On the practical integration of anomaly detection techniques in industrial control applications

An industrial process control application of level and temperature is considered. The nonlinear mathematical model of the system is cast as a linear parameter varying (LPV) system. A linear matrix inequality (LMI) type of controller is successfully designed using the LMI unified approach to regulating both controlled variables, namely; temperature and level. The closed loop system is then implemented through computer simulation to show the effectiveness of the controller in performing the combined level-temperature regulation. Basically, this combined level and temperature industrial control application is used to demonstrate the effectiveness of post-modern controllers; in this case LMI based controllers.

This paper presents the modeling and controlling of a fuzzy logic controller (FLC) for achieving improved dynamic performance of the Brushless DC (BLDC) motor drive. The performance of fuzzy and the PI controller based BLDC motor drives is investigated under the different operating conditions such as change in reference speed, parameter variations and the load disturbance. BLDC motors are used in industrial control, automation and instrumentation system applications. Based on other applications the conventional controllers like P, PI and PID controllers are used in the BLDC motor drive control systems to achieve the desired level of transient and steady state responses. However, the major problem in the conventional PI controller there is some variations in the parameter and some load disturbances are occur and do not yield the better transient and the steady state responses under the operating conditions. In this paper, the modeling and controlling of fuzzy logic controller is presented its performance and it compared with the PI controller shows the error capability and usefulness of the fuzzy controller in the control applications.

In this paper, an integrated system to control and manage a state-of-the-art industrial computer numerical control (CNC) machine (Studer S33) using a commercially available tablet (Samsung Galaxy Tablet S2) is presented as a proof of concept (PoC) for the ubiquitous control of industrial machines. As a PoC, the proposed system provides useful insights to support the further development of full-fledged systems for Industrial Internet of Things (IIoT) applications. The proposed system allows for the quasi-decentralisation of the control architecture of conventional programmable logic controller (PLC)-based industrial control systems (ICSs) through data and information exchange over the transmission control protocol and the internet protocol (TCP/IP) suite using multiple agents. Based on the TCP/IP suite, a network device (Samsung Galaxy Tablet S2) and a process field net (PROFINET) device (Siemens Simatic S7-1200) are interfaced using a single-board computer (Raspberry Pi 4). An override system mainly comprising emergency stop and acknowledge buttons is also configured using the single-board computer. The input signals from the override system are transmitted to the PROFINET device (i.e., the industrial control unit (ICU)) over TCP/IP. A fully functional working prototype is realised as a PoC for an integrated system designated for the wireless and ubiquitous control of the CNC machine. The working prototype as an entity mainly comprises a mobile (handheld) touch-sensitive human-machine interface (HMI), a shielded single-board computer, and an override system, all fitted into a compact case with physical dimensions of 300 mm by 180 mm by 175 mm. To avert potential cyber attacks or threats to a reasonable extent and to guarantee the security of the PoC, a multi-factor authentication (MFA) including an administrative password and an IP address is implemented to control the access to the web-based ubiquitous HMI proffered by the PoC.

This article explores the widespread application and importance of the Programmable Logic Controller (PLC) in industry. PLC, as an industrial controller designed specifically for industrial environments, occupies an important position in the field of industrial automation control due to its advantages of being less susceptible to interference, high reliability, easy programming, fast installation, and small size. With the rapid development of PLC technology, great progress has been made in the development of technology, hardware, and software, resulting in increasingly powerful functionalities and significantly enhanced system development and compatibility. This paper mainly analyzes the design ideas and applications of PLC in life and industry in detail, aiming to research PLC and find more scenes in industry fields in which PLC can participate. PLC has a wide range of applications and significant importance in industry. The continuous progress and innovation of its technology will bring more opportunities and challenges to the field of industrial automation control. In the future, with the deepening development of advanced manufacturing models such as Industry 4.0 and intelligent manufacturing, PLC technology is expected to play a greater role in more fields and promote industrial automation to a higher level.

This paper investigates the strict reliable and timely requirements of the hard real traffic based control packets in the industrial control applications. As a result, a framework is proposed with two novel approaches intended to meet the strict deadline requirements and reliability requirements of the industrial control packets. The first novel approach, timed control panel incorporates timed token protocol to provide guaranteed channel access time to each station present in the wireless ring structure. The second novel approach, adaptive sub-MAC Hybrid Automatic Repeat Request (HARQ) reduces the packet error rate and the packet loss rate by reducing the size of MAC frame by half. The mathematical analysis and simulation results show that the proposed framework ensures in providing the reliable and timely communications for Industrial control applications.

Current wireless technologies for industrial applications, such as WirelessHART and ISA100.11a, use a centralized management approach in which a central network manager handles the requirements of the static network. However, such a centralized approach has several drawbacks. For example, it cannot cope with dynamicity/disturbance in large-scale networks in a real-time manner while it also incurs a high communication overhead and latency for exchanging management traffic. In this thesis, we address the drawbacks of the centralized management approach utilized in WirelessHART and ISA100.11a for real-time industrial monitoring and control applications. More specifically, we propose new decentralized network management schemes to provide an end-to-end reliable and real-time communication for battery-powered and harvested-powered devices in a distributed manner. These schemes enable the network devices to join the network, schedule their communications, establish end-to-end connections by reserving communication resources to address real-time requirements, and cope with network dynamicity (e.g., node/edge failures) in a distributed manner. To evaluate wireless protocols in the domain of industrial monitoring and control, a reference point is needed. To that end, we developed a WirelessHART simulator in NS-2 as a reference point to evaluate other protocols. We validated the WirelessHART simulator with a WirelesHART deployment at an industrial plant. To the best of our knowledge, this is the first implementation that supports the WirelessHART network manager as well as the whole stack of the WirelessHART standard. To address the requirements of battery-powered I/O devices, we propose a distributed management scheme to address real-time and reliable communication requirements. This scheme considers the full mesh topology in which I/O devices are capable of participating in routing and distributed network management tasks, such as communication resources scheduling. We then propose a second distributed management scheme for hybrid networks to be used for real-time industrial wireless automation. This scheme addresses the requirements of energy constrained I/O devices. In this scheme, the I/O devices cannot participate in routing and distributed management tasks. The routers can dynamically reserve communication resources and manage the I/O devices in the local star sub-networks. We demonstrate that the proposed scheme achieves higher network management efficiency compared to the ISA100.11a standard, without compromising the latency and reliability requirements of industrial wireless networks. To better support and address the requirements of energy harvested I/O devices, we extend ISA100.11a. The proposed extension makes management more decentralized by delegating a part of the management responsibility to the routers in the network. It also allows the I/O devices to choose the best routers according to different metrics using local statistics and advertised routers’ ranks.

Programming languages such as C, QuickBASIC and Programmable Logic Controller (PLC) ladder logic have been part of Engineering Technology curriculums for years. The increasing availability of powerful and low-cost computing hardware, graphical user interface based multitasking operating systems, visual programming languages, and new programming standards have provided the environment for the implementation of Rapid Application Development (RAD) programming techniques. Examples of these techniques such as menu, text, graphical, and icon based programming are presented. Their widespread use for mainstream industrial control and data acquisition applications have resulted in a migration away from the use of traditional programming languages. The implications of this migration for the content of Engineering Technology curriculums are explored.

The paper provides a review of application research of multi-agent theories in industrial process control. Firstly, we introduce characteristics of industrial process control. Then, a comprehensive description of some research achievements for multi-agent theory problems, such as the architecture, algorithm, coordination, cooperation, negotiation, and communication, applied in industrial process control, is introduced to identify main research lines. Further multi-agent theories and applications in industrial process control are discussed in detail, and their significance is revealed, which applies directions for the further research and improvement.

As the digital control field incorporates new technology (e.g., bubble memory, very large scale integration (VLSI), fiber optics, Josephsen junctions, etc.), the development of new control tools is advancing at a rapid pace. The board-level microcomputer (MC) and the programmable controller (PC) are two types of controller spinoffs from today's technology. The similarity in the architecture and functions of these units makes proper selection difficult. Guidelines for the selection of MC or PC in industrial control applications are provided.

Touch screen is monitoring equipment used in industrial field, whose applications in industrial control will be more and more widely. With the continuous development of PC technology, the traditional man-machine interface will gradually be replaced by the man-machine interface as touch screen and so on. This paper studies structure and function of modular production system (MPS). It emphasizes on how MPS is reformed based on EV touch screen configuration and PROFIBUS-DP Field Bus. S7-300PLC as master communications with S7-200 PLCS through PROFIBUS-DP Field Bus and touch screen communications with S7-300PLC through the MPI adapter constitutes a control network. The touch screen is configured by EV5000 Configuration software, to complete the dynamic process monitoring of MPS system module, and improve the monitoring software so that it will have a simple user login management, production management, production information display and alarm functions.

Knowing when a process has changed would simplify the search for and identification of the special cause. Consequently, having an estimate of the process change point following a control chart signal would be useful to process engineers. Much of the literature on change point models and techniques for statistical process control applications consider processes well modelled by the normal distribution. However, the Poisson distribution is commonly used in industrial quality control applications for modelling attribute-based process quality characteristics (e.g., counts of non-conformities). Some commonly used control charts for monitoring Poisson distributed data are the Poisson cumulative sum (CUSUM) and exponentially weighted moving average (EWMA) control charts. In this paper, we study the effect of changes in the design of the control chart on the performances of the change point estimators offered by these procedures. In particular, we compare root mean square error performances of the change point estimators offered by the Poisson CUSUM and EWMA control charts relative to that achieved by a maximum likelihood estimator for the process change point. Results indicate that the relative performance achieved by each change point estimator is a function of the corresponding control chart design. Relative mean index plots are provided to enable users of these control charts to choose a control chart design and change point estimator combination that will yield robust change point estimation performance across a range of potential change magnitudes.

The characteristics and applications of the system for welding machines based on SCM , based on PLC control system and PC-based industrial control system was introduced. It has certain significance to the design of welding machine control system.

Knowledge Engineering for Industrial Expert Systems

Programmable logic controllers (PLC) as the backbone of industrial automation adapt to each subsequent wave of technology. This is still true today, almost six decades after the first Modicon 084 programmable controller developed for General Motors. Innovations such as artificial intelligence, cloud and edge computing, IIoT, 5G networks, augmented and virtual reality are penetrating all possible areas of industry, and PLC controllers are no exception. Equipped with a modern functional arsenal, these compact industrial computer systems become the basic building block of intelligent automation, digitalization and Industry 4.0, enabling dynamic regulation and management of industrial processes based on data via real-time feedback. The global market for PLC systems is estimated at US$ 12.2 billion in 2024. It is expected to exceed 15 billion dollars by 2029. PLC controllers, which traditionally serve as the basis of process and discrete industrial automation, are becoming more widespread today adopting the principles of Industry 4.0 in various sectors. The impact on the increase in the need for them is the increased application of industrial robots in the automotive, electrical engineering and other industries. The industrial robotics sector is among the leading contributors to development of PLC systems and is becoming a key driver of the further development of the programmable controller market, and forecasts are that this trend will continue with the development of increasingly widespread robotization in factories around the world. According to the data of the IFR (International Federation of Robotics) from 2024. almost 4.3 million robots are already in operation.

This paper proposes a machine vision module for PLCs (Programmable Logic Controllers). PLC is the industrial controller most widely used in factory automation system. However most of the machine vision systems are based on PC (Personal Computer). The machine vision system embedded in PLC is required to reduce the cost and improve the convenience of implementation. In this paper, we newly propose a machine vision module based on PLC. The image processing libraries are implemented and integrated with the PLC programming tool. In order to interface the libraries with ladder programming, the ladder instruction set was also designed for each vision library. By use of the developed system, PLC users can implement vision systems easily by ladder programming. The developed system was applied to sample inspection system to verify the performance. The experimental results show that the proposed system can reduce the cost of installing as well as increase the ease-of-implementation.