Available online at www.sciencedirect.com ScienceDirect Energy Reports (2022) 972–978 www.elsevier.com/locate/egyr 2021 8th International Conference on Power and Energy Systems Engineering (CPESE 2021), 10–12 September 2021, Fukuoka, Japan Design of PLC-based system for linearity output voltage of AC–DC converter Sawai Pongswatda , Krit Smerpitaka ,∗, Farzin Asadib , Teerawat Thepmaneea a School of Engineering, King Mongkut’s Institute of Technology Ladkrabang, Ladkrabang, Bangkok, 10520, Thailand b Department of Electrical and Electronics Engineering, Maltepe University, Istanbul, Turkey Received 26 October 2021; accepted November 2021 Available online 26 November 2021 Abstract This paper presents the PLC-Based system for controlling the SCR power module which is AC–DC converter proposes to linearity output voltage with trigger signal The technique converted the trigger signal by arccosine function and analog module in the PLC Converted signal from PLC system is fed to SCR power module instant the traditional signal Proposed of this paper describes the PLC hardware configuration, compute/math and trigonometric functions with Studio 5000 software In addition, the interfacing, parameters configuration, and monitoring are considered for testing The technique with PLC-based, devices configuration and experimental results have been presented will be useful for electric power supply in the industry with more and more demand to apply the PLC system to develop the traditional industry to semi or automatic control in the industry © 2021 The Author(s) Published by Elsevier Ltd This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/) Peer-review under responsibility of the scientific committee of the 2021 8th International Conference on Power and Energy Systems Engineering, CPESE 2021 Keywords: PLC-based; SCR; AC–DC converter; Trigger; Studio 5000 Nomenclature PLC SCR IEC PID Programmable Logic Controller Silicon Controlled Rectifier International Electrotechnical Commission Proportional–Integral–Derivative Introduction The electrical power supply, SCR power module, power factor control uses PLC act as the main or master controller In the industrial automation, the control signal is fed from controller By the way, the standard signal is ∗ Corresponding author E-mail address: krit.sm@kmitl.ac.th (K Smerpitak) https://doi.org/10.1016/j.egyr.2021.11.137 2352-4847/© 2021 The Author(s) Published by Elsevier Ltd This is an open access article under the CC BY-NC-ND license (http: //creativecommons.org/licenses/by-nc-nd/4.0/) Peer-review under responsibility of the scientific committee of the 2021 8th International Conference on Power and Energy Systems Engineering, CPESE 2021 S Pongswatd, K Smerpitak, F Asadi et al Energy Reports (2022) 972–978 linearity with the trigger signal, but the output voltage is not proportional to the signal In many applications, the output voltage of thyristor module is applied to many kinds of load such as heating system, oven, electrical drive, so on The nonlinearity between trigger signal and SCR output voltage is a factor that impact for tuning the controller to optimal control New technology by hardware and software can support the tradition system modify to industrial automation based on PLC system The software standard based on IEC 61131-3 improves the design of industrial control systems using commercial PLCs has been introduced [1] Real time prototype design and implementation of automatic control system for electricity power distribution to the load using Programmable Logic Controller has been proposed [2] In an industrial automation, PLC controllers have been used in the industry Many applications applied PLC based system to implement the industrial process for monitoring, controller tuning, devices diagnostics have been presented [3–6] The paper presents the application that apply the arc cosine function, compute/math function of IEC 61131-3 to program by ladder language The experiment performs with new engineering program from Rockwell Automation that is Studio 5000 It is applied with Allen Bradley PLC to solve nonlinearity Vdc output In addition, the SCR power regulator is an important power module to convert AC to DC power for dc drive Theorem 2.1 AC–DC converter Topology of the AC–DC power module is shown in Fig The SCRs S1 and S2 will become forward-biased when the source becomes positive but will not conduct until gate signals are applied Similarly, S3 and S4 will become forward-biased when the source becomes negative but will not conduct until they receive gate signals The waveform of load voltage is shown in Fig Frequency of the load voltage is two times bigger than the source voltage Angle α is the angle interval between the forward biasing of the SCR and the gate signal application Fig Topology of the AC–DC converter Fig Waveform of load voltage of AC–DC converter The average (dc component) of the waveform shown in Fig is: ∫ π Vdc = Vm sin(ωt)d(ωt) π ∝ Vm = (1 + cos α) π 973 (1) S Pongswatd, K Smerpitak, F Asadi et al Energy Reports (2022) 972–978 Graph of + cos α is shown in Fig As the trigger angle decreases, the average value of output voltage increases In addition, the output voltage is nonlinearity with trigger angle The proposed technique to solve the condition by generating trigger signal with PLC-Based for linearity output voltage Fig Graph of trigger angle in radian with output voltage ) Vm ( + cos(cos−1 xout) π Vm = (1 + xout) π Vdc = (2) √ In Thailand, the grid voltage is 220 Vrms, so Vm equals to 220 ≈ 311 V The Vdc equation is expressed by Vm (1 + xout) π 311 = (1 + x) π Output voltage of proposed technique is equal to Vdc = Vdc = 99 (1 + xout) (3) where, xout is the synthesized signal from PLC to trig the SCR’s of AC–DC power module 2.2 PLC-based system The proposed system installs Allen-Bradley PLC which consists of CPU module, Digital Input module, Digital Output module, Analog Input module, and Analog Output module Hardware specification and catalog number can be shown by Table 2.3 Compute/math, trigonometric functions [7] Sequence control and compute/math functions develop with Studio 5000 engineering program that apply ladder language to execute arccosine function (ACS), subtract (SUB), divide (DIV), multiply (MUL), and so on Compute/Math and Trigonometry Function are available depend on controller model and engineering program ACS function computes the arc cosine of source and returns the real result The ACS instruction takes the arc cosine of the source value and stores the result in the destination (in radians) 974 S Pongswatd, K Smerpitak, F Asadi et al Energy Reports (2022) 972–978 Table I/O modules list and configuration data Module No Name Catalog number CPU & Power Supply Digital Input (DI) Digital Output (DO) Analog Input (AI) 1769-L30ER 1769-IQ16A 1769-OW8/B 1769-IF4B (4 Ch) Analog Output (AO) 1769-OF4/A (4 Ch) Available I/O Signal Data format Digital 16 Points Digital Points −10 10 Vdc Vdc 10 Vdc Vdc 20 mA 20 mA −10 10 Vdc Vdc 10 Vdc Vdc 20 mA 20 mA Integer Short Integer RAW/Proportional Engineering Unit Scaled for PID Percent Range RAW/Proportional Engineering Unit Scaled for PID Percent Range 2.4 AI/AO configuration AI and AO configuration are used to select type and range This selection lets configure each channel individually and provides the means of designating signal of the input/output This work selection configures each AI and AO channel to accept digital data in percent range format that is shown by Fig Fig Page of AO module properties Design of PLC-based system PLC-Based system is designed with Allen-Bradley PLC and Studio 5000 software The system uses software language standard based on IEC-61131-3 that is Ladder language Compute/Math and Arc Cosine function are 975 S Pongswatd, K Smerpitak, F Asadi et al Energy Reports (2022) 972–978 applied to execute trigger signal feed to AO The proposed technique uses the functions instead scaling function In addition, the trigger signal feed to SCR AC–DC power module in order to linearity output voltage Fig Block function to execute trigger signal of proposed and traditional technique Main program can be shown block function by Fig The Compute/Math functions calculate and scale the value from control function fit to Arc Cosine function Output value from Arc cosine function in radian is scaled again then feed to AO module in percentage (0–10,000) AO module converts percentage between 0–10,000 to CV voltage 0–10 V Each function can be shown in detail of offline state by Fig Fig Ladder diagram and initial value of offline state Testing and result The testing performs by simulation the PV signal feed to AI module then executes the trigger signal with proposed technique and feed out to AO module Block diagram for testing can be shown by Fig Online screen of main program by Studio 5000 and Allen-Bradley PLC shown by Fig For testing start by adjusts PV signal from 0–10 V and feed to AI module The module converts analog 0–10 V to digital 15 bits then move digital value every scan 976 S Pongswatd, K Smerpitak, F Asadi et al Energy Reports (2022) 972–978 time to control function and DIV of Compute/Math function The control function is configured in manual mode, so that the AI value is directly move to DIV The block function of proposed technique executes and synthesized signal to trig the SCR’s of AC–DC power module Synthesized signal is 0–10 V available trigger angle π -0 radian Fig Block diagram for Testing Fig Online screen of main program In Thailand, the grid voltage is 220 Vrms The Vdc outputs of SCR’s of AC–DC power module with trig by traditional and proposed technique are expressed by Fig The graph of output voltage shown the Vdc output versus trigger signal that show linearity of output Conclusion In this paper proposed technique to create a trigger signal for SCR AC–DC power converter by using PLCBased system The system was implemented with Allen-Bradley PLC with Studio 5000 software In addition, the arc cosine function and Compute/Math function applied to fit scale the trigger signal The synthesized trigger signal in order to trig the SCR AC–DC power converter between π to radian that supply output voltage to max The output voltage linearity with assigned signal agrees well with designed The technique with PLC-based, AI, AO configuration and experimental results have been presented will be useful for electric power supply in the industry with more and more demand to apply the PLC system to develop the traditional industry to semi or automatic control in the industry 977 S Pongswatd, K Smerpitak, F Asadi et al Energy Reports (2022) 972–978 Fig Output value of SCR AC–DC power converter versus trigger signal Declaration of competing interest The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper Acknowledgments The software licenses and hardware of this work have been supported by Rockwell Automation Thai and Petro Instrument Co., Ltd., respectively Moreover, the authors would like to thank staffs of both companies that guideline the technique for implementation and testing References [1] Basile Francesco, Chiacchio Pasquale, Gerbasio Diego On the implementation of industrial automation systems based on PLC IEEE Trans Autom Sci Eng 2013;10(4) [2] Aldi BI, Kadadevarmath JS, Bannibagi NP Design and implementation of a PLC based electricity supply switching control system IOSR J Electr Electron Eng 2016;11(3):43–50, e-ISSN: 2278-1676, p-ISSN: 2320-3331, Ver III [3] Pongswatd S, Smerpitak K, Weerathaweemas S, Chamnanakson S Design and implementation of internet-based remote monitoring for continuous vacuum pans in sugar factory ICIC Express Lett Part B Appl 2018;9(5):429–36 [4] Pongswatd S, Smerpitak K, Kummool S Hmi implementation using radar chart for dual-loop system ICIC Express Lett 2019;13(8):753–60 [5] Rerkratn A, Laosuwan I, Tammaruckwattana S, Parnklang J Integration of WirelessHART Devices Into Mitsubishi PLC For Plant Monitoring In: International conference on control and robotics engineering, vol Thailand 2018 p 209–12 [6] Mohod S, Raut A PLC SCADA Based Fault Detection System for Steam Boiler In Remote Plant In: International conference on intelligent computing, instrumentation and control technologies, vol 2019 p 1007–10 [7] Rockwell Automation rockwell%/studio%/help/enu/v32/rs5000/14751.htm 978 ... the gate signal application Fig Topology of the AC–DC converter Fig Waveform of load voltage of AC–DC converter The average (dc component) of the waveform shown in Fig is: ∫ π Vdc = Vm sin(ωt)d(ωt)... Vdc outputs of SCR’s of AC–DC power module with trig by traditional and proposed technique are expressed by Fig The graph of output voltage shown the Vdc output versus trigger signal that show linearity. .. with PLC-Based for linearity output voltage Fig Graph of trigger angle in radian with output voltage ) Vm ( + cos(cos−1 xout) π Vm = (1 + xout) π Vdc = (2) √ In Thailand, the grid voltage is 220