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Author: search.filters.author.Thepmanee, TeerawatSubject: search.filters.subject.Programmable logic controller

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    Hybrid Posi cast - based PID - PDA Control Using System Identification for Continuous Tunnel Kilns
    (2026-06-30)
    Pannil, Pittaya
    ;
    Sungsorn, Teenapong
    ;
    Trisuwannawat, Thanit
    ;
    Julsereewong, Amphawan
    ;
    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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    EXPERIMENTAL STUDY ON ENERGY CONSUMPTION OF TEMPERATURE CONTROL BY USING ON-OFF INTELLIGENT FUNCTION
    (2023-05-01)
    Pongswatd, Sawai
    ;
    Sopha, Watcharapon
    ;
    Asadi, Farzin
    ;
    Smerpitak, Krit
    ;
    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
    ;
    Niyomtamarat, Patipak
    ;
    Kummool, Sart
    ;
    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.