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    Toward Interoperable SCADA: Node-RED-Based Edge Integration of Heterogeneous PLCs and IoT Devices
    (2025-01-01) ;
    Kaewchaiwong, Sattachai
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    Ukakimaparn, Prapart
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    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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    Hybrid Posi cast - based PID - PDA Control Using System Identification for Continuous Tunnel Kilns
    (2026-06-30) ;
    Sungsorn, Teenapong
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    Trisuwannawat, Thanit
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    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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    AVAILABILITY THROUGH FIELD DEVICE DIAGNOSIS IN FEEDFORWARD CONTROL: A CASE STUDY OF FOUNDATION FIELDBUS-BASED TEMPERATURE CONTROL
    (2022-02-01) ;
    Suwanmanee, Ittimon
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    Weerathaweemas, Songchai
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    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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    Modification of Cockcroft-Walton-based high-voltage multipliers with 220 V and 50 Hz input for non-thermal food processing apparatus
    (2020-08-01)
    Jaiwanglok, Anurak
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    Eguchi, Kei
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    A design of high-voltage multipliers to generate underwater shockwaves is one of the most important factors for successfully providing non-thermal food processing in a cost-effective manner. To be capable of fully utilizing the Cockcroft-Walton-based high-voltage multipliers for underwater shockwave generation, this paper presents a topological modification of three interesting design approaches in bipolar structure for 220 V and 50 Hz AC input to generate more than 3.5 kV DC output within short time periods. In addition to Cockcroft-Walton multipliers (CWMs), the first modified scheme employs a positive full-wave rectifier (FWR) and positive voltage multiplier block (VMB), the second modified scheme employs positive/negative half-wave rectifiers (HWRs), and the last modified scheme employs a switched-capacitor AC-AC converter. To comparatively analyze their performances, the digitally controlled operations of the modified realization schemes as well as their electrical characteristic estimation based on a four-terminal equivalent model are described in detail. The effectiveness of three modified circuit configurations and the correctness of the given theoretical analysis are verified through SPICE (Simulation Program with Integrated Circuit Emphasis) simulation results. The formulas achieved from theoretical estimation are particularly useful when designing the proposed high-voltage multipliers (HVMs) because good agreement between the theoretical and simulation results can be achieved.
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    Switched capacitor-based high voltage multiplier with 220v@50hz input for generating underwater shockwaves
    (2020-01-01)
    Jaiwanglok, Anurak
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    Eguchi, Kei
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    Non-thermal food processing using underwater shockwaves is a cost-effective technology for preserving food items with minimal impacts on their nutritious property. In order to generate underwater shockwaves, a high voltage multiplier is the major element for system hardware implementation. To support the 220V and 50Hz AC input for generating 3.7kV DC output, this paper presents the high voltage multiplier based on switched capacitor technique. The proposed circuit consists of three main components, which are AC-DC rectifier, level shift driver, and parallel-connected voltage multiplier circuit. The theoretical relationship analysis utilizing a 4-terminal equivalent circuit is described for investigation of not only the output voltage but also the energy loss due to internal resistance and the power efficiency of the proposed high voltage multiplier. In addition, the operations of the proposed circuit are also simulated by using PSPICE program to confirm its workability.
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    Process safety enhancement of feedforward control using foundation fieldbus
    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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    Item type:Publication,
    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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    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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    Alternative of high voltage multipliers utilizing Cockcroft–Walton multiplier blocks for 220 V and 50 Hz input
    (2020-12-01)
    Jaiwanglok, Anurak
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    Eguchi, Kei
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    In order to be practical for converting 220 V and 50 Hz AC input into high DC output ranged between 3.5 and 4.0 kV to create underwater shockwaves in non-thermal technique for processing foods, this article presents an alternative approach for modifying conventional high voltage multipliers without magnetic elements, which are based on the use of parallel-connected Cockcroft–Walton multiplier blocks (CWMBs) in bipolar structure. The basic three-stage CWMB scheme as well as the effect of different capacitor values on its output is described. The modified high voltage multiplier with improved response speed consists of a full-wave rectifier (FWR), a two-phase driver block, a parallel-connected positive CWMB, and a parallel-connected negative CWMB. Both output voltage and power efficiency of the proposed scheme can be demonstrated by theoretical analysis results. Moreover, simulation results showing the characteristics of the proposed high voltage multiplier are also included.
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    Safety enhancement for basic process control using 4-20 milliampere signal transmission
    (2021-08-01) ;
    Muangmool, Phongphiphat
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    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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    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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    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.