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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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Toward Interoperable SCADA: Node-RED-Based Edge Integration of Heterogeneous PLCs and IoT Devices
(2025-01-01)
Smerpitak, Krit
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Kaewchaiwong, Sattachai
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Ukakimaparn, Prapart
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Julsereewong, Amphawan
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Pongswatd, Sawai
This article presents a novel approach to supervisory control and data acquisition (SCADA) design that emphasizes interoperability through edge integration, using Node-RED as an open-source programming platform deployed on an industrial edge computer. The proposed architecture integrates multiple-vendor programmable logic controllers (PLCs) and an Internet of Things (IoT) gateway at the edge layer to enable seamless interoperability across local control systems. A lab-scale case study demonstrates the feasibility of this integration, featuring four remote terminal units (RTUs) communicating concurrently with a SIMATIC IPC327G edge computer via standard protocols. Specifically, a SIMATIC S7-1200 (RTU-1), MELSEC iQ-F FX5U (RTU-2), and CompactLogix 1769-L30ER (RTU-3) control an object sorting station, a parcel sorting station, a water temperature control station, respectively, while a UG65 gateway (RTU-4) enables bidirectional data transfer between the edge computer and LoRaWAN devices. The inclusion of InfluxDB alongside Node-RED supports data logging and reporting functionalities. By distributing protocol translation, data processing, and shop-floor supervisory control to the edge layer, the architecture achieves real-time, vendor-neutral data orchestration while maintaining compatibility with a higher-level SCADA master terminal unit (MTU) or cloud system. Experimental results from both functional and performance testing confirm the system’s viability as a cost-effective, vendor-agnostic solution for modern industrial automation, offering a scalable model for multi-protocol industrial environments.
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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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Using an android devices as mobile extensible HMIs
(2020-07-01)
Cheypoca, Thepjit
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Anuntahirunrat, Kongsuk
In this paper, an android application monitoring and control with programmable logic controller (PLC) system is proposed, which helps the production engineer self-correct the system without restriction of time and place. The proposed android application consists of smart phone, access point and PLC Siemens S7-1200. The feasibility of this method is illustrated by experimental using different parameter databases. Recognition results show this approach is efficient.
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Simplified and systematic plc programming technique: A case study of burner control for thermal oil heater
(2015-01-01)
Khaefoi, Supakit
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Smerpitak, Krit
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Pongswatd, Sawai
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Julsereewong, Amphawan
This article presents a technique to simplify and systematize programmable logic controller (PLC) programming for ease of engineering. A PLC-based burner control for thermal oil heater is examined as an illustrative case study. Based on the proposed method, two example cases of PLC programming for the modified burner control by adding input devices and alarm and shutdown conditions are described. Performance of the proposed technique is demonstrated through experimental tests done by nine engineers with difference experiences for ladder-logic-based PLC programming. Experimental results show that the proposed technique provides ease of reusing and modifying the existing ladder logic code and saving of time for writing the programs.
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A joint controller-simulator programming by demonstration method for PLC devices
(2006-12-01)
Changsakol, Phissanu
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Chotikakamthorn, Nopporn
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Wongwirat, Olarn
In this paper, a problem of visual programming of PLC (programmable logic controller) devices is described. A programming by demonstration method is developed so that a problem-domain expert can program such devices without computer programming skill. The method is novel in the sense that, unlike other programming-by-demonstration methods, it requires little a priori knowledge of the controlled system model, nor it needs to interact with a real system. A simulation model, which captures the laws of nature governing the system behavior, is jointly programmed with a control device (PLC). A PLC programming tool, developed based on the proposed joint controller-simulator programming by demonstration paradigm, can generate a high-level structure text program code, from the demonstrated actions as performed by a user. © 2006 IEEE.

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