TABLE OF CONTENTS
CHAPTER
1
TITLE
DECLARATION
ii
ACKNOWLEDGEMENTS
iv
ABSTRACT
v
ABSTRAK
vi
TABLE OF CONTENTS
vii
LIST OF TABLES
ix
LIST OF FIGURES
x
LIST OF ABBREVIATIONS
xiii
INTRODUCTION
1.1 Project background
2
PAGE
1
1.1.1 DC Belt Conveyor System
1
1.1.2 DC Tachogenerator
2
1.1.3 Programmable Logic Controller
3
1.2 Project Objectives
4
1.3 Project Scopes
5
1.4 Project Report Outline
5
LITERATURE REVIEW
2.1
System Model
6
2.2
Control Strategies
8
2.3
Implementation of Advance Control Technique
2.4
in PLC
10
Summary
11
viii
3
METHODOLOGY
3.1 Mathematical Model
3.2
Parameter Identification
3.3 Simulation of PID Speed Controller
12
16
20
3.4 Implementation of PLC Based PID Speed
Controller
3.5
Simulation of Adaptive Fuzzy PID Speed
Controller
3.6
5
28
Implementation of PLC Based AFPID Speed
Control
4
23
32
RESULTS AND DISCUSSION
4.1 Simulation results
36
4.2 Experimental results
40
CONCLUSION
5.1
Project Conclusion
48
5.2
Future Works
49
REFERENCES
51
ix
LIST OF TABLES
TABLE NO.
4.1
TITLE
PAGE
PLC Based PID and AFPID Overshoot against Speed
with Initial Load Condition
38
4.2
PLC Based PID Controller Performance Analysis
42
4.3
PLC Based AFPID Controller Performance Analysis
42
x
LIST OF FIGURES
FIGURE NO.
TITLE
PAGE
1.1
DC Belt Conveyor System
2
1.2
Driver Unit for DC Belt Conveyor System
2
1.3
DC Tachogenerator
3
1.4
Siemens S7-300 PLC
4
3.1
Schematic of Typical DC Belt Conveyor System
13
3.2
Typical Mechanical Loading on a Motor
14
3.3
Simplified Conveyor Load Model
14
3.4
Experimental Setup for System Identification
16
3.5
Screen Cap of Tachogenrator Signal
17
3.6
Importing Experimental Data to Matlab’s SIDT
18
3.7
Working data and Validation data
18
3.8
Process Model Estimation in SIDT
19
3.9
Parameter Estimation Results and Validity
19
3.10
Structure of PID Speed Control of DC Belt Conveyor
System
3.11
21
Simulation Model of PID Speed Control of DC Belt
Conveyor System
21
3.12
Open-loop Response of the Simulated System
22
3.13
Ciancone Correlation
23
3.14
Structure of PLC Based PID Speed Control of DC Belt
Conveyor System
3.15
3.16
24
Experimental Setup for PLC Based PID Speed Control
of DC Belt Conveyor System
24
PLC’s Structured Programming for PID Controller
25
xi
3.17
PID Programming
3.18
Process Reaction Curve from Open-loop Test on the
Real Hardware of DC Belt Conveyor System
3.19
26
27
Structure of AFPID for Speed Control of DC Belt
Conveyor System
28
3.20
Mamdani’s Type FIS Developed in MAtlab
28
3.21
Membership Function for e and e of AFPID
Simulation Model
3.22
Membership Function for K P , K I and K D of
AFPID Simulation Model.
3.23
29
30
How PID Parameter Should React to the Output Response
in AFPID
31
3.24
Fuzzy Rules of AFPID Simulation
31
3.25
Simulation Model of AFPID Speed Control of DC Belt
Conveyor System
3.26
32
Structure of PLC Based AFPID Speed Control of DC Belt
Conveyor System
32
3.27
Membership Function for and of PLC Based AFPID
33
3.28
Membership Function for K P , K I and K D
34
3.29
Program Structure of AFPID Speed Control
35
4.1
Output Responses of PID and AFPID Controllers
in No-load Condition
4.2
37
Performances of PID Versus AFPID against Set-point
Changes
38
4.3
Controller Response to the Sudden Change in Load
39
4.4
PLC Based Controller Response to Low Speed
Set-point with Initial Load Conditions
4.5
PLC Based Speed Controller Response to Medium
Speed Set-point with Initial Load Conditions
4.6
41
PLC Based Speed Controller Response to High Speed
Set-point with Initial Load Conditions
4.7
40
Tracking Performance of PLC Based PID vs PLC
41
xii
Based AFPID against Load
4.8
43
Tracking Performance of PLC Based PID Vs PLC
Based AFPID against Speed. With Initial Load
Conditions
4.9
PLC Based PID and AFPID Response Time against
Load
4.10
44
45
PLC Based PID and AFPID Response Time against
Speed with Initial Load Condition
45
4.11
PLC Base PLC Based PID and AFPID Overshoot against
46
4.12
Speed with Initial Load Condition d PID and AFPID
Overshoot against Load
47
xiii
LIST OF ABBREVIATIONS
AFPID
- Adaptive Fuzzy PID
ARX
- Auto-Regressive with Exogenous
ARMAX
- Auto-Regressive Moving Average with Exogenous
BJ
- Box-Jenkins
DC
- Direct Current
FB
- Function Block
FC
- Function
LAD
-Ladder Logic
OB
- Organization Block
OE
- Output Error
PID
- Proportional Integral Derivative
PLC
- Programmable Logic Cntroller
SI
- System Identification
SIDT
- System Identification Toolbox
STL
- Structured Text Language