Improving Boiler Efficiency Using PLC Controller

2018 ◽  
Author(s):  
Hung Tang ◽  
Ma'moun Abu-Ayyad
Keyword(s):  
Manufacturing Industries ◽  
Programmable Logic ◽  
Steam Temperature ◽  
Operator Console ◽  
Variable Frequency Drives ◽  
Boiler Efficiency ◽  
Water Feed ◽  
Machine Interface ◽  
High Degree ◽  
Manual Mode

Boiler systems have many factors that affect the efficiency of the air conditioning process. A traditional control system is complicated and requires physical hardware and software programming. The modern operator console is more compact and works better. Regardless of the boiler system, the operator can run it automatically, allowing changes in many variables such as fuel input, air combustion, water feed flow, steam temperature, etc. In fact, it is impossible to control all of these variables simultaneously in the manual mode. Modern systems have been developed to a high degree of precision that can provide excellent results in maintaining high levels of efficiency, reliability, and safety. The Programmable Logic Controller (PLC) was developed in 1968, and since then it has improved rapidly and applied to many manufacturing industries. Besides the Allen Bradley PLC, other modules were developed such as Human Machine Interface (HMI), Variable Frequency Drives (VFDs), and safety components. In this paper, the Allen Bradley PLC ControlLogix family 1756 model is used to control the boiler system. In addition, this work focuses on improving the boiler efficiency by comparing between the manual and automatic control the fuel-air ratio.

The Control System Design of Copper Sleeve Press-Fit Machine

2012 ◽  
Vol 174-177 ◽  
pp. 394-398
Author(s):  
Xin Ma ◽  
Hong Li Li
Keyword(s):  
Control System ◽  
Work Force ◽  
Protective Measures ◽  
Press Fit ◽  
Automatic Mode ◽  
The Press ◽  
Machine Interface ◽  
Automobile Parts ◽  
High Degree ◽  
Manual Mode

The copper sleeve press-fit machine is a kind of device applied in automobile parts processing. The machine is used to press nine copper sleeves into a mold with nine holes. An automatic control system based on PLC is designed. CPU 224 of Siemens S7-200 series PLC is adopted as the core controller. The machine can be operated by either the human-machine interface or the pushbutton panel. There are all ten cylinders in this machine. The operation sequence and interlock protection of the ten cylinders are controlled by the PLC. In this system there are some necessary fault alarms and protective measures. The machine can be operated in manual mode or automatic mode. The press-fit machine is designed to operate simple with the high degree of automation and reliability, thereby saving work force and enhancing the efficiency of automobile parts production.

scholarly journals Improved Mutual Understanding for Human-Robot Collaboration: Combining Human-Aware Motion Planning with Haptic Feedback Devices for Communicating Planned Trajectory

Sensors ◽  
2021 ◽  
Vol 21 (11) ◽  
pp. 3673
Author(s):  
Stefan Grushko ◽  
Aleš Vysocký ◽  
Petr Oščádal ◽  
Michal Vocetka ◽  
Petr Novák ◽  
...  
Keyword(s):  
User Study ◽  
Haptic Feedback ◽  
Fundamental Aspect ◽  
Task Completion ◽  
Good Efficiency ◽  
Notification System ◽  
Movement Data ◽  
Novel Approach ◽  
Machine Interface ◽  
High Degree

In a collaborative scenario, the communication between humans and robots is a fundamental aspect to achieve good efficiency and ergonomics in the task execution. A lot of research has been made related to enabling a robot system to understand and predict human behaviour, allowing the robot to adapt its motion to avoid collisions with human workers. Assuming the production task has a high degree of variability, the robot’s movements can be difficult to predict, leading to a feeling of anxiety in the worker when the robot changes its trajectory and approaches since the worker has no information about the planned movement of the robot. Additionally, without information about the robot’s movement, the human worker cannot effectively plan own activity without forcing the robot to constantly replan its movement. We propose a novel approach to communicating the robot’s intentions to a human worker. The improvement to the collaboration is presented by introducing haptic feedback devices, whose task is to notify the human worker about the currently planned robot’s trajectory and changes in its status. In order to verify the effectiveness of the developed human-machine interface in the conditions of a shared collaborative workspace, a user study was designed and conducted among 16 participants, whose objective was to accurately recognise the goal position of the robot during its movement. Data collected during the experiment included both objective and subjective parameters. Statistically significant results of the experiment indicated that all the participants could improve their task completion time by over 45% and generally were more subjectively satisfied when completing the task with equipped haptic feedback devices. The results also suggest the usefulness of the developed notification system since it improved users’ awareness about the motion plan of the robot.

scholarly journals PROGRAMMABLE LOGIC CONTROLLER TRAINING STANDS FOR EDUCATIONAL PURPOSES

2020 ◽  
pp. 274-280
Author(s):  
Michal Kelemen ◽  
Peter Ján Sinčák
Keyword(s):  
Programmable Logic Controller ◽  
Future Application ◽  
Programmable Logic ◽  
Training Set ◽  
Controlled System ◽  
Small Device ◽  
Logical State ◽  
Machine Interface ◽  
Practical Experiences ◽  
Application Developers

Urgency of the research. Programmable logic controller are devices for controlling of various systems also in industry. If controlled device is complicated, it is problem to debug application, because of risk of its damage. For this purpose is better to use hardware training stand for testing of your designed application. Target setting. Training stand is as compact small device which is easy to move to another place. Also it allows to connect other hardware device for testing. Logical state hardware simulator is also designed for simulation of logic system with any user inputs with buttons or switches and also witch coloured lights for visualisation of output state.Actual scientific researches and issues analysis. Training set allows to make simulation of control system with real parts before its practical use with expensive controlled system, where any mistake can cause a huge economist loses, but errors occurred during the simulation on training set only make warning and shows the weak place on design. Uninvestigated parts of general matters defining. The questions of the networked structure of programmable logic controller structures are uninvestigated, so the next research will be focused to this. The research objective. The main goal is to create a compact device for training future application developers with a programmable logic controller, but it is also usable for developers from practice, who need to debug the program before installing it into real operation. The statement of basic materials. Existing training sets are large and expensive devices that are not easy to carry and cannot be expanded. Working with such devices is quite complicated. The designed training stand is a flexible and easily portable device. Conclusions. Main contribution is that students will gain practical experiences and skills that are essential for PLC programmers. This device supports also own creativity of students, because it allows to modify hardware composition. It uses the DIN rail system similar as in real installation cabinet. The stand also includes the human-machine interface for training of practical using of these devices.

scholarly journals PID Controller Implemented in Festo CDPX

2019 ◽  
Vol 260 ◽  
pp. 02008
Author(s):  
Primož Podržaj
Keyword(s):  
Control Systems ◽  
Pid Controller ◽  
Control Algorithm ◽  
Closed Loop ◽  
Pi Control ◽  
Programmable Logic ◽  
Educational Tool ◽  
Level Control ◽  
Loop Control ◽  
Machine Interface

In this paper, we describe the procedure for the implementation of the PID controller in the Festo CDPX operator unit. These units enable the execution of the control algorithm and human machine interface in a single unit. In our laboratory the unit is used to teach the students about the basics of control systems. For this purpose, one of the most common closed loop control systems for the education purposes was selected. It is a water level control system. In this paper the design of the whole system is presented. The need for a PI control algorithm is also explained. The programming of the operator unit CDPX, both in Festo CoDeSys and Designer Studio is explained. Such a simple system has turned out to be a great educational tool for Control Theory and Programmable Logic Controller related subjects.

Experimental and Simulation Study on the Effects of Twisted Coil Plates on the Performance of Fire Tube Boiler

2014 ◽  
Vol 564 ◽  
pp. 234-239
Author(s):  
M.K. Roslim ◽  
Suhaimi Hassan ◽  
K. Izzati
Keyword(s):  
Flue Gas ◽  
Operating Time ◽  
Width Ratio ◽  
Gas Temperature ◽  
Steam Temperature ◽  
Ansys Fluent ◽  
Boiler Efficiency ◽  
Twist Ratio ◽  
Fluent Simulation ◽  
Tube Coil

Influences of twisted coil plate insert on the performance of fire tube boiler using were experimentally investigated. In this study, the twisted coil plate was placed inside the tube to illustrate boiler performance. The performances of boiler were studied in terms of operating time taken, exhaust flue gas temperature, steam temperature and boiler efficiency. The boiler was operated with 50%, 100% and without tube coil plate inserts at low and high fire burner setting. Based on the results obtained, effect of twisted plate insert and without insert were observed. There is an enhancement in boiler performance in terms of boiler efficiency. The ANSYS Fluent simulation showed the effect of width ratio and twist ratio. Therefore, the experimental results indicate that using twisted coil plate in the boiler is one of the best ways to improve boiler performance.

scholarly journals Perancangan dan Simulasi Trainer Human Machine Interface (HMI) untuk media pembelajaran berbasis CX Designer PLC

2020 ◽  
Vol 4 (2) ◽  
pp. 136-145
Author(s):  
Fitroh Anugrah Kusuma Yudha ◽  
Bambang Riyanta
Keyword(s):  
Programmable Logic Controller ◽  
Human Machine Interface ◽  
Programmable Logic ◽  
Machine Interface

Penelitian ini bertujuan untuk membuat rancangan media pembelajaran pada mata kuliah Programmable Logic Controller (PLC) berupa trainer Human Machine Interface (HMI) berbasis CX Designer yang terintergrasi dengan CX-Programmer. Desain HMI yang tepat akan membuat pengujian program lebih mudah dan efisien. Sebagai media pembelajaran HMI memberikan efektifitas informasi yang dibutuhkan, sehingga perencanaan dapat dilakukan dengan efisiensi yang maksimal. Metode penelitian yang digunakan adalah metode eksperimental dan pembuatan rancangan produk berupa trainer untuk penguji program oleh mahasiswa atau operator. Dapat disimpulkan hasil dari penelitian ini bahwa penggunaan simulasi HMI berbasis CX Disigner dapat digunakan untuk memahami logika rangkaian suatu program dengan sangat mudah dan cepat untuk melatih ketrampilan pemograman PLC.

scholarly journals SISTEM MONITORING SUHU MELALUI SISTEM KOMUNIKASI PROGRAMMABLE LOGIC CONTROLLER TO PERSONAL COMPUTER

2016 ◽  
Vol 7 (3) ◽  
Author(s):  
Triyanto Pangaribowo ◽  
Hibnu Yulianda
Keyword(s):  
Personal Computer ◽  
Programmable Logic Controller ◽  
Human Machine Interface ◽  
Programmable Logic ◽  
Machine Interface

Pada penelitian ini memanfaatan PLC (Programable Logic Controller) untuk  monitoring  suhu  yang  diterapkan  pada  Building  Auto  System.  PLC merupakan  suatu  controller  yang  umum  digunakan  pada  dunia  industri.  PLC digunakan untuk memonitoring sistem kerja panel dalam satu gedung dalam jarak yang  jauh  dengan  memanfaatkan  komunikasi  PLC  sebagai  indicator  status ON/OFF  serta  pembacaan  suhu.  Sebagai  interface  antara  PLC  dan  user,  maka digunakan HMI (Human Machine Interface).Pemanfaatan PLC sebagai monitoring dilakukan pada sebuah gedung yang memiliki  sistem  kontrol  dalam  jumlah  yang  banyak  serta  memiliki  jarak  yang jauh.  Pada  penelitian  ini  dilakukan  pengujian  sistem  monitoring  menggunakan koneksi  PLC  To  PC,  PLC  To  PLC  dengan  PC.  Untuk  koneksi  menggunakan protocol  Modbus  serial  RS485.Aplikasi  yang  dirancang  untuk  sistem  monitoring ini  lebih  efektif,  karena  dapat  menghemat  waktu  dan  memudahkan  dalam mengetahui status suatu kontrol apakah bekerja atau tidak.Berdasarkan  hasil  Analisa  dan  pengukuran  respon  waktu  sistem  terhadap perubahan suhu untuk setiap kenaikan rata-rata 2,4 oC pada sistem koneksi PC to PLC  rata-rata  2,6  detik,  dan  Pada  sistem  monitoring  PLC  to  PLC  yang ditampilkan pada layar PC memiliki respon waktu terhadap perubahan suhu untuk setiap  kenaikan  rata-rata  2,3  oC  rata-rata  2,67  detik.  Sistem  monitoring  mampu bekerja pada jarak 100 meter Kata kunci : PLC To PC ,Monitoring, HMI, Modbus.

Rancang Bangun Sistem Kendali Level Air Berbasis Programmable Logic Controller dan Human Machine Interface

Kilat ◽  
2021 ◽  
Vol 10 (2) ◽  
pp. 272-279
Author(s):  
Tri Wahyu Oktaviana Putri ◽  
Muhammad Imbarothur Mowaviq ◽  
Ibnu Hajar
Keyword(s):  
Pulse Width ◽  
Pulse Width Modulation ◽  
Programmable Logic Controller ◽  
Human Machine Interface ◽  
Programmable Logic ◽  
Machine Interface ◽  
Modulation Level ◽  
Analog Output

hingga industri. Salah satu penerapan perlunya mengendalikan level air adalah pada boiler suatu pembangkit. Berbagai pengendalian terhadap suatu besaran di industri tentu memerlukan perangkat pengendali. Programmable Logic Controller (PLC)  Rancang bangun sistem kendali level air dengan menggunakan PLC dan Human Machine Interface (HMI) ini menggunakan perangkat utama yaitu PLC FX3U yang dilengkapi dengan input analog, output analog, dan output PWM (Pulse Width Modulation). Level/ ketinggian air adalah objek yang akan dikendalikan. Suplai air diatur oleh pompa air DC yang terdiri atas pompa inlet dan pompa outlet. Sedangkan untuk sensor ketinggian air menggunakan sensor ultrasonic HC-SR04. Untuk memudahkan pengoperasian PLC, PLC dapat dikombinasikan dengan HMI yang mana terhubung di dalam jaringan dengan PLC. Untuk aplikasi jangka panjang, rancang bangun sistem kendali level air berbasis PLC FX3U dan HMI dapat difungsikan sebagai media pembelajaran di kelas pada mata kuliah yang berkaitan dengan elektronika industri, PLC, maupun mata kuliah lain. Berdasarkan pengujian dengan menggunakan kontroler PID di dalam PLC, diperoleh hasil bahwa ketinggian air dapat dikendalikan dengan eror rata-rata sebesar 3%. Nilai tersebut disebabkan karena perilaku dinamik air.

scholarly journals PLC/HMI-Based Implementation of a Real-Time Educational Power System Protective Relays Platform

Electronics ◽  
2020 ◽  
Vol 9 (1) ◽  
pp. 118
Author(s):  
Jawad Radhi Mahmood ◽  
Ramzy Salim Ali ◽  
Raed A. Abd-Alhameed
Keyword(s):  
Power System ◽  
Real Time ◽  
Engineering Students ◽  
Operation Time ◽  
Human Machine Interface ◽  
Time Response ◽  
Programmable Logic ◽  
Protective Relaying ◽  
Machine Interface ◽  
Protective Relays

Engineering laboratories are key elements in engineering learning and are essential for a concrete understanding of engineering topics and experiments. These key laboratories are no longer just hardware-dependent, they are a creative combination of programmable hardware and also user-defined driving software. In this work, an educational power system protective relaying laboratory platform was designed and implemented using a programmable logic controller (PLC) and human–machine interface (HMI) in order to introduce engineering students to the operating mechanisms experimentally. It engaged the students in selecting settings and upgrading the inverse definite minimum time (IDMT) protection relays for overcurrent, overvoltage, undervoltage, and differential current. With the platform and the help of the HMI, the students mastered (or came close to mastering) the field of protective relays, especially those explicitly implemented in the platform. The students were also able to see the real-time response that is equivalent to the relay operation time of the protective relays under the various possible settings, and the kinesthetic learning that was involved gave them a deeper understanding of what is involved in relays upgrading.

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