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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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Improving Accuracy in Image-Recognition Systems with Techniques for Handling Similar-Looking Items in Inventory Management
(2025-01-01)
Smerpitak, Krit
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Kummool, Sart
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Asadi, Farzin
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Ar-Karachaiphong, Chitsanuwit
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Sopha, Watcharapon
Inventory management is crucial for businesses dealing with many visually similar items. This paper presents the development of an automated board game detection system utilizing computer vision and deep learning to enhance the accuracy and efficiency of tracking visually similar inventory. The dataset used to train the model was collected using a Pi Camera Module 3 mounted on a Raspberry Pi 5, ensuring consistency in captured images. To improve the model's performance, images were annotated using CVAT, and dataset augmentation was applied using Augmentations, incorporating transformations such as flipping, brightness adjustment, blurring, and noise addition. These augmentations allowed the model to learn and differentiate board games under varying environmental conditions accurately. The selected model was YOLOv8m, chosen for its balance between accuracy and computational efficiency. The model was trained for 20 epochs using a learning rate of 0.0005, a batch size of 12, and augmentation techniques such as Mosaic and MixUp. Additionally, overfitting prevention techniques including early stopping, dropout, and weight decay were applied. After training, the model was converted into the ONNX format to optimize it for deployment on embedded devices and then uploaded to the Raspberry Pi 5 for realworld testing. The system was evaluated on 10 visually similar or small-sized board games, with 10 tests per game, totaling 100 trials. The results showed that the model successfully classified all board games without a single error. Moreover, these findings demonstrate that the proposed system effectively identify board games with high accuracy while maintaining real-Time processing capability. The use of data augmentation and model optimization significantly improved object classification performance, making it a promising approach for inventory management in board game cafes and similar environments.
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DIAGNOSTIC DATA-BASED SAFETY AND AVAILABILITY ENHANCEMENTS FOR AN ALTERNATIVE OF FEEDFORWARD CONTROL USING FOUNDATION FIELDBUS
(2023-06-01)
Sittigon, Jirasak
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Suwanmanee, Ittimon
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Ukakimaparn, Prapart
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Julsereewong, Amphawan
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Kummool, Sart
To enhance plant safety and production availability in case of transmitter failures for an alternative of Foundation Fieldbus (FF)-based feedforward control, this article proposes a practical technique for configuring control strategy using function block diagram concept. The proposed configuration technique is based on fault diagnostic data automatically accessed from FF transmitters to take actions for operating the studied FF-based control loop that utilizes a Bias/Gain (BG) function block to build feedforward summing function outside of a proportional-integral-derivative (PID) function block. The minor 'Uncertain' problem can be treated as severe 'Bad' problem to increase the safety of the control loop. On the other hand, the 'Uncertain' status can be configured to be treated as 'Good' status to improve the availability of the control loop. Six options for configuring function blocks to operate the temperature control performed at the DeltaV host system are described as a case study to demonstrate the workability of the proposed technique. Experimental results of the alternate feedforward control loop configured with different parameter options confirm that the diagnostic data provided by the transmitters used are very useful for implementing either the interested control loop with increased safety or the interested control loop with increased availability. Therefore, the user can strike a balance between safety and availability for the FF-based feedforward control utilizing BG function block.
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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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AVAILABILITY THROUGH FIELD DEVICE DIAGNOSIS IN FEEDFORWARD CONTROL: A CASE STUDY OF FOUNDATION FIELDBUS-BASED TEMPERATURE CONTROL
(2022-02-01)
Kummool, Sart
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Suwanmanee, Ittimon
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Weerathaweemas, Songchai
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Julsereewong, Amphawan
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Sittigorn, Jirasak
For endusers, requiring an action to enable a fieldbus-based process control that is not hazardous to continue its operation in the event of transmitter failures, it is essential to understand how diagnostic capability of field instruments is helpful in availability enhancement. In order to effectively implement a feedforward control strategy with increased availability, this article presents a control configuration method when utilizing a Foundation Fieldbus (FF)-based temperature feedforward control as an illustrative case study. Four function block assignment options for configuring the studied control strategy during engineering phase are described. The ‘Uncertain’ measurement status provided by temperature transmitters is treated as ‘Good’ measurement status in all control configuration options for availability goal by reducing process downtime. In addition, based on experimental results, a simplified Petri net model for logical behavior representation of the interested FF-based feedforward is also proposed.
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Reliability enhancement of LNG fuel gas supply system in combined-cycle power plant
(2020-12-01)
Thepmanee, Teerawat
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Nachasingha, Chakri
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Kummool, Sart
This article aims to present a technique to enhance reliability of liquefied natural gas (LNG) fuel gas supply system (FGSS) of gas turbine unit in a combined-cycle power plant. In order to prevent unplanned plant shutdowns, the proposed technique is based on the use of failure modes, effects, and diagnostic analysis (FMEDA) to identify and evaluate the effects of possible failure modes, to determine what could minimize the chance of failures, and to design a new safety interlock. The studied FGSS consists of gas analytical system (GAS) in 2-out-of-2 voting scheme, shutdown valve system (SDV) in 1-out-of-2 voting scheme, fuel gas controller (FGC), and engineering/operator workstations. Two automatic GAS subsystems with different measurement methods are installed in the GAS. One of two GAS subsystems uses three gas chromatography analyzers in 2-out-of-3 voting scheme. The gas chromatography results and diagnostic alarm historian are utilized to consider the failure behavior. The reliability models for the GAS subsystem using gas chromatography and the overall FGSS are also included to confirm the effectiveness of utilizing diagnostic information from the gas analyzers. Based on the FMEDA results, the new safety interlock with no additional software and hardware costs can be achieved. The workability of the proposed safety interlock is demonstrated by test results.
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Process safety enhancement of feedforward control using foundation fieldbus
(2020-04-01)
Julsereewong, Amphawan
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Kummool, Sart
This paper presents a practical technique in engineering phase for enhancing safety of Foundation Fieldbus (FF)-based feedforward control through propagation of measurement validity and status information in the loop using function block language to prevent hazards in the presence of a transmitter failure. The proposed technique is based on fault diagnosis of FF devices to increase the safety beyond that found in basic control loops using traditional technologies. For hybrid architecture by assigning basic and advanced function blocks to execute in H1 field instruments and H1 interface module, respectively, all possible cases for configuring parameter options not only to shut the loop down when the failure occurs but also to resume the loop to normal when the failure disappears are described. The feedforward on temperature control of H1 segment configured and operated on the DeltaV integrated host is used for experimentally testing the correctness of the defined parameter options to provide function block interlocks and failsafe actions as well as fault recovery mechanisms. In addition, the Petri net model to represent the control loop behaviors for comparing the process safety enhancement in different scenarios from five cases of parameter configurations is also included.
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Hmi implementation using radar chart for dual-loop system
(2019-08-01)
Pongswatd, Sawai
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Smerpitak, Krit
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Kummool, Sart
This article presents a method to implement the Human Machine Inter-face (HMI) for providing high visibility of dual-loop system to encourage good operations and maintenance practices. The proposed method is based on the employment of radar chart to display key performance metrics of simultaneous and independent control of two identical loops for extensive event monitoring. Two level control loops utilizing two Proportional-Integral-Derivative (PID) function blocks of a single Programmable Logic Controller (PLC) are used as the case study to show the workability of the proposed HMI implementation. Each loop consists of a transmitter for measuring the controlled level an inverter for inverting the PLC output to adjust a pump speed, and a power meter form easuring the pump power consumption. The transmitter outputs from both control loops are applied to the PLC analog input module, and then separately scaled to be available to each PID block. The PLC analog output module is used to pass the PID block outputs for manipulating inlet flow rates. The performance metrics including the set point, process variable, manipulated variable, and pump power consumption of both control loops are detected and collected by the HMI/Supervisory Control and Data Acquisition (SCADA)station. All detected data of four performance metrics are represented on the axes of radar chart in real time by using the Wonder ware In Touch software. The script functions to save and load the specified data to the SQL server database are also created on the HMI/SCADA station. Experimental results confirm that the proposed HMI implementation can function correctly.
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Feedforward hybrid control using foundation fieldbus: A case study of temperature control with DeltaV system
(2018-06-08)
Pannil, Pittaya
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Jaroenla, Sutee
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Julsereewong, Amphawan
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Kummool, Sart
With Foundation Fieldbus (FF) technology, a control strategy can incorporate function blocks running in both host controller and field devices, which is known as hybrid control. This paper focuses on implementation of feedforward hybrid control by utilizing basic function blocks in H1 field devices and advanced function block in host controller to provide a guideline for detailed design to specify of the FF philosophy to be used in a greenfield or brownfield project for maximizing end user achievement. A laboratory-scale FF H1 segment configured and operated on the DeltaV host system for feedforward on temperature control is used as an illustrative case study to analyze three different configurations by assigning control function block into different field devices in terms of the network load for scheduled communications during segment macrocycle. Experimental results obtained from the preferred control loop with minimum scheduled traffic load verify that an improvement in disturbance response can be achieved. Using control block in field device for FF-based hybrid architecture can, therefore, be applied for creating the feedforward control with disturbance anticipation capability.
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Condition monitoring based on failure modes and effects analysis using scada software for wirelesshart devices
(2018-04-01)
Kummool, Sart
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Thepmanee, Teerawat
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Pongswatd, Sawai
This paper presents the design and implementation of condition monitoring for WirelessHART devices by using the supervisory control and data acquisition (SCADA) software called WW InTouch. The design of the proposed system is based on a concept of failure modes and effects analysis (FMEA) for creating the human machine interface (HMI) on the operator workstation. The implementation of the proposed system is based on a technique of WirelessHART-Modbus TCP data transfers by mapping the HART tag names from the field wireless devices to the Modbus registers in the WirelessHART gateway. The script functions running on the HMI for detecting the published diagnostic data of the monitored devices and for identifying the FMEA results of device and power supply failures are created. A WirelessHART temperature transmitter and a wired HART control valve positioner connected with Wireless THUM adapter are employed as the interested field devices for monitoring their abnormal operating conditions to verify the workability of the proposed system. Experimental results from the failure mimic show that the proposed system based on FMEA can function correctly.

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