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
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
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
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
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
About PlantCommunication
OPCSimulink Models and ResultsRole of MATLAB/Simulink
Flow Loop Plant
Figure: Flow Loop Plant
Pritesh Shah,Prof Sudhir Agashe
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
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
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
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
About PlantCommunication
OPCSimulink Models and ResultsRole of MATLAB/Simulink
OPC Communication Block Diagram
Figure: OPC Communication Setup
Pritesh Shah,Prof Sudhir Agashe
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
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
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
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
About PlantCommunication
OPCSimulink Models and ResultsRole of MATLAB/Simulink
Simulink Model for Fractional PID Controller
Figure: Simulink ModelPritesh Shah,Prof Sudhir Agashe
About PlantCommunication
OPCSimulink Models and ResultsRole of MATLAB/Simulink
Subsystem for Plant
Figure: Simulink Model
Pritesh Shah,Prof Sudhir Agashe
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
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
About PlantCommunication
OPCSimulink Models and ResultsRole of MATLAB/Simulink
FIS for Fuzzy Controller
Figure: Fuzzy FIS
Pritesh Shah,Prof Sudhir Agashe
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
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
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
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
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
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
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
About PlantCommunication
OPCSimulink Models and ResultsRole of MATLAB/Simulink
Thank [email protected]
Pritesh Shah,Prof Sudhir Agashe