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The purpose of this study is to determine the usefulness and efficiency of a SCADA system implemented with PLC and HMI on industrial machinery. This research compares a classic manual control system based on physical buttons and relays to a SCADA system based on PLC and HMI.
System demonstrations
SCADA (Supervisory Control and Data Acquisition) is a computer-based monitoring and control system used to regulate, monitor, and collect data from a process such as manufacturing or power generation.
Four major components support the SCADA system:
- Input and output devices, including temperature sensors, air pressure sensors, count sensors, and so on, are directly linked to the PLC, which is utilized as a data-collecting tool to determine the present state of the running system.
- RTUs (Remote Telemetry Units) are computers, specifically a PLC (programmable logic controller), that gather sensor data and deliver it to a SCADA master or a human-machine interface (HMI). RTUs convert analog/digital signals generated by sensors into calls that can be transmitted to the SCADA Master, depending on the protocol.
- SCADA Master / Human Machine Interface (HMI) allows people to operate, monitor, and acquire data directly from the system.
- A communication network that connects SCADA Masters to RTUs over an RS232 network.
According to the term, the PLC concept is:
- Programmable: displays the capacity to store programs in memory that can be readily modified in function or usefulness.
- Logic: displays the ability to do arithmetic and logic operations such as comparing, adding, multiplying, dividing, decreasing, negating, AND, OR, etc.
Human-Machine Interaction (HMI)
The purpose of the HMI (Human Machine Interface) is to view technology or systems in real-time so that the HMI design may be changed to make physical operations easier. The HMI attempts to improve the connection between the machine and the operator by utilizing the computer screen, touch screen, and HMI micro panel display, as well as to meet the data needs of the system’s end-users. In the manufacturing business, HMI is a Graphic User Interface (GUI) displayed on a computer screen that machine operators and users that want machine operational data may encounter.
Starting with the control section, the SCADA system employing PLC and HMI delivers input to the PLC process section, which processes it according to the program and then forwards it to the output module to activate the relay junction. If the relay is active, the relay contacts deliver a 220 VAC voltage to the load that demands a 220 VAC voltage, and if the relay is inactive, the PLC input and output modules must be examined. The line painting model’s display system comprises various pieces of technology. As part of the process’s feedback loop, data from the thermocouple and photoelectric sensors is returned to the control system.
The PLC processes the following inputs and outputs from the corresponding switches and keypads:
The start switch sends the input signal to the PLC, which processes it according to the software set into the PLC. Begin with the PLC input-output part of the relay, and verify its indicator light if R8 is not active owing to PLC outputs.
- The input signal from F1 keypad screens 2, 3, 4, 5, 6, 7, and 8 is transferred to the PLC, which is processed following the software stored in the PLC. If the PLC generates outputs, the relay and loads will be activated. If the loads are turned off, you should examine the PLC’s input/output and relay/load sections.
- Screens 2, 3, 4, 5, 6, 7, and 8 of the F2 keypad supply the input signal to the PLC, which is then processed following the program entered into the PLC; pushing the keypad will halt production regardless of the loads being controlled.
- To reset the number to zero, just hit F1 and F2 on the keyboard. The HMI digitally displays the status of the load and counter.
Discussion of the findings
The circuit models are realized and tested using the prior arrangement based on the system representation in the previous section. Sensor Data Collection Procedures for SCADA systems: Acquire data from field equipment to identify the real-time state of running operations, such as the on/off position of devices, motor speed, temperature, pressure, counter, etc. Units for Remote Telemetry (Network Communication): Data exchange between sensors and RTU/PLC, RTU/PLC, and SCADA master/HMI. In this situation, the RTU acts as a link between the sensors and the SCADA network. The sensor/relay input signal is converted by RTU into the proper protocol format and sent to the SCADA master.
Conclusion
The process of designing and manufacturing SCADA systems based on PLC (Programmable Logic Controller) and HMI (Human Machine Interface) consists of two designs: hardware and software. Hardware includes PLC input/output design, power, and power circuits, and software includes a ladder diagram PLC and displays on the HMI. After testing the system, it is concluded that the entire system can function adequately, operators can more easily control, monitor, and retrieve the data required, it is easier to maintain and solve problems that arise, the use of HMI (human-machine interface) simplifies installation wiring, and the results obtained in this research have two benefits. The first is that the SCADA system may increase the efficiency of the production process while making it easier to operate.
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