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APPLYING MELSOFT GEMINI SOFTWARE FOR DIGITAL TWIN CREATION IN AUTOMATION SYSTEM PROJECT PHASES
(2026-08-01)
Thepmanee, Teerawat
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Sopha, Watcharapon
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Asadi, Farzin
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Pongswatd, Sawai
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Kummool, Sart
In the era of Industry 4.0, Digital Twin (DT) technology played a critical role in advancing manufacturing systems, particularly in real-time process simulation, performance optimization, and strategic decision-making. This study presents the application of MELSOFT Gemini software to develop DT for simulated industrial automation project phases. The system is designed to enable seamless data access and integration from physical devices into the DT in accordance with ISO 23247. The development process comprises two phases. The pre-deployment phase involves creating 3D models and simulating system behavior within a virtual environment prior to actual implementation. The Synchronized Operation phase enables visualization in MELSOFT Gemini through the transmission of data from physical devices via Operational Technology (OT) systems and Autonomous Mobile Robots (AMRs), using standard protocols such as OPC UA. The developed system accurately replicates the actual production process, provides early safety alerts, supports connectivity with various device types, and allows for future scalability all while maintaining compliance with the ISO 23247 framework. These findings demonstrate the potential of MELSOFT Gemini as a core platform for implementing practical, industry-ready DT systems.
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Hybrid Posi cast - based PID - PDA Control Using System Identification for Continuous Tunnel Kilns
(2026-06-30)
Pannil, Pittaya
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Sungsorn, Teenapong
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Trisuwannawat, Thanit
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Julsereewong, Amphawan
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Thepmanee, Teerawat
This paper proposes a hybrid Posicast-based proportional-integral-derivative with proportional-derivative-acceleration (PID-PDA) controller for temperature regulation in delay-dominant continuous tunnel kilns. The controller is developed based on a system-identified second-order-plus-dead-time (SOPDT) model derived from industrial data and implemented in discrete time for programmable logic controllers (PLCs). A unified framework enables comparison with a standard PLC-based proportional-integral (PI) controller, an internal model control (IMC)-tuned PI controller, and a Smith Predictor-PI controller under identical conditions. Simulation results demonstrate faster response, negligible overshoot, and reduced tracking error, with improved settling time and lower, integral of absolute error (IAE), integral of squared error (ISE), and integral of time-weighted absolute error (ITAE), while maintaining comparable control effort. Robustness analysis confirms stable performance under plant perturbations, with IAE variations within approximately ± 10 (servo) and ± 1 (disturbance). The controller is validated on an Allen-Bradley PLC in a silicon controlled rectifier (SCR)-based heating system. Experimental results show improved steady-state performance, including reduced bias, lower mean absolute error (MAE) and root mean squared error (RMSE), reduced oscillation amplitude, and compliance within the ± 1 temperature band. The proposed approach provides a practical, robust, and high-performance solution for upgrading existing PLC-based systems without hardware modifications.
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FUNCTION BLOCK IMPLEMENTATION OF PROPORTIONAL-INTEGRAL-DERIVATIVE GAIN SCHEDULING ON DISTRIBUTED CONTROL SYSTEM MODELED CENTUM VP
(2024-12-01)
Thepmanee, Teerawat
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Pedyod, Chalermpon
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Julsereewong, Amphawan
This article presents an engineering technique to practically implement a gain scheduling for a proportional-integral-derivative (PID) control loop, which consists of software function blocks executing in an industrial distributed control system (DCS) modeled CENTUM VP. The main feature of the proposed technique is to use a standard graphical language of function block diagram, which supports simplicity and reality for industrial applications. The implementation of the PID loop with gain scheduling by using regulatory control blocks and calculation blocks is described. The proportional band, integral time, and derivative time of the PID control block are continuously adjusted with a scheduling variable, which is selectively set to be the manipulated output value, setpoint value, process variable, control deviation value, or other measured variables. Based on a virtual test function of the DCS, simulation results of the PID loops with/without gain scheduling to control a simulated first-order plus time-delay process are included to demonstrate the performance of the implemented gain scheduler. Compared with the PID block with constant tuning parameters, the PID block with varying tuning parameters can provide better stability and performance of setpoint tracking.
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Family of Fibonacci-Type Marx Generators with a Single Inductor in a Three-Phase Configuration
(2024-01-01)
Eguchi, Kei
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Ishibashi, Takaaki
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Julsereewong, Amphawan
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Thepmanee, Teerawat
High-voltage discharge applications have seen a widespread adoption of solid-state Marx generators (SSMGs) in recent years. In this paper, we propose a new hybrid solid-state Marx generator (HSSMG) with a single inductor. Through the application of a three-phase Fibonacci scheme, the HSSMG is capable of achieving a substantial increase in voltage output. Furthermore, the proposed HSSMG is able to generate high voltage efficiently with fewer components. The integration of the Fibonacci and boost modules is a crucial idea in the proposed technique, where the boost module increases the output voltage of the Fibonacci module to achieve higher output voltage. Regarding the proposed two-stage HSSMG, the theoretical feasibility of the proposed topology is confirmed by theoretical analysis and Simulation Program with Integrated Circuit Emphasis (SPICE) simulations. As a result of comparative analysis, it was found that the number of circuit components of the proposed two-stage HSSMG is approximately half that of the traditional SSMG. Moreover, the newly suggested two-stage HSSMG accomplishes more than 86% power efficiency at 5 W.
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EXPERIMENTAL STUDY ON ENERGY CONSUMPTION OF TEMPERATURE CONTROL BY USING ON-OFF INTELLIGENT FUNCTION
(2023-05-01)
Pongswatd, Sawai
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Sopha, Watcharapon
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Asadi, Farzin
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Smerpitak, Krit
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Thepmanee, Teerawat
In order to save electrical energy for on-off temperature control, a useful concept of on-off intelligent function to execute in a programmable logic controller (PLC) is presented. An implementation of PLC-based control system based on electric heating is also described as a case study to demonstrate the performance of the proposed function. IEC 61131-3-based ladder diagrams were created by using Studio 5000 software to run in the PLC modeled CompactLogix L30ER. Compared with the traditional on-off control action, the proposed on-off intelligent function can minimize energy consumption of a heater used in the implemented temperature control by 4.57%-6.65%.
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PLC FUNCTION BLOCK CREATION FOR MINIMIZING DATA LINK LIMITATION ON CC-LINK-BASED CONVEYOR HANDLING SYSTEM
(2022-07-01)
Pongswatd, Sawai
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Niyomtamarat, Patipak
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Kummool, Sart
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Thepmanee, Teerawat
In order to solve a facing network capacity problem when improving an existing conveyor handling system controlled by programmable logic controllers (PLCs) on master-slave control and communication link (CC-Link) network at a wooden pallet manufacturer, this article presents a software technique for short-term solution. For new requirements to upgrade a pallet sortation to be automated by installing new robotic handling unit, a slave PLC using an interface module modeled FX2N-32CCL (or slave PLC1) cannot receive all specified data of pallet production models from an existing master PLC using intelligent module modeled QJ61BT11N in one communication cycle due to limited data links. To overcome this limitation, a PLC function block creation based on data sorting approach is proposed. Two new function blocks named FB SEND and FB RECEIVE are created based on IEC61131-3 standard for adding to the existing ladder diagrams, which execute on the master PLC central processing unit (CPU) and slave PLC1 CPU, respectively. Experimental results verify that the created function blocks can provide data transfers correctly between the specified sources and destinations. The data received at the slave PLC1 CPU are similar to the data sent from the master PLC CPU. With the proposed solution, the desired conveyor handling system can be upgraded according to user’s requirements.
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Design of PLC-based system for linearity output voltage of AC–DC converter
(2022-04-01)
Pongswatd, Sawai
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Smerpitak, Krit
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Asadi, Farzin
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Thepmanee, Teerawat
This paper presents the PLC-Based system for controlling the SCR power module which is AC–DC converter proposes to linearity output voltage with trigger signal. The technique converted the trigger signal by arccosine function and analog module in the PLC. Converted signal from PLC system is fed to SCR power module instant the traditional signal. Proposed of this paper describes the PLC hardware configuration, compute/math and trigonometric functions with Studio 5000 software. In addition, the interfacing, parameters configuration, and monitoring are considered for testing. The technique with PLC-based, devices configuration and experimental results have been presented will be useful for electric power supply in the industry with more and more demand to apply the PLC system to develop the traditional industry to semi or automatic control in the industry.
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Implementation of control and SCADA system: Case study of Allen Bradley PLC by using WirelessHART to temperature control and device diagnostic
(2022-04-01)
Thepmanee, Teerawat
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Pongswatd, Sawai
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Asadi, Farzin
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Ukakimaparn, Prapart
System integration for process automation promoted the technologies that were accessed to functions and data of field device, controller, and SCADA system. In addition, the data from filed devices can apply to solve device diagnostic and preventive maintenance. This paper describes the practical technique to configure and implement of control and SCADA system that focus on integration of field device, PLC controller, and SCADA system. The paper presents case study of Allen-Bradley (AB) PLC by using WirelessHART device to temperature control and device diagnostic through SCADA system. PLC's input/output (I/O) modules are installed that consists of Modbus module, digital I/O module, analog I/O module. In addition, Prosoft configuration builder and Studio 5000 software are new software to build add on Modbus instruction and ladder diagrams, respectively. The experiments perform in case study of temperature control by using Proportional–Integral–Derivative (PID) function in the AB PLC. Wonderware InTouch SCADA software is implemented to monitor the process mimic, trend, and alarm. Moreover, the technique can support the operators and engineers to make decision for process control and devices diagnostic.
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PFD analysis of LNG fuel gas supply system for improving combined-cycle power plant safety
(2022-04-01)
Thepmanee, Teerawat
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Julsereewong, Amphawan
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Pongswatd, Sawai
In order to determine an unavailability of each safety function subsystem that influences on an overall unavailability of entire protection system for safety analysis and enhancement, a modeling is required. This article presents a safety system modeling to evaluate the detected–undetected failures and repairable behaviors of each safety function subsystem in the studied fuel gas supply system (FGSS), which is utilized in a combined-cycle power plant. The proposed modeling deals with probability of failure on demand (PFD) analysis for calculation of the unavailability of three safety function subsystems, which are gas analytical subsystem (GAS), fuel gas controller subsystem (FGC), and shutdown valve subsystem (SDV). The interested GAS includes two different groups of gas analyzers in 2-out-of-2 (2oo2) voting scheme, when using three gas analyzers in each group in 2-out-of-3 and diagnosis (2oo3D) voting scheme. The interested FGC consists of two controllers in 2oo2 voting scheme, when the structure of each controller is in 1-out-of-1 and diagnosis (1oo1D) voting scheme. The interested SDV consists of two shutdown valves, which are installed in 1-out-of-2 (1oo2) voting scheme. The reliability block diagram is utilized for representative of combination of all three safety function subsystems, and the fault tree is utilized for calculation of PFD unavailability of each safety function subsystem. As the results obtained from the proposed safety function modeling, the influence of three safety function subsystems on the total unavailability of the FGSS is described. In addition, an example of the proposed modeling application to provide two guidelines for effective engineering design and operation is also presented. The first is a guideline to implement an effective human machine interface (HMI) at an operator workstation for real-time monitoring of the studied FGSS in the presence of failures that can be automatically detected by device diagnosis. The latter is a guideline to maintain and troubleshoot the failures that can be revealed by proof test. Based on diagnostic information and proof test results, operation and maintenance savings can be achieved.
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Safety enhancement for basic process control using 4-20 milliampere signal transmission
(2021-08-01)
Julsereewong, Amphawan
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Muangmool, Phongphiphat
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Thepmanee, Teerawat
To enhance safety of basic process control using traditional 4-20 mA current loops with/without transmitting a return signal of actual actuator position back to a host, this article presents a useful technique to provide fault-state and fault-recovery actions in four patterns. The proposed technique is a design of control drawings configured in a distributed control system (DCS) host for conventional proportional-integral-derivative (PID) loops with/without feedforward path to improve actions of the control loops in response to sensor and actuator failures. The configuration design based on functions of failure status propagation and failure mode shedding for eight control drawings that contain software function blocks for running on the DCS host modeled CENTUM VP is described. Simulation results by employing the DCS virtual test function verify that all designed control drawings can successfully perform the desired fault-state and faultrecovery actions for process safety enhancement.

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