Simulation of industrial processes with programmable logic controller

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Supervisor:
Oláh István
Department of Automation and Applied Informatics

A systematic and well-documented testing of a finished system is a very important part of the development of industrial control systems. By means of a Programmable Logic Controller, realistic digital simulations can be run on the finished system.

The ultimate aim of the thesis is to develop a system to a specified controller, simulating determined industrial processes, which can be connected to external PLC devices for further testing.

In the thesis, you can read about the realization of two of such tasks, which often can be found under industrial circumstances.

The first project is about a flow rate sensor working in a water pipe, where the aim is to count the impulses arriving from this sensor, and determine the actual flow rate in the pipe from this data. Another task is to make the software retrospectively save former flow rate values.

The second project is about modeling a water plant, where the PLC is the physical model of the plant itself. The main goal of this water plant is to ensure the desired level of water pressure existing in the main water pipe network. In case of being disconnected from an external control PLC, the model should have an own, automated control mode, which can regulate the valves and pumps being responsible for the actual water pressure. During the realization of such a system, a PID controller should be developed. This controller should regulate asynchronous AC pump motors equipped with Variable Frequency Drives (VFD-s), which are also parts of the plant model.

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