Implementation of Siemens S7-1200 PID Control on Festo Labvolt 3531 Plant Level Controller with Topkapi SCADA Using Modbus Communication Protocol

Hadi Supriyanto; Muhammad Nursyam Rizal; Sugeng Wibowo

doi:10.37899/journallamultiapp.v5i2.1356

Hadi Supriyanto Politeknik Manufaktur Negeri Bandung, Teknik Otomasi Manufaktur dan Mekatronika
Muhammad Nursyam Rizal Politeknik Manufaktur Negeri Bandung, Teknik Otomasi Manufaktur dan Mekatronika
Sugeng Wibowo Politeknik Manufaktur Negeri Bandung, Teknik Otomasi Manufaktur dan Mekatronika

DOI: https://doi.org/10.37899/journallamultiapp.v5i2.1356

Keywords: Siemens S7 1200, PID, SCADA Topkapi, Labvolt 3531, Waterfall

Abstract

Plant Festo LabVolt 3531 is a DCS, SCADA and process control system trainer based on the Allen Bradley Controllogix 5572 PLC and Factorytalk View SCADA. This research aims to provide another controller solution that can be used on the Festo Labvolt 3531 plant besides the Allen Bradley Controllogix 5572 PLC and FactoryTalk View SCADA. So that students have alternatives and variations of other technologies in learning. In this research, the Siemens S7-1200 PLC was used as a replacement for the Allen Bradley Controllogix 5572 PLC and Topkapi SCADA as a replacement for FactoryTalk View SCADA. As validation of the test, PID control was used to regulate the water level in both tubes at the Festo Labvolt 3531 plant. The test results for several specified height levels showed that the Siemens S7-1200 PLC with PID control integrated into Topkapi SCADA using the mobus communication protocol was successfully implemented , where the resulting control response has an average steady-state error of less than 2% and the delay between the interface and the device on the plant is 0s.

References

Goecks, L. S., Habekost, A. F., Coruzzolo, A. M., & Sellitto, M. A. (2024). Industry 4.0 and Smart Systems in Manufacturing: Guidelines for the Implementation of a Smart Statistical Process Control. Applied System Innovation, 7(2), 24. https://doi.org/10.3390/asi7020024.

Moll, I. (2021). The myth of the fourth industrial revolution. Theoria, 68(167), 1-38. https://doi.org/10.3167/th.2021.6816701.

Upadhyay, D., & Sampalli, S. (2020). SCADA (Supervisory Control and Data Acquisition) systems: Vulnerability assessment and security recommendations. Computers & Security, 89, 101666. https://doi.org/10.1016/j.cose.2019.101666.

Anggraeni, P., Martawireja, A. R. H., & Hudalloh, W. A. (2023). Implementation of Task Routing on SCADA-Based Modular Production System Using Topkapi Vision Software. https://doi.org/10.5220/0011892000003575.

Herath, H. M. K. K. M. B., Ariyathunge, S. V. A. S. H., & Priyankara, H. D. N. S. (2020). Development of a data acquisition and monitoring system based on MODBUS RTU communication protocol. Development, 5(6), 433-440. https://doi.org/10.38124/ijisrt20jun479.

Roldan, H. L. (2019). Evaluating the Resiliency of Industrial Internet of Things Process Control Using Protocol Agnostic Attacks.

Febriono, A. P., & Lukman, S. (2023). Sistem Informasi Pelaporan Proyek Berbasis Web Pada Pt Adikara Bangun Nusantara Menggunakan Methode Waterfall. Jurnal SIKOMTEK, 13(1), 1-8.

Adhikari, S. (2018). Operator Machine Control using Siemens PLC and HMI. The University of Toledo.

Dominic, S., Löhr, Y., Schwung, A., & Ding, S. X. (2016). PLC-based real-time realization of flatness-based feedforward control for industrial compression systems. IEEE Transactions on Industrial Electronics, 64(2), 1323-1331. https://doi.org/10.1109/TIE.2016.2612160

Alzahrani, A., Wangikar, S. M., Indragandhi, V., Singh, R. R., & Subramaniyaswamy, V. (2023). Design and implementation of SAE J1939 and modbus communication protocols for electric vehicle. Machines, 11(2), 201. https://doi.org/10.3390/machines11020201

Folgado, F. J., Calderón, D., González, I., & Calderón, A. J. (2024). Review of Industry 4.0 from the Perspective of Automation and Supervision Systems: Definitions, Architectures and Recent Trends. Electronics, 13(4), 782. https://doi.org/10.3390/electronics13040782

Salkić, A., Muhović, H., & Jokić, D. (2022). Siemens S7-1200 PLC DC Motor control capabilities. IFAC-PapersOnLine, 55(4), 103-108. https://doi.org/10.1016/j.ifacol.2022.06.017.

Slavíček, L., Balda, P., & Schlegel, M. (2021, June). Comparison of Siemens and REX controls PI (D) autotuners. In 2021 23rd International Conference on Process Control (PC) (pp. 212-218). IEEE. https://doi.org/10.1109/PC52310.2021.9447480.