This document describes the development of a dynamic control system for industrial applications using a Siemens S7-300 PLC and various sensors. The system uses two-position control, feedforward control based on linear relationships between process variables, and feedback control using a PID algorithm. It allows both manual and automatic control modes. Data is exchanged between the PLC and SCADA software using OPC/DDE communication.

1. BY
JAYARAM .K.S(31708107043)
INTERNAL GUIDE-Mr. VIJAYA RAMRAJ
RANGAM ,M.E., (Assistant PROFESSOR)
Department Of ICE
DYNAMIC CONTROL SYSTEM
WITH RESPECT TO A LINEAR
RELATIONSHIP

2. INTRODUCTION
• To analyze the operation of a control system on a real
time basis which can be applied in an industrial field.
• System Control is achieved by using a Two
postion,feed forward and a feedback loop with Alarm
circuitry for interlocks operation.
• To develop a security based control system using
SCADA for controlling and monitoring system
parameters.

3. • Temp Sensor (LM 35 -10mV/°C)
• Pressure Sensor (M5100)
• PAC (Siemens S7-300)
• VFD(MM440)
• 3 phase IM
• Tachogenerator
• OPC /DDE (KEPSERVER EX V4.0)
• SCADA (Wonderware software)
COMPONENTS

4. FLOW OF CONTROL
START
Auto
LM 35
SCAD
A
PLC
Frequency
Converter (V/f)
3 ph
IM
Yes
Set speed
N
o
Analog i/p
Analog
olp
Selector S/W
Manual
Tachogen
FEEDBACK
FEEDFORWARD
• PV – O/P of tachogen (y’)
• CV – Actual speed
• SP – Set speed (y)
• e = PV ~ SP

5. FIELD APPLICATION
RECYCLING
WASTE PAPER
TONNES OF
PAPER IS
ROLLED
DIMENSIONS
MAINTAINED –
ROLLING MILLS
IF ANY DIFFERENCE IN
DIMENSION ON EITHER END
BASED ON LINEARITY OF
DIMENSION vs RPM , SPEED IS SET
1. PAPER INDUSTRY
INLET VAPOURS
IN KOD
HEAT DUE TO
EXOTHERMIC
REACTION
INC IN TEMP SHOWS
INC IN VAPOUR
NEED MORE
COMPRESSION
INCREASE IN
SPEED OF IMPELLER
IMPELLER
COMPRESSES
VAPOUR
HEAT REDUCED
RESULTS
COMPRESSION
REDUCTION
2. CHEMICAL INDUSTRY

6. • It regulates the temperature based on a set point within a band
to achieve an on/off control action of the heating element
• This is measured with a help of a temperature sensor (LM35)
which gives an unconditional signal (10mV/°C)
TWO POSITION CONTROL
SYSTEM

7. • Predictive control as the rpm is determined based on
temperature/pressure using the principle of linearity
(y=mx+C).
FEEDFORWARD CONTROL
SYSTEM
rpm (y)
temp/press
(x)
x1 x2
y1
y2
x
y Temp/Pressure
vs. rpm
(linearity)
FEEDFORWARD

8. • Variable speed is achieved using VFD that
generates variable frequency supply with constant
voltage to frequency ratio.[Performance range :
0.12 – 250KW]
MICROMASTER 440

9.  MOTOR PLATE DETAILS
• Select Motor Type – Asyn.motor ( 3ph IM )
• Rated Motor Voltage – 415 V
• Rated Motor Current – 1.4 A
• Rated Motor Power – 0.37 KW
• Rated Motor cosØ – 0.8
• Rated Motor Efficiency – 70%
• Rated Motor Frequency – 50 Hz
• Rated Motor Speed – 1440 rpm
 CONTROL MODE
• Selection Of Command Source – BOP
COMMISSIONING THE DRIVE BASED
ON APPLICATION

10. • The PID controller algorithm is used to reduce the error
between SP and the PV which is compensated by CV,
reduce amplitude & oscillations, quick settling and act as
an Energy Management System.
• In this system we have designed a PID controller with
Manual and Auto mode to enhance ease of operations
FEEDBACKWARD CONTROL SYSTEM

11. MANUAL Vs. AUTO MODE
CONTROLLER
FREQUENCY
CONVERTER
TACHOGEN
Analog i/p
temp (x)
Slope
cal
Analog o/p
rpm (y)
3 ph
IM
V/f
Actual speed (y’)
SCADA
LM 35
CONTROLLER
FREQUENCY
CONVERTER
TACHOGEN
3 ph
IM
V/f
Actual speed (y’)
Set speed
Manually in % (y)
SCADA
Analog voltage
(0 – 10)V
MPI

12. ORGANIZATION BLOCKS (OB’S)
• 122 OB’s ,29 priorities
• There are 5 types :
1. Main Program Scan
(OB1, lowest priority )
2. Errors
3. Interrupts
4. Startup
5. Background cycle
(OB90, highest priority )
RACK SYSTEM :
 CR – Centralized Rack
 ER – Expansion Rack
 UR-Universal Rack
• Slot 1 : Power Supply
• Slot 2 : CPU modules
• Slot 3 : IM modules
• Slot (4-11) : SM modules

13. Function Call ( FC’s in OB1)
• Variable declaration table :
• IN , OUT & TEMP

14. DATA BLOCK (DB’S)
• Contains only variable declaration section
• Can be viewed in “declaration” or “data” view
• Makes use of memory interface
• There are two types
• Shared DB
• Instance DB

15. FAULT – ALARM SYSTEM
ALARM
HEALTHY
ACK
SIREN
LAMP

16. CIRCUIT DIAGRAM

17. HARDWARE SETUP

22. OPC/DDE :
• Open Process Control / Dynamic Data Exchange method of
interprocess communication so that one program can
communicate or control another program
PARAMETERS FOR OPC :
• Channel Configuration
• Device Configuration
• Address Configuration
OPC/DDE
(KEPSERVER)
MS-EXCEL

23. OPC – DA

24. SIEMENS S7 MPI
S7-300 CONTROLLER
OPC
DDE CLIENT DRIVE
OPC MS-EXCEL
OPC – DX

25. DDE CLIENT DRIVE

26. PROGRAMMING
S7300.doc

27. THANK YOU