increasingly depending on automation. The automation cycle can be
arranged as; the human operator (supervisor) gives commands to the control system, then it
manipulates the command and feedback signals from sensors and produces a control signals
that can be transformed into action through the actuators. Recently, programmable (digital)
systems, such as industrial PC, Microcontroller and PLC, are dominated in control system
implementation. The control tasks of an industrial process, using digital controller, are
classified into Sequence control, Direct Digital Control (DDC) and Supervisory control. These
tasks can be carried out using single control system or multi-control system. Therefore, the
control system may be centralized or distributed [2].
Temperature control plays an important role in most of real industrial system, such as steam
generation, metal processing, paper production, air conditioning, etc., in order to satisfy the
performance index either in transient or steady state. Most of temperature control systems are
of complex nature and have multi variables. Moreover, they have delay time. Hence,
temperature controller should be robust and adaptable to deal with this problem efficiently.
Unfortunately, most of the modern control techniques, which solve these problems, are not
applied in industry due to the limitation of industrial controller either in functionality, response
time or cost. Many techniques of temperature control are scattered in literature, either classical,
such as PID and adaptive PID, or modern, such as Fuzzy, Adaptive Fuzzy and Model Predictive
Control (MPC) as given for example [3] & [4].
Rare of those techniques can be implemented using PLC in low level of automation due to the
time and computation constraints, but they are frequently implemented in high level
(Distributed Control Level) which has a high capability of computation and processing time.
Since, many of advanced control techniques are addressed by researchers, most of them are
still difficult to implement specially in most of industrial system that have up to level three
(field level, individual control level and group control level) of automation hieratical [7].
PID controller structure is simple and it can satisfy the requirements of many industrial
processes. Therefore, PID control is still the most widely used control law in most industrial
loop. However, for some complex processes, such as systems with large time lag or inertia, it
is difficult for the conventional PID controller to obtain better control effect.
So, the main objective of the work is to implement adaptable PID based on analogical gate in
the field level using PLC.
The proposed controller is tested and implemented for a real industrial temperature process.
The process is supervised using an HMI which is used to monitor, tune and operate the process
locally.
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The project that we aimed to design in our final year project is “Adaptable PID Controller for
Industrial Hot and Cold Chamber”. In this project, there is a Chamber which we have to control
for Hot and Cold the fluid.
Hot and cold chambers have wide applications like food processing, metal production and
climate testing in quality control etc. rapid transition of heat cause thermal shock and shock
intensity changes depending on the range of heat transition widely PID is used for the hot and
cold chamber control systems. In this project, there are many limitations in PLC and Hardware.
1.2 The motivation of the Project:
We get motivation to select this project from our visit to a Textile Industry where we saw in
the printing press machine of garments, there is a problem during the printing on the garments
it should control the heat of the print (stamp) for that purpose we were queries about that how
to control the temperature (hot & cold) of that printing press for different material of garment.
1.3 Problems and Challenges:
There is no built-in Adaptable PID block available in any PLC. Normally PLC contains only
PID which is insufficient to control industrial hot and cold chamber.
1.4 Possible Solutions:
The possible solutions to our problems are as under
1.4.1 Solution I
Normally PID is used for the control of hot and cold chamber others include Fuzzy, Model
Predictive Control (MPC) etc., rare of these can be implemented using PLC due to time,
computation constraints and cost. [2]
1.4.2 Solution II
The second solution is going towards the adaptable control schemes specifically Adaptable PID
[3].
1.5 Proposed Solution:
The solution that we proposed is solution number 2 which is to make the control scheme
Adaptable by using PID.
1.6 Objectives:
The objectives that we want to get from this project are as under
 Develop skills in the appropriate software for DELTA/SIEMENS PLC.
 Interfacing the Sensors & Actuators.
 To design a hot and cold chamber.
 Implement the proposed algorithm in the PLC for the execution of control action of the
plant.
 Develop the skills in supervising the control action of the plant by means of HMI software.
 Evaluate the comparative response of Conventional & Adaptable PID in HMI software.

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1.7 Organization of the Report:
Chapter 2 discusses the literature review of the project.

Chapter 3 discusses the Methodology of the project.

Chapter 4 results and discussion about the project.

Chapter 5 discusses the conclusion and benefits of the project.

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 CHAPTER 2
LITERATURE REVIEW

2.1 Information:
For the solution of the problem statement, we went through different sources i.e. reviewing
various research papers, consulting with different industrialist. After all this, we came to the
solution for this problem that to make our PID Adaptable we must use Analogical Gates which
are based on behavior fusion technique.
The approach we have adopted is both simple and novel. We employ Analogical gates on a set
whose elements are continuous in time. These gates can be regarded as a fuzzy operation. Using
analogical we construct behavior circuits that process individual behavior to produce a desired
“plausible” overall behavior. The philosophy of adapted PID controller based on analogical
gates. It does not depend on the changing of PID controller parameters but it depends on
changing the share of each controller term on the total control action. [3]
The industrial Hot & Cold Chamber can be used for quality control testing of the product in
both cool and hot environments. As per the requirement of fast response when the setpoint
changes throughout the process, the adaptable PID controller is favorable for the quick control
action. [6]
Industries such as textile, food, and pharmaceutical use hot and cold chamber for heat treatment
of their products, they can get benefits using our adaptable PID controller, without having to
change to Fuzzy and MPC which will take time and cost much more.
Now discuss the topics including industrial Hot & cold Chamber, PLC, Solenoid Valves, OPC
temperature sensor, temperature transmitter, Solid State Relay (SSR).

2.2 Programmable Logic Controller:

A programmable logic controller (PLC) or programmable controller is a digital computer used
for automation of electromechanical processes, such as control of machinery on factory
assembly lines, amusement rides, or light fixtures. PLCs are used in many industries and
machines.
A PLC is a computer-based device that has standard interface modules. Initially, it replaced
relay devices, which are programmed with a use of a ladder diagram (a standard electrical
wiring diagram). As PLC became more flexible, both High Level and Low-Level languages
became available to the PLC programmer. PLC’s have the flexibility of computers, as well as
a standard interface with processes and devices. They are widely accepted in the industry for
controlling a single device to a complex manufacturing facility.

2.2.1 History of PLC:

The advent of the PLC began in the 1960′s and 1970′s to replace traditional “hard-wired”
controls and has since become the predominant choice for industrial controls. Before PLCs,
much of machine control relied on contacts and relays providing hard-wired “logic” for
machine controls. Changes to the logic were labor intensive and costly. [10]
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In 1968, GM’s Hydromantic division specified the design criteria for what would become the
first programmable logic controller. They requested a solid-state system that would:
 Survive the industrial environment
 Be easily programmed by plant engineers and technicians, and
 Be easily reprogrammed and re-used
The Automotive Industry was a major early adopter of programmable logic controllers (PLC).
They wanted a programming method that could be easily understood by their existing controls
engineers and technicians. The result of this desire was a programming language called Relay
Ladder Logic (or “ladder logic”).
The layout of Ladder Logic is very similar to reading the diagrams for hard-wired relay
controls. Ladder Logic is still one of the most popular “language” for programming PLCs, but
many others have developed over the years.

2.2.2 Functions and Uses of PLC:

The functionality of the PLC has evolved over the years to include sequential relay control,
motion control, process control, distributed control systems, and networking. The data
handling, storage, processing power and communication capabilities of some modern PLCs
are approximately equivalent to desktop computers. PLC-like programming combined with
remote I/O hardware, allow a general-purpose desktop computer to overlap some PLCs in
certain applications.
Regarding the practicality of these desktop computer-based logic controllers, it is important
to note that they have not been generally accepted in heavy industry because the desktop
computers run on less stable operating systems than do PLCs, and because the desktop
computer hardware is typically not designed to the same levels of tolerance to temperature,
humidity, vibration, and longevity as the processors used in PLCs. [10]. In addition to the
hardware limitations of desktop-based logic, operating systems such as Windows do not lend
themselves to deterministic logic execution, with
the result that the logic may not always respond to
changes in logic state or input status with the
extreme consistency in timing as is expected from
PLCs.

2.2.3 Advantages of PLC:

A PLC system provides many benefits to control
solutions, from reliability and repeatability to
programmability. Without question, the
“programmable” feature provides the single
greatest benefit for the use and installation of
programmable controllers. Eliminating hardwired
control in favor of programmable control is the
first step towards achieving a flexible control
system. Once installed, the control plan can be
Fig. 2.1: Programmable Controller I/O Connection
manually or automatically altered to meet day-

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to-day control requirements without changing the field wiring. This easy alteration is possible
since there are no physical connections between the field input devices and output devices (see
Figure2.4), as in hardwired systems. The only connection is through the control program,
which can be easily altered. [10]

2.2.4 PLC Manufacturers:

Following is the list of some recognized PLC manufactures.
 Marvell Technology Group, a producer of storage, communications, and consumer
semiconductor products
 Mitsubishi, a group of autonomous Japanese multinational companies
 Fatek, Core technology for automation
 Alstom, a French multinational company
 Motorola, a telecommunications company based in Schaumburg, Illinois
 Omron, an electronics company based in Kyoto, Japan
 Panasonic, a Japanese multinational electronics corporation
 Siemens, a German multinational conglomerate company
 Delta, a European Electronics company
 LG
 Allen Bradley
 Schneider Electric

2.3 Delta PLC Overview:

Delta's DVP series programmable logic controllers offer high-speed, stable and highly reliable
applications in all kinds of industrial automation machines. In addition to fast logic operation,
bountiful instructions and multiple function cards, the cost-effective DVP-PLC also support
various communication protocols, connecting Delta's AC motor drive, servo, and human-
machine interface and temperature controller through the industrial network into a complete
“Delta Solution” for all users.
2.3.1 Delta DVP 20 SX2:
The 2nd generation DVP-20 SX2 PLC,
shown in Figure 2.6, offers 14 digital
points and 6 built-in 12-bit analogs I/O
points. It is extendable with DVP-S
series left-side and right-side extension
modules.2.4.2 Applications
Used for PID temperature/humidity
control, 2-axis AC motor drives constant
speed control, temperature control using
an analog signal monitoring of a whole
factory. (PLC EASY LINK) and Modbus
implementation.
Fig 2.2: Delta DVP 20 SX2 PLC

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2.3.2 Specifications of Delta DVP 20 SX2:

Table 2.1: Specification of Delta DVP 20 SX2

Specifications Details
MPU points 20 (8DI/6DO, 4AI/2AO)

Max I/O points 494 (14 + 480)

Program capacity 16k steps

Built-in RS-232, RS-485 & USB ports, compatible with

COM port
ASCII/RTU protocol. Can be master or slave.

High-Speed Pulse Supports 2 points (Y0, Y2) of 100kHz and 2 points (Y1,
Output Y3) of 10kHz independent high-speed pulse output.

2.3.3 Communication in Delta DVP 20 SX2:

We have several methods to communicate our PC with the Delta PLC’s, and many users don’t
know some of them. On the other side, every time is more difficult to found RS232 serial
ports in the computers, and the USB to RS232 converters are not as much trustable as they
must. It is also having a port for RS-485.
2.3.4 A/D Conversion in Delta DVP Series PLC:
In industrial automation, many measuring units are transmitted by analog signals. The most
frequently adopted range for the signals is voltage -10V ~ 10V and current -20mA ~ 20mA.
To use the analog signals as the parameters for PLC operations, you have to convert them into
digital values first. For example, the voltage -10V ~ 10V is first converted into values -32,000
~ +32,000 by an A/D module, and the PLC will read/write the control registers (CR) in the
A/D module. The signals sent back to the PLC for operations will be digital K-32,000 ~
K32,000. In industrial automation, many measuring units are transmitted by analog signals.
The most frequently adopted range for the signals is voltage -10V ~ 10V and current -20mA
~ 20mA. To use the analog signals as the parameters for PLC operations, you have to convert
them into digital values first. For example, the voltage -10V ~ 10V is first converted into
values -32,000 ~ +32,000 by an A/D module, and the PLC will read/write the control registers
(CR) in the A/D module. The signals sent back to the PLC for operations will be digital
K-32,000 ~ K32,000. [11]
2.3.5 D/A Conversion in Delta DVP Series PLC:
To convert digital values into a respective analog voltage or current signal, D/A conversion is
available, integer values are provided in special registers defined in the datasheet to take analog
output from the D/A terminals of PLC. The AD and DA specifications for Delta DVP 20 SX2
are shown in table 2.2 showing analog I/O range, Digital conversion range, and resolution.

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 Table 2.2: Delta DVP 20 SX2 AD and DA Specifications

2.4 Communication Between PC & PLC:

When the PC is connected to the PLC for purposes of monitoring and supervision, the PLC is
usually designed to control the industrial plant or machine while communicating with a PC,
which is an integral part of the plant-wide automation system. Such a connection usually allows
the PLC to handle the operation of the process, while the PC is there as an Overseer.[11]
In order to implement the monitoring and supervisory functions, the PC has to be equipped
with a suitable software package.
2.4.1 Hardware Protocol of Compunction:
The physical connection between the PC and the PLC can be implemented in one of two
ways:
1. Via a serial point-to-point link
2. Using a communication network

2.5.1.1 Serial Link:

The serial point-to-point links are normally based on the RS-232, RS-485, and RS-422
standards. With reference to the International Standards, Organization (ISO) model for Open
System Interconnection (OSI).3 these standards are concerned only with the features of the
physical layers used by the links; that is. the levels of electrical signals their timing and so on.
Consequently, in order to transfer process data over the connection. It is necessary to develop
a suitable protocol which has to be implemented on both the PC and the PLC sides. [11]
The transmission speeds available with such connections are relatively low; typical values are
9.6 Kbps. I9.2 Kbps. and 38.4 Kbps. For these reasons, such links are only used to transfer
small amounts of data. Because otherwise, the overall transmission system would become
very slow. Finally, the distances covered with serial connections are limited to some tens of
meters.
2.5.1.2 Communication Network:
The use of communication networks to connect “intelligent” devices is dramatically
increasing in the processing industries. The communication networks used can be grouped into
two categories:
1. Local area networks (LANs)
2. Fieldbuses

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Considering the PC-PLC connection, both of these solutions require the use of interface boards
in order to implement the particular protocol used by the networks.
2.5 OPC:
OLE (which stands for Object Linking and Embedding) for Process Control OPC is the name
for a standards specification developed in 1996 by an industrial automation industry task
force. The standard specifies the communication of real-time plant data between control
devices from different control system
manufacturers. The OPC specification was
based on the OLE, COM (component object
model) and DCOM (distributed component
object model) technologies developed by
Microsoft for the Microsoft Windows
operating system family. The specification
defined a standard set of objects, interfaces,
and methods for use in process control and Fig 2.3: OPC Server as Linking Software
manufacturing automation applications to
facilitate interoperability. The most common OPC specification is OPC Data Access, which
is used to read and write real-time data. When vendors refer to OPC generically, they typically
mean OPC Data Access. [9]
2.5.1 What is OPC?
OPC is a software interface standard that allows Windows programs to communicate with
industrial hardware devices as shown in Figure 2.10. OPC is implemented in server/client pairs.
The OPC server is a software program that converts the hardware communication protocol
used by a PLC into the OPC protocol. The OPC client uses the OPC server to get data from
or send commands to the hardware.
The acronym "OPC" comes from "OLE (Object Linking and Embedding) for Process Control".
Since OLE is based on the Windows COM (Component Object Model) standard, under the
hood OPC is essentially COM. Over a network, OPC relies on DCOM (Distributed COM),
which was not designed for real-time industrial applications and is often set aside in favor of
OPC tunneling.
2.5.2 History of OPC:
OLE for Process Control (OPC), which stands for Object Linking and Embedding. (OLE) for
Process Control, is the original name for standards specification developed in 1996 by an
industrial automation industry task force. The standard specifies the communication of real-
time plant data between control devices from different manufacturers.
As of November 2011, the OPC Foundation has officially renamed the acronym to mean
"Open Platform Communications" although they also use the tagline "Open Productivity &
Connectivity" on their website. The change in name reflects the applications of OPC
technology for applications in Process Control, discrete manufacturing, building automation,
and many others.

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OPC has also grown beyond its original OLE (Object Linking and Embedding)
implementation to include other data transportation technologies including XML, Microsoft's
.NET Framework, and even the OPC Foundation's binary-encoded TCP format. [11]
After the initial release in 1996, the OPC Foundation was created to maintain the standard.
Since then, standards have been added and names have been changed. As of June 2006, "OPC
is a series of standards specifications". (Seven current standards and two emerging standards.)
"The first standard (originally called simply the OPC Specification"), is "now called the Data
Access Specification", or (later on the same page) "OPC Data Access", or OPC Data Access
Specification.
2.5.3 Uses of OPC:
The OPC Specification was based on the OLE, COM, and DCOM technologies developed by
Microsoft for the Microsoft Windows operating system family. The specification defined a
standard set of objects, interfaces, and methods for use in process control and manufacturing
automation applications to facilitate interoperability. The most common OPC specification is
OPC Data Access, which is used to read and write real-time data. When vendors refer to OPC
generically, they typically mean OPC Data Access (OPC DA). OPC DA itself has gone
through 3 major revisions since its inception. Versions are backward compatible, in that a
version 3 OPC Server can still be accessed by a version 1.
OPC Client, since the specifications, add functionality but still require the older version to be
implemented as well. However, a Client could be written that does not support the older.
Functions since everything can be done using the newer ones, so a DA 3 compatible Client
will not necessarily work with a DA 1.0 Server. [9]
In addition, OPC DA specification, the OPC Foundation also maintains the OPC HDA
(Historical Data Access) specification. In contrast to the real-time data that is accessible with
OPC DA, OPC HDA allows access and retrieval of archived data.
2.5.4 Design of OPC:
OPC was designed to provide a common bridge for Windows-based software applications and
process control hardware. Standards define consistent methods of accessing field data from
plant floor devices. This method remains the same regardless of the type and source of data.
An OPC Server for one hardware device provides the same methods for an OPC Client to
access its data as any and every other OPC Server for that same and any other hardware device.
The aim was to reduce the amount of duplicated effort required from hardware manufacturers
and their software partners, and from the SCADA and other HMI producers in order to
interface the two the new hardware device their work was done to allow any 'top end' to access
their device, and once the SCADA producer had developed their OPC Client their work was
done to allow access to any hardware, existing or yet to be created, with an OPC compliant
server.
OPC servers provide a method for many different software packages (so long as it is an OPC
Client) to access data from a process control device, such as a PLC or DCS. OPC Client/Server
architecture is shown in Figure 2.8 Traditionally, any time a package needed access to data
from a device, a custom interface, or driver, had to be written. The purpose of OPC is to define
a common interface that is written once and then reused by any business, SCADA, HMI, or

10
custom software packages. There is nothing in the OPC specifications to restrict the server to
providing access to a process control device. OPC Servers can be written for anything from
getting the internal temperature of a microprocessor to the current temperature in Monument
Valley.
Once an OPC Server is written for a particular device, it can be reused by any application that
is able to act as an OPC client. OPC servers use Microsoft’s OLE technology (also known
as the Component Object Model, or COM) to communicate with clients. COM technology
permits a standard for real-time information exchange between software applications and
process hardware to be defined. It is important to note that some OPC specifications are
published; others are available only to a member of the OPC Foundation. [9]
2.5.5 KEP Server EX:
KEP Server EX is the industry’s leading connectivity platform that provides a single source
of industrial automation data to all of your applications. The platform design allows users to
connect, manage, monitor, and control diverse automation devices and software applications
through one intuitive user interface. KEP Server EX leverages OPC (the automation industry’s
standard for interoperability) and IT-centric communication protocols (such as SNMP,
ODBC, and web services) to provide users with a single source for industrial data. The
platform is developed and tested to meet our customers’ performance, reliability, and ease-of-
use requirements.
KEP Server EX provides data access for client applications (such as MES and SCADA) and
IoT and Big Data analytics software via OPC, proprietary protocols (including GENIO, Suite
Link/Fast DDE, and Splunk), IT protocols (including MQTT, REST, ODBC, and SNMP), and
flow measurement export to common Oil & Gas industry formats.
2.5.5.1 Business Value
KEP Server EX provides the connectivity, usability, and performance required by the modern
enterprise—offering competitive benefits that can be experienced from the plant floor to IT to
the boardroom.
 IoT-ready, connecting Operations with IT and enabling Business Intelligence and
Operational Excellence across the enterprise
 Fully compatible with the Thing Worx Manufacturing Accelerator, including the Thing
Worx Controls Advisor app that provides remote real-time visibility into connectivity
across all factories
 Compatible with leading hypervisors, such as VMware and Hyper-V, for flexible
deployment on public and private clouds
 Integrates with IT applications for visibility into assets on the plant floor at any time and
from any location
 Enhanced messaging security via SSL and TLS for secure, authenticated, and encrypted
communications across various network topologies
 Advanced application security features to meet site security requirements
 Sophisticated access control to the server, data source, and data values

11
  Multiple redundancy options to ensure resiliency, high-reliability, and uptime in critical
applications
 Streamlined interface for simple installation, configuration, maintenance, and
troubleshooting. [9]
2.6 Selection of Sensors:
First of all, we will select sensors according to our application we know that our chamber
having temperature range 0 0C to 100 0C so we can use RTD-PT100 as a temperature sensor.
2.6.1 RTD-PT100:
Resistance Temperature Detectors (RTDs) are sensors that measure temperature by correlating
the resistance of the RTD element with temperature. Most RTD elements consist of a length of
fine coiled wire wrapped around a ceramic or glass core.
2.6.1.1 Working Principle of RTD:
An RTD (resistance temperature detector) is a temperature sensor that operates on the
measurement principle that a material’s electrical resistance changes with temperature. The
relationship between an RTD’s resistance and the surrounding temperature is highly
predictable, allowing for accurate and consistent temperature measurement. By supplying an
RTD with a constant current and measuring the resulting voltage drop across the resistor, the
RTD’s resistance can be calculated, and the temperature can be determined.
2.6.1.2 RTD Configurations:
In addition to different materials, RTDs are also offered in two major configurations: wire
wound and thin film. Wire wound configurations feature either an inner coil RTD or an outer
wound RTD. An inner coil construction consists of a resistive coil running through a hole in a
ceramic insulator, whereas the outer wound construction involves the winding of the resistive
material around a ceramic or glass cylinder, which is then insulated. [5]
The thin film RTD construction features a thin layer of resistive material deposited onto a
ceramic substrate through a process called deposition. A resistive meander is then etched onto
the sensor, and laser trimming is used to achieve the appropriate nominal values of the sensor.
The resistive material is then protected with a thin layer of glass, and lead wires are welded to
pads on the sensor and covered with a glass dollop.
Thin film RTDs have advantages over the wire wound configurations. The main advantages
include that they are less expensive, are
more rugged and vibration resistant, and
have smaller dimensions that lead to better
response times and packaging capabilities.
For a long time wire wound sensors
featured much better accuracy. Thanks to
recent developments, however, there is
now thin film technology capable of
achieving the same level of accuracy.

Fig. 2.4: 2 Wire Configuration RTD Connection Diagram

12
 2.6.1.3. Operations of RTD:
An RTD takes a measurement when a small DC current is supplied to the sensor. The current
experiences the impedance of the resistor, and a voltage drop is experienced over the resistor.
Depending on the nominal resistance of the RTD, different supply currents can be used. To
reduce self-heating on the sensor the supply current should be kept low. In general, around
1mA or less of current is used.
An RTD can be connected in a two, three, or four-wire configuration. The two-wire
configuration is the simplest and also the most error-prone. In this setup, the RTD is connected
by two wires to a Wheatstone bridge circuit and the output voltage is measured. The
disadvantage of this circuit is that the two connecting lead wire resistances add directly two the
RTD’s resistance and an error is incurred.
The four-wire configuration consists of
two current leads and two potential leads
that measure the voltage drop across the
RTD. The two potential leads are high
resistance to negate the effect of the
voltage drop due to current flowing during
the measurement. This configuration is
ideal for canceling the lead wire
resistances in the circuit as well as
eliminating the effects of different lead Fig. 2.5: 3 Wire Configuration RTD Connection Diagram
resistances, which was a possible problem
with the three-wire configuration. The four-wire configuration is commonly used when a
highly accurate measurement is required for the application.
In combination with the wiring diagrams shown, a more complex circuit is often employed.
There are many different options for circuits when working with an RTD. The two most
important features of this circuit are the current generation and signal conditioning. For
purposes of linearity, it is important that the current generation circuit supplies a stable
excitation to the RTD. Once a stable excitation current is applied to the RTD, the signal
conditioning path of the circuit cancels lead resistances, gains the signal and converts the signal
to digital using an ADC, which can then be read by a controller.

2.7.1 Temperature Transmitter:

A temperature transmitters convert the thermocouple or RTD signal to a 4-20 mA output
signal and are the ideal solution for many remote temperature
measurement applications. 4-20mA transmitters have definite
advantages over conventional temperature measuring devices,
but must be selected with caution in order to avoid “ground
loop” problems.
A temperature transmitter draws current from a remote dc
power supply in proportion to its sensor input. The actual signal
is transmitted as a change in the power supply current. Fig 2.6: Temperature
Specifically, a thermocouple input transmitter will draw 4 mA Transmitter
of current from a dc power supply when measuring the lowest

13
temperature of the process. Then, as the temperature rises, the thermocouple transmitter will
draw proportionally more current, until it reaches 20 mA. This 20-mA signal corresponds to
the thermocouple’s highest sensed temperature. The transmitter’s internal signal-conditioning
circuitry (powered by a portion of the 4-20 mA current) determines the temperature range that
the output current signal will represent.
The table below shows the specification of the temperature transmitter.
Table 2.3: Specifications of Temperature Transmitter

Temperature Transmitter Description

Input RTD PT-100 Temperature Sensor

Temperature Range 0 – 400 0C or 0 752 0F

Output 4 – 20 mA
Power Loop powered 24V DC 50 mA

Dimensions 50 mm diameter

2.7.2 Solid State Relay:

A solid-state relay (SSR) is an electronic switching device that switches
on or off when a small external voltage is applied across its control
terminals. SSRs consist of a sensor which response to an appropriate
input (control signal), a solid-state electronic switching device which
switches power to the load circuitry, and a coupling mechanism to
enable the control signal to activate this switch without
mechanical parts. The relay may be designed to switch
either AC or DC to the load. It serves the same function as
an electromechanical relay but has no moving parts.
Packaged solid-state relays use power semiconductor devices such
Fig 2.7: Solid State
as thyristors and transistors, to switch currents up to around a Relay (SSR)
hundred amperes. Solid-state relays have fast switching speeds
compared with electromechanical relays, and have no physical
contacts to wear out. Application of solid-state relays must consider
their lower ability to withstand momentary overload, compared with
electromechanical contacts, and their higher "on" state resistance.
Unlike an electromechanical relay, a solid-state relay provides only
limited switching arrangements (SPST switching).

2.7.3 Solenoid Valve:

A solenoid valve is an electromechanical device in which
the solenoid uses an electric current to generate a magnetic field and
Fig 2.8: Solenoid Valve

14
thereby operate a mechanism which regulates the opening of fluid flow in a valve.
Solenoid valves differ in the characteristics of the electric current they use, the strength of the
magnetic field they generate, the mechanism they use to regulate the fluid, and the type and
characteristics of fluid they control. The mechanism varies from the linear action, plunger-
type actuators to pivoted-armature actuators and rocker actuators. The valve can use a two-port
design to regulate a flow or use a three or more port design to switch flows between ports.
Multiple solenoid valves can be placed together on a manifold.
Solenoid valves are the most frequently used control elements in fluidics. Their tasks are to
shut off, release, dose, distribute or mix fluids. They are found in many application areas.
Solenoids offer fast and safe switching, high reliability, long service life, good medium
compatibility of the materials used, low control power and compact design.

Table 2.4: Specifications of Temperature Transmitter

Input 220 – 230 V AC

Frequency 50 – 60 Hz
Power 8W
Temperature Range -35 to 105 0C
Pressure Range 45 Bar

15
 CHAPTER 3
METHODOLOGY

3.1 Concepts:

The adaptation of PID is carried out using analogical gates. Analogical gates are a method of
describing multi-valued logical statements. The scope of operation of binary logic-based
systems to true multi-valued logic-based systems is widened based on the analogical gate.
Furthermore, the design and implementation of these gates for practical systems have proven
to be efficient and simple.
Throughout the following treatment, we use an exponential function in two variables x and y.

𝑎𝑥 2 +𝑏𝑥𝑦
−( 2 2 )
𝑓(𝑥, 𝑦) = 𝑒 𝑥 +𝑦 (3.1)
Where x, y ℇ R also a & b are constants. The above-mentioned function can be regarded as a
two-dimensional membership function on a “Fuzzy” input set of two behaviors. [3]
We will use this function to design and implement the analogical gates and these are used in
our tuning network of the adaptable PID controller. The block diagram for the tuning network
is given below.

Fig 3.1: Block diagram of PID tuning Network

Where UP, UI and Ud are proportional, integral and derivative control action respectively. Here
the operator ∧ and ⨁ are used for analogical-INVOKE and analogical-OR. These gates are
needed to be programmed in the PLC in order for the adaptable PID to work.
Furthermore, simulation of the control scheme in MATLAB, I/O interfacing between PLC and
hot and cold chamber, implementation of design adaptable PID for the control system and
finally the development of monitoring interface for the entire process.

16
3.1.1 Block Diagram of the Project:
The block diagram of the project is shown in fig. the temperature sensor gives the input to the
controller (PLC) according to that the controller gives output to heating and cooling source i.e.
heater and valve (as switching of valve gives the path to cooling source).

Fig 3.2: Block diagram showing different section of project

17
3.1.2 Process Flow Diagram:

Fig. 3.3: Process flow diagram of project

3.2 Temperature Controlling:

In the temperature controlling section basically we control the high-power electric heater of
(2.5 KW) there are different methods to control the heater but we adopt the method here PID-
controller with solid state relay this method is based upon PWM (pulse width modulation).
3.2.1 Heater Control Technique:
Since obtaining an accurate mathematical model is so difficult in addition to parameter
uncertainties and disturbance-adapted PID controller is preferred. The adaptation of PID is
carried out using the analogical gate. Analogical gates are a method of describing multi-valued
logical statements. The scope of operation of binary logic-based systems to true multi-valued
logic-based systems is widened based on the analogical gate. Furthermore, the design and
implementation of these gates for practical physical systems have proven to be efficient and
simple. [3] Analogical gates are of two kinds; symmetric and asymmetric. Symmetric gates
perform commutative operations similar to their logical counterparts OR, AND & XOR.
Asymmetric gates perform competence operations In adaptable PID controller, two gates are
employed OR and Invoke gates.

18
 3.2.1.1 Analogical-OR
In the analogical-OR gate, both inputs contribute to the output in relation to their magnitudes
and in the absence of one input; the output linearly tracks the other. the used formulation for
the analogical OR-gate is
𝒛 = 𝒙⨁𝒚 = 𝒙 ∗ 𝝃(𝒚, 𝒙) + 𝒚 ∗ 𝝃(𝒙, 𝒚) (𝟑. 𝟐)
𝑎𝑥 2 +𝑏𝑥𝑦
−( 2 2 )
𝑊ℎ𝑒𝑟𝑒 𝜉(𝑥, 𝑦) = 𝑒 𝑥 +𝑦 𝑎𝑛𝑑 𝑥, 𝑦 𝜖 𝑅
The parameter a and b are taken as a = 1.02889, b = 0.3574.
3.2.1.2 Analogical-Invoke
The invoke gate is characterized such that as the x-input grows, the share of the y-input to the
output increases. The absence of the x-input inhibits the output. In the absence of the y-input,
the x-input is linearly passed to the output. The used formulation or Invoke gate is
𝒛 = 𝒙 ∧ 𝒚 = 𝒙 ∗ 𝝃𝟏 (𝒚, 𝒙) + 𝒚 ∗ [𝟏 − 𝝃𝟐 (𝒙, 𝒚)] (𝟑. 𝟑)
Where
𝑎 𝑥 2 +𝑏 𝑥𝑦 𝑎 𝑥 2 +𝑏 𝑥𝑦
−( 1 2 12 ) −( 2 2 22 )
𝜉1 (𝑥, 𝑦) = 𝑒 𝑥 +𝑦 & 𝜉2 (𝑥, 𝑦) = 𝑒 𝑥 +𝑦 𝑎𝑛𝑑 𝑥, 𝑦 𝜖 𝑅
a1=1.4749267, b1=0.9280491, a2=2.6317713 and b2=-0.2287955.
The philosophy of adapted PID controller based on analogical gate does not depend on the
changing of PID controller parameters but it depends on changing the share of each controller
term on the total control action. As shown in Fig.4, output control command of adaptable PID,
"Upid", is given by analogical gates tuning proportional part "Up", integral part "Ui" and
derivative part "Ud" as in equations (3.4) and (3.5). [3] Two analogical gates will be used
sequentially. The first gate is selected to be asymmetric and the second gate is symmetric.
Analogical –INVK will be followed by analogical –OR as
𝑈𝑝 = 𝐾𝑝 𝑒(𝑡)
𝑡
𝑈𝑖 = 𝐾𝑖 ∫ 𝑒(𝜏) 𝑑𝜏
0
(3.4)
𝑑
𝑈𝑑 = 𝐾𝑑 𝑒 (𝑡) ]
𝑑𝑡
𝑈𝑝𝑖 = 𝑈𝑝 ∧ 𝑈𝑖
𝑈𝑝𝑑 = 𝑈𝑝 ∧ 𝑈𝑑 ] (3.5)
𝑈𝑝𝑖𝑑 = 𝑈𝑝𝑖 ⨁ 𝑈𝑝𝑑

3.2.2 Mathematical model of the heater:

Electrical heaters are usually difficult to control as they require large power.
There are basically two methods to control heaters.

19
These are:

 Phase angle control solid state relay

 Pulse width modulation control
3.2.2.1 Phase angle control
This is one of the common methods of power control where the start of each half-cycle is
delayed by an angle. Thyristors (or triacs) are usually used in such circuits and the triggering
angle is varied in order to change the power delivered to the heater element. Figure 8 shows a
typical thyristor-based phase angle control circuit. Assuming that the heater has a pure
resistance R, and the supply voltage has a peak value Vmax, it can be shown that the power
delivered to the heater element is:
𝑉 2 𝑟𝑚𝑠 𝑉 2 𝑚𝑎𝑥
𝑃= = (𝜋 − 𝛼 + 0.5 𝑠𝑖𝑛 2𝛼) (3.6)
𝑅 2𝜋𝑅

Where, each half cycle is delayed by an angle 90, (shown in fig. 3.5).

Fig. 3.4 Phase Angle control Schematic and

waveform

3.2.2.2 Pulse width modulation control

In this method, the heater current is turned on an off as in a pulse width modulated waveform,
where the period of the waveform is fixed but the ratio of the on-time to off-time is varied
according to the control voltage. If the applied voltage is AC., the output is a burst of full-
wave rectified pulses, where the pulse width of the on-time varies (see Figure 3.5).
In this project, a 220 V 3000W heater is used. A pulse width modulated voltage is applied to
the heater element in order to control the heating. The heater can be modeled as follows:

20
 Fig. 3.5: PWM output with AC wave.

A pulse width modulated waveform is

generated from the controller as shown in
Figure 3.7, where M and S are the marks and the
space of the waveform and T is the period, i.e.
T = M + S. This waveform is used to control an
SSR switch where the heater element is
connected as a load of this device.
The rms value of the current through the heater
element can be calculated as:

𝑻
Fig. 3.6: PWM output of PLC
𝟏
𝑰𝒓𝒎𝒔 = √ ∫ 𝒊𝟐 (𝒕)𝒅𝒕
𝑻
𝟎

𝑴
𝑰𝒓𝒎𝒔 = 𝑰𝒐 √ 𝑻 (3.6)

Assuming the heating element has a pure resistance, R, the average power delivered to the
heater can be calculated as

𝑷𝑨𝑽 = 𝑹𝑰𝟐𝒓𝒎𝒔
𝑴
= 𝑹𝑰𝟐𝒐
𝑻
𝑰𝟐𝒐
∝=𝑹
𝑻
𝑷𝑨𝑽 = ∝ .𝑴 (3.7)
Assuming the heating element has a pure resistance, R, the average power delivered to the
heater can be calculated as.
In this project,
R = 40 Ω Io = 5.5 A T= 2s
Thus, the transfer function of the heater is, from equation 3.7
PAV = 600 M
𝑷𝑨𝑽
Or = 𝟔𝟎𝟎 (3.8)
𝑴

Where M is in seconds and Power in watts.

21
3.3 System Identification By MATLAB:
We use MATLAB for System modeling by its toolkit system identification. System
Identification Toolbox provides MATLAB functions, Simulink blocks, and an app for
constructing mathematical models of dynamic systems from measured input-output data. It
creates and use usesssels of dynamic systems not easily modeled from first principles or
specifications. In this, we can can usee-domain and frequency-domain input-output data to
identify continuous-time and discrete-time transfer functions, process models, and state-space
models. The toolbox also provides algorithms for embedded online parameter estimation.
The toolbox provides identification techniques such as maximum likelihood, prediction-error
minimization (PEM), and subspace system identification. To represent nonlinear system
dynamics, you can estimate Hammerstein-Weiner models and nonlinear ARX models with
wavelet network, tree-partition, and sigmoid network nonlinearities. The toolbox performs
grey-box system identification for estimating parameters of a user-defined model. You can use
the identified model for system response prediction and plant modeling in Simulink. The
toolbox also supports time-series data modeling and time-series forecasting. [12]

Fig. 3.7: System Identification tool of MATLAB

We modeled close loop control system when conventional PID is used as a controller. The
sensors and actuators transfer function are known which are just straight-line equations and by
using the general transfer function of closed-loop control for negative feedback.

22
 𝐶(𝑠) 𝐺(𝑠)
= (3.9)
𝑅(𝑠) 1 + 𝐻(𝑠)𝐺(𝑠)
∴ 𝐺(𝑠) = 𝐺𝑐 (𝑠) 𝐺𝑃 (𝑠)
Where,
C(s) = Process Variable
R(s) = Reference Variable
H(s) = Loop Transmission
G(s) = Forward Path
Gc(s) = Controller
GP(s) = Plant

3.3.1 Close loop transfer function:

The close loop transfer function is

2.975 × 10−5
𝑇𝑟𝑎𝑛𝑠𝑓𝑒𝑟 𝐹𝑢𝑛𝑐𝑡𝑖𝑜𝑛 = 2
𝑠 + 0.0084𝑠 + 2.839 × 10−5
On substituting above transfer function, Gc(s) & H(s) in equation 3.9 and solving for
GP(s) we get
2.80 × 10−5 𝑠
𝐺𝑃 (𝑠) = 4
𝑠 + 100𝑠 3 + 23.84𝑠 2 + 0.19𝑠 + 6.53 × 10−4
For the calculation of GP (s) see Appendix I

3.4 Communication Between PC And PLC:

OPC protocol is used for communicating PC with PLC, the communication is made for
conveying image processing results from PC to PLC, for process controlling purpose and for
process monitoring purpose.
OPC Protocol is applicable in Server/Client pair. In OPC, the OPC server has the low-level
driver that talks the communication protocol of the field device.
The OPC server is not 'on' the PLC, the OPC server resides on a PC somewhere and the OPC
server talks the PLC's protocol in order to fetch or send data to the PLC, which it then transfers
to the OPC client. Figure 3.5 shows the OPC Server/Client architecture. The application in this
project includes the image processing and monitoring and controlling of the process. The
application itself has OPC client which communicates with the OPC server and server then
communicates with PLC.

23
 Fig. 3.8: OPC Architecture

KEP-SERVER OPC Simulation Server configuration shown in fig. 3.9

Fig. 3.9: OPC KEP-server Simulation Server Configuration

3.5 Project Hardware:

The complete hardware of the project is shown in fig. 3.10

Fig. 3.10: Complete Hardware view

24
3.5.1 Hot and Cold Chamber:
In our industrial hot and cold chamber there is an inner main tank in which fluid (water) is to
be heat or cool. There are two coiling of copper pipes in it one coiling is in the inner tank for
cooling the fluid and another one is outside the main tank which provides a diverting path to
the cooling source. there is a glass wool and spray foam insulation in between the inner tank
and outer (diverting) coil. This chamber also contains RTD PT-100 of sensing the current
temperature and a heater as a heating source. These all setup is covered up with wooden box
insulated with aluminum foil. The stages of this chamber fabrication are shown in fig. 3.11

Fig. 3.11 Stages of fabrication of hot and cold chamber

25
3.5.1.1 Methods to calculate the volume of the tank:
The volume of a cylindrical tank can be found by the following formula,
Vtank = 𝜋𝑟 2 ℎ (2.1)

Where ‘r’ is the radius of the bottom and ‘h’ is the height of the cylinder
as shown in fig.

3.5.1.2 Specifications of Tank:

 Length of the tank is 20 inches.
 The diameter of the tank is 14 inches.
 The total capacity of the tank is 50 liters.
 14 B&S Gauge thin sheet is used in the manufacturing of tank.
 The total mass of the tank is 30 kg. Fig. 3.12: Cylindrical tank

3.5.2 Insulation of a tank:

The tank is required to insulate to protect it from heat losses. Insulation of the tank is done by
glass wool insulator and spray foam.
3.5.2.1 Glass Wool:
Glass wool is an insulating material made from fibers of
glass arranged using a binder into a texture similar to wool.
The process traps many small pockets of air between the glass,
and these small air pockets result in high thermal insulation
properties. Glass wool is produced in rolls or in slabs, with Fig. 3.13 Glass Wool
different thermal and mechanical properties.
3.5.2.2 Spray Foam:
Spray foam is a chemical product created by two
materials, isocyanate and polyol resin, which react when mixed
with each other and expand up to 30-60 times its liquid volume
after it is sprayed in place. This expansion makes it useful as a
specialty packing material which forms to the shape of the
product being packaged and produces a high thermal insulating
value with virtually no air infiltration. Fig. 3.14 Spray Foam

3.5.3 Cooling Source:

For cooling the fluid in the system, we used the outer of Air
Conditioner (AC) as it is the cheapest and reliable source. Its
capacity is 1 ton one ton is equal to the amount of heat
required (288,000 Btu) to melt one ton of ice in a 24-hour
period.

Fig. 3.15: Cooling Source (outer)

26
3.5.4 Heating Source:
For heating the fluid in the system, we used a 3-phase electric heater with 2.5KWatt power.

3.6 Optocoupler Circuit:

In this circuit, we use an N25 optocoupler for switching digital output devices at the PLC
output circuit diagram and simulation shown below.

Fig. 3.16: Simulation of optocoupler circuit

3.7 Software:
Software implementation includes mainly the programming the PLC and communication setup
between PLC and PC and HMI software for monitoring and controlling the process.
3.7.1 WPL Soft:
WPL Soft is a program-editing software made for the Delta DVP-PLC series used under
WINDOWS. Except for general program planning and other general functions (e.g. cut, paste,
copy, multi-windows, etc.) of WINDOWS, WPL Soft, in addition, has provided various
Chinese/English commentary-editing and other special functions (e.g. survey and edit the listed
register, the setup, the data readout, the file saving, and monitor and set up diagrams of various
contacts, etc.). [11] What follows is the system requirement to comply with the operation
environment of WPL Soft:

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 Table 3.1: Specifications WPL Soft

Item System Requirement

Operation system Windows 95/98/2000/NT/ME CPU

CPU Pentium 90 or above

Memory 16MB or above (32MB or above is recommended)

Hard drive Capacity: at least 50MB or above CD-ROM (to install WPL Soft)

Monitor Resolution: 640×480, 16 colors or above

Mouse The mouse of general use or the device compatible with

Windows

Printer With the driver program of Windows installed

At least one of the ports among COM1 ~ COM4 should be

RS-232 port
connected with PLC

Compatible PLC model The Delta DVP-PLC Series

To program the controller, we used WPL soft. The complete program (Algorithm of Adaptable
PID) and logic are attached in Appendices II.

3.7.2 OPC KEP Server:

We used OPC KEO Server for communicating between PLC (Delta DVP 20SX2) and PC
(HMI-WinCC Flexible).

Fig. 3.17 KEP Server Channel (FYP)

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3.7.3 WinCC Flexible:
We developed HMI in WinCC Flexible. This HMI is used for process’s status indications,
communicating with PLC through OPC KEP Server, serve as an operating panel, monitor
process flow, data logging for the comparison of the responses of Conventional PID and
Adaptable PID and their individual trends. The snapshots of the HMI are in fig. 3.18 to 3.20.

Fig. 3.18 Main Screen in HMI

Fig. 3.19 Trends in HMI

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 Fig. 3.20 Process flow in HMI

3.7.4 MATLAB:
We used MATLAB for the obtaining comparison between the
response of the system through Adaptable PID and Conventional
PID. We were made two .csv files and make the comparative
response of both by MATLAB.

3.8 Overall Algorithm:

Following are the steps involved in the overall algorithm for the
Adaptable PID.

1. Error is generated by taking feedback from the temperature

transmitter (TT).
2. Proportional, integral and derivative control
action are generated separately.
3. Each control action is then passed into the tuning
network.
4. the final output is used to actuate the SSR.
The SAMA (Scientific Apparatus Makers
Association) diagram of overall algorithm shows
in fig. 3.18. Fig. 3.21 SAMA diagram of Overall Algorithm

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 CHAPTER 4
RESULTS AND DISCUSSION

4.1 Simulation Results:

The Comparative simulated result from MATLAB of Conventional PID and Adaptable
PID shown in fig 4.1

Fig. 4.1 Comparative Simulated Response of PID & Adaptable

PID
From the above simulation result the response parameters of both the controller is shown in
table 4.1
Table 4.1: Comparative Simulated Results of PID & Adaptable PID

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4.2 Practical Results:
The experimental result for both the controller Conventional and Adaptable PID is found by
Logging their data in .csv file in HMI software WinCC flexible. These files will access in
MATLAB and their comparative result shown in fig. 4.2

Fig. 4.2 Comparative Experimental Response of PID & Adaptable PID

From the above simulation result the response parameters of both the controller is shown in
table 4.1

Table 4.2: Comparative Experimental Results of PID & Adaptable PID

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4.3 Comparison of Simulation and Practical Results:

Table 4.3: Comparative Results of Simulation and Experiment of PID & Adaptable PID

Rise
Transient % %
Parameters Time Ess (0C) % Ess
Time (s) Overshoot Undershoot
(s)

PID
Simulation 300 2200 1.63 3.44 0.60 0.99

Experimental 450 2500 1.66 4.50 0.84 1.4

Adaptable PID

Simulation 375 650 0.06 0.00 0.04 0.06

Experimental 500 700 0.12 0.01 0.1 0.16

The selected parameters in the process simulation are implemented through the programming
of PID controller in Delta PLC (DVP 20 SX2) with the following parameter Kp = 100, Ki= 23
and Kd= 1. The practical PID and Adaptable PID response of the process is shown in fig. 4.3
for a step temperature 60°C.

A comparison between the practical results of PID and adapted PID is summarized in Table
4.3 It is noted that adaptable PID controller has produce faster response by 1800s and reduce
the steady state error (ESS) by 88% than the PID controller these due to the online tuning of
control command of PID controller (Up,Ui and Ud) based on analogical gate technique that
explained previously.

However, both simulation and practical results are well correlated and insure the effectiveness
of the proposed adaptable PID algorithm.

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 CHAPTER 5
CONCLUSION AND RECOMMENDATIONS

5.1 Conclusion:
Industrial Hot and cold chamber have wide applications like food processing, metal
production and climate testing in quality control etc. but from high to low transition of heat
and vice versa using these can cause thermal shock and shocks intensity changes depending
on the range of heat transition widely PID is used for the hot and cold chamber control
systems others include Fuzzy, Model Predictive Control (MPC) etc., rare of these can be
implemented using PLC due to time, computation constraints and cost. In case of PID
obtaining mathematical model is so difficult in addition to parameter uncertainties and
disturbance and cannot compensate for the continued changes in both, due to inherent
characteristics of the chamber, so in order to solve the above-mentioned problems, PID
needs to be adaptable.
The approach we have adopted is both simple and novel. We employ Analogical gates on
a set whose elements are continuous in time. These gates can be regarded as a fuzzy
operation. Using analogical we construct behavior circuits that process individual behavior
to produce a desired “plausible” overall behavior. The philosophy of adapted PID controller
based on analogical gates. It does not depend on the changing of PID controller parameters
but it depends on changing the share of each controller term on the total control action.
Finally, although PLCs have built-in application for PID controller there is no option for it
to be adaptable, so we will provide an adaptable PID controller implemented in PLC by
using analogical gates for our hot and cold chamber.

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[5] E. Badreddin, "Fuzzy relations for behavior-fusion of mobile robots",Proc. IEEE Conf. on
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[12] https://www.mathworks.com/help/ident/

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