PROBLEM DEFINITION & POSSIBLE SOLUTIONS

PROBLEM DEFINITION
In the modern era of revolutionized Industrial Automation and distributed control system, every industry want to automate and centralize all of their projects and operating plants that can be monitored and controlled within a single room and decreasing man power. Programmable Logic Controllers, which serves as an enabling technology by providing such an interface between utility and load that could follow a communication protocol. In an operating industry a problem of interfacing and networking different brands (vendor) of PLCs with a single HMI PG/PC device has vital significance and for that purpose it needs solutions like Communication processors and other communicating devices. So covering these issues we have to find the solution.

PROBLEM DESCRIPTION
To monitor and control four plants, each on an individual PLC & one field device, through a communication protocol. The task is to design a cost effective system for the implementation with following elements: Physical Field Model Remote Terminal Unit (PLC) Communication Equipment Human Machine Interface Physical field model (Plant), in the project we decided to integrate four plants, two with digital I/Os and others with analog I/Os.
Plant#01 (Digital I/Os)

Four Story Elevator Station (12 digital inputs & 05 digital outputs).
Plant#02 (Digital I/Os)

Industrial Height wise Sorting Conveyor Station(03 digital inputs & 5 digital outputs).
Plant#03 (Digital & Analog I/Os)

Water Flow & Level Control Industrial Monitoring Station(02 Analog Inputs & 03 digital outputs).
Plant#04 (Digital & Analog I/Os)

Variable Frequency AC Motor Industrial Control Station (Via LG VFD as a field device)

POSSIBLE SOLUTIONS
The task is to communicate number of PLCs implemented via communication protocol, in that three PLCs & a field device gather data from remote filed devices and communicate with a central control room computer, equipped with HMI software. This task actually involves the selection of communication protocol equipment and HMI software. We are using one ABB PLC and one Fatek PLC and one Delta PLCs and LG VFD as a field device in the project. Let us look at the probable solution for achieving the task.

Available communication Protocols

To establish communication between PLCs to PLC and with field devices device, following communication standers are available[1]: MODBUS PROFIBUS FOUNDATION FIELDBUS HART(Highway Addressable Remote Transducer) INTERBUS Below the figure represents the worth wide utilization of communication protocols widely used Figure 1.1.3(a): Comparison of Worldwide utilization of in the field of industrial automation. communication
protocols for PLCs Communication

Modbus and Profibus are the second most significant communication protocols widely used in the industries for the implementation & communication. While HART (Highway Addressable Remote Transducer) is the first most according to its implementation & sustainable with very harsh environments usage & good performance. Foundation Field bus also has significant demand in the industry &Interbus also used in some industries. So these can be the possible solutions for the implementation & communication of different vendors PLCs[1].

ASSIGNED TASK
To solve the stated problem following important and significant tasks are assigned and listed below: 1. Selection Of Communication Protocol For Solution 2. Modbus Communication Description 3. Block Diagram Of System 4. Hardware Description For Implementation 5. Modbus Addressing Of Slave Devices 6. Plant Descriptions 7. Slave Programming For Communication 8. Master Programming ForCommunication Of Three Salves. 9. Programming Each PLC For RespectivePlant 10. Human machine Interface (HMI) development & interfacing with Master PLC using OPC server

SELECTION OF COMMUNICATION PROTOCOL FOR SOLUTION

The major driving force for the present day Industrial and Information Technology revolution is the development in Electronics Engineering, particularly Programmable Logic Controllers, which serves as an enabling technology by providing such an interface between utility and load that could follow a communication protocol. For this, it is widely used in several industries to generate valuable solutions to the complex industrial issues. Modbus is the second most significant communication protocols widely used in the industries for the implementation & communication. Different vendor PLCs communication is a big deal in industrial automation & the assigned project will lead us to understand the queries & solutions for the communication of different vendor PLCs via Modbus communication. Different plants and setup of PLCs are used to implement automation techniques which are comprised of three different PLCs and a field device as the key component by which four plants are controlled and monitor through HMI application. The featured following characteristics: Completely Automated Communication of different Vendor PLCs & Field devices. Modbus Communication implementation via RS-485(half duplex). User Friendly & Monitoring and Controlling through single HMI.

MODBUS COMMUNICATION DESCRIPTION

Modbus has its roots in the late seventies of the previous century. It is 1979 when PLC manufacturer Modiconnow a brand of Schneider Electric's Telemecanique published the Modbus communication interface for a multi drop network based on master/client architecture. Communication between the Modbus nodes was achieved with messages. It was an open standard that described the messaging structure. The physical layer of the Modbus interface was free to choose. The original Modbus interface ran on RS232, but later Modbus implementations used RS-485 because it allowed longer distances, higher speeds and the possibility of a true multi-drop network. In a short time hundreds of vendors implemented the Modbus messaging system in their devices and Modbus became the de facto standard for industrial communication networks[3].

Modbus Master-Slave Communication

Modbus controllers communicate using a master-slave technique, in which only one device (the master) can initiate a communication sequence. The sequence begins with the master issuing a request or command on the bus (a 'query'), which is received by the slaves. The slaves respond by taking appropriate action, supplying requested data to the master or informing the master that the required action could not be carried out. The master can address individual slaves or can transmit a message to be received by all slaves through a broadcast message. The response confirms that the message was received, understood and acted upon, or it informs the master that the action required could not be carried out.

Figure 2.2.2(a): Modbus Master-Slave Communication

If the query requests data from the slave, this will be returned as part of the response. Messages broadcasted to all slaves do not require responses. Modbus slaves will only transmit on the network when required to do so by the master. Slaves never transmit unsolicited messages.
RS-485 compatible serial interface

Modbus slaves will only transmit on the network when required to do so by the master. Slaves never transmit unsolicited messages. If the slave cannot carry out the requested action, then it will respond with an error message. This error message, known as an exception response, indicates to the master: - the address of the responding slave - the action it was requested to carry out - an indication of why the action could not be completed Modbus does not specify how numerical data shall be encoded within a message. This is decided by the equipment manufacturer and a wide range of options are available. Modbus ports frequently employ RS232-C compatible serial interfaces, although RS422/RS485 interfaces are also used. The type of interface used defines the connector pin-outs, the cabling and the signal levels; these are not defined in Modbus. Transmission rates and parity checking are not defined either and will depend on the serial interface used and the options made available by the manufacturer of each individual Modbus device. Modbus supports up to 247 slaves from addresses 1 to 247 (JBUS 1 to 255), address 0 is reserved for broadcast messages. In practice, the number of slaves that can be used is determined by the physical communication link that is chosen. For example RS485 is limited to a total of 31 slaves[3].
Modbus Message Structure

The Modbus communication interface is built around messages. The format of these Modbus messages is independent of the type of physical interface used. On simple interfaces like RS485 the Modbus messages are sent in plain form over the network.

Modbus message structure

Field Function code Data Description Code defining message type Data block with additional information Device address Address of the receiver

Error check Numeric check value to test for communication errors Table3.2.2(c): Modbus Message Structure .

Each Modbus message has the same structure. Four basic elements are present in each message. The sequence of these elements is the same for all messages, to make it easy to parse the content of the Modbus message. A conversation is always started by a master in the Modbus network. Addressing in the message header is used to define which device should respond to a message[4].
Modbus Serial Transmission Modes (Modbus ASCII & Modbus RTU)

Serial Modbus connections can use two basic transmission modes, ASCII or RTU, remote terminal unit. The transmission mode in serial communications defines the way the Modbus messages are coded. With Modbus/ASCII, the messages are in a readable ASCII format. The Modbus/RTU format uses binary coding which makes the message unreadable when monitoring, but reduces the size of each message which allows for more data exchange in the same time span. All nodes on one Modbus network segment must use the same serial transmission mode. A device configured to use Modbus/ASCIIcannot understand messages in Modbus/RTU and vice versa.When using Modbus/ASCII, all messages are coded in hexadecimal values, represented with readable ASCII characters. Only the characters 0...9 and A...F are used for coding. For every byte of information, two communication-bytes are needed, because every communication-byte can only define 4 bits in the hexadecimal system. With Modbus/RTU the data is exchanged in a binary format, where each byte of information is coded in one communication-byte.

Properties of Modbus/ASCII and Modbus/RTU

Modbus/ASCII Characters Error check Frame start Frame end Gaps in message Start bit Data bits Parity Stop bits ASCII 0...9 and A..F Modbus/RTU Binary 0...255

LRC Longitudinal CRC Cyclic Redundancy Check Redundancy Check character ':' characters CR/LF 1 sec 1 7 even/odd 1 none 2 3.5 chars silence 3.5 chars silence 1.5 times char length 1 8 even/odd 1 none 2

Table4.2.2(d): Modbus serial transmission modes

Modbus messages on serial connections are not sent in a plain format. They are framed to give receivers an easy way to detect the beginning and end of a message. When using Modbus/ASCII, characters are used to start and end a frame. The colon ':' is used to flag the start of a message and each message is ended with a CR/LF combination. Modbus/RTUon the other hand uses time gaps of silence on the communication line for the framing. Each message must be preceded by a time gap with a minimum length of 3.5 characters.

1.2.2(e) Modbus Addressing

The first information in each Modbus message is the address of the receiver. This parameter contains one byte of information. In Modbus/ASCII it is coded with two hexadecimal characters, in Modbus/RTU one byte is used. Valid addresses are in the range 0...247. The values 1...247 are assigned to individual Modbus devices and 0 is used as a broadcast address. Messages sent to the latter address will be accepted by all slaves. A slave always responds to a Modbus message. When responding it uses the same address as the master in the request. In this way the master can see that the device is actually responding to the request.

Device and Modbus address ranges

Device address 1...10000
*

Modbus address address - 1 address - 10001 address - 40001

Description Coils (outputs) Inputs Holding registers

10001...20000* 40001...50000
*

Table 5.2.2(e): Modbus addressing Within a Modbus device, the holding registers, inputs and outputs are assigned a number between 1 and 10000. The same addresses are used in the Modbus messages to read or set values. Unfortunately this is not the case. In the Modbus messages addresses are used with a value between 0 and 9999[4].
Modbus Function Codes

The second parameter in each Modbus message is the function code. This defines the message type and the type of action required by the slave. When a Modbus slave answers a response, it uses the same function code as in the request. However, when an error is detected, the highest bit of the function code is turned on. In that way the master can see the difference between success and failure responses[4].

BLOCK DIAGRAM OF SYSTEM

Industrial Grade System Integration using Modbus Communication consists of three different brands of PLCs and a field device. Every device & every standard utilized in the project is of industrial grade. Master is controlling the whole process and communicated with the entire slave by single shielded twisted pair cable following RS-485(half duplex). Human Machine Interface (HMI) connected with the master via RS-232 as shown the block diagram below.

Each PLC as a slave is controlling different plants according to the programming and controlled by the master (HMI). However, the master PLC is also controlling a plant according to the programmed subroutines. The last slave i.e. third slave is a field device which is Modbus supported thats why its directly connected with the master & controlling AC motor station.

PLC HARDWARE DESCRIPTION FOR IMPLEMENTATION

Industrial Grade System Integration using Modbus Communication consists of three different brands of PLCs and a field device as described in the table below. Master ABB PLC (AC500) Analog Inputs = 08 Analog Outputs = 08 Digital Inputs = 08 Digital Output = 08 Digital Inputs = 08 Digital Output = 06 Analog Inputs = 04 Analog Outputs = 02 Digital Inputs = 08 Digital Output = 06 ----

Slave-I Slave-II

FATEK PLC (FBs-14MAR) DELTA PLC (DVP20EX2)

Slave-III

LG VFD (SV-iG5)

Industrial ABB PLC has chosen as a master & FATEK & DELTA PLCs are acting as slaves while a LG field device is also used as third slave as its a field device so it has no any I/O. The list of the Softwares utilized for the Master & slave programming are listed in the table below. Hmi Software ABB PLC (AC500) FATEK PLC (FBS-14MAR) DELTA PLC (DVP20EX2) Simulation Softwares SIEMENS(Wincc Flexible 2008) Codesys_V2.3 Winproladder_3.1 Wplsoft_V2.20 Modscan_32&Modsim_32

Table6.2.4(a): Different bands of PLC & their I/O descriptions.

SIEMENS (WinCC Flexible 2008) is used as the front end HMI software.

MODBUS ADDRESSES OF SLAVE DEVICES

Every Modbus supported device has Modbus slave addresses for the protocol communication configuration. Following figure below shows the Modbus addresses of all the three slaves PLCs and field device. Every Fatek PLC has its Communication Parameter setting at port2 having Baud Rate, Parity, Data Bit, Stop bit, Reply delay time, Transmission delay time, receive timeout interval time & Protocol setting for the communication with the master. LG Field device variable frequency drive (VFD) reference operations are also highlighted in the above figure for different operations e.g. Forward, Reverse, Start & emergency Stop.
PLANT HARDWARE DESCRIPTIONS

Following are the four hardware plants controlled by master & each slave: a. b. c. d. Four Story Elevator Control Station (Control via Master) Industrial Height wise Sorting Conveyor Station (Control via SlaveI) Water Flow & Level Control Industrial Monitoring Station(Control via SlaveII) Variable Frequency AC Motor Industrial Control Station (Control via SlaveIII)

Four Story Elevator Control Station

Four Story Elevator Control Station plant is a prototype of an elevator having 4 floors. The system primarily designed to explicitly illustrate the essential components of the Roped Elevator System. This sort of an exercise is extremely helpful in understanding the concept s of a complete Control system and has been designed in a simple yet realistic manner. The exercise aims for the accurate controlling of the elevator buckets height digitally with a PLC. The exercise carefully and wisely divided into different task to cover the practical implementation as well as the theoretical aspects of the project [2]. The four story elevator prototype contains the limit switches as the gate & Floor sensors & inner & outer call buttons and a heavy geared DC motors& four seven segment displays used to display the floor position of the elevator box. Total 17 digital I/Os are required for the operation of the plant including 12 digital inputs & 05 digital outputs. The plant is controlled via ABB master PLC having total 32 digital I/Os including 16 digital inputs & 16 digital outputs.
Industrial Height wise Sorting Conveyor Station

Sorting is any process of arranging items in some sequence and/or in different sets, and accordingly, it has two common, yet distinct meanings: Ordering is arranging items of the same kind, class, nature, etc. in some ordered sequence. Categorizing is grouping and labeling items with similar properties together (by sorts). In our project we use no. of sensors and actuators for different defined height objects (boxes) Three sensors of OMRON which are Photoelectric (IF) sensors used[9]. Three actuators are used to sort different height objects to their respective destination One Conveyer belt is used for taking object in forward direction A sensor (also called detector) is a device that measures a physical quantity andconverts it into a signal which can be read by an observer or by an instrument. Three photo sensors are used of Omron brand in which they are located in different. Three actuators are used to actuate three different types of objects in which they all are situated to their respective sensor position (at bottom of their respective sensors).These actuators are commonly made by the simple DC Motors. All DC motors are of 24 DC volts. These actuators are made in a less U-shaped mechanism to actuate objects easily to their respective destination. Total 08 digital I/Os are required for the operation of the plant including 03 digital inputs & 05 digital outputs. The plant is controlled via Fatek PLC Slave-I having total 14 digital I/Os including 08 digital inputs & 06 digital outputs.
Water Flow & Level Control Industrial Monitoring Station

Industries require a source to acquire the plants data and their monitoring on computers. Today, electronics apart from other applications is committed to designing and developing of broad range of electronic systems used in automated processes serving in an industrial environment. Liquid flow and level control is one of them that ensure safe, fault free and proper operation of process industries. PLC can be used to control liquid flow and level control. The achievement of this plant is that it has provided process industry with an easy access alternate which is cost efficient and equally reliable. In this system the important parameters of any process industry is monitored and controlled. The physical parameters will be sensed by appropriate sensors the ten turn pot generate analog signals which will be conditioned by the use of signal conditioners after thatthe analog signals are fed to the PLC analog inputs[2]. Two 10 turn pots are used for the flow & level feedback in the control tank while a solenoidal valve is also present to drain the water from tank. The pots are calibrated such that the motorize valve & level can be input from HMI & achieve at the graduated scale. Total 03 digital outputs & two analog inputs are required for the operation of the plant. The plant is controlled via Delta PLC Slave-II having total 14 digital I/Os including 06 analog I/Os.

Variable Frequency AC Motor Industrial Control Station

LG Variable Frequency Drive (VFD) is used to control the parameters of AC Motor and vice versa. The motor we used to control its parameters is Induction Motor.Induction Motor is actually the AC Motor in which power is supplied to it by means of electromagnetic induction process. We used 750 watts induction motor in this project because it is easily available in our PLC Lab. And the total capacity of VFD to drive Induction Motor is 1HP (horse power). VFD used in our project is LG brand and its serial no. is SV008IG5. The basic available operating functions in VFD are[11]: DC Braking Frequency Limit Frequency Jump Second Jump Second Function Slip Compensation Reverse Rotation Prevention Auto Restart PID Control But we used only three parameters of it to drive Induction Motor: On-Off Controlling Forward-Reverse Direction Controlling Speed Controlling LG Variable Frequency Drive (VFD) is a field devicedirectly connected to the master via Modbus (RTU) communication as LG VFD is Modbus supported and utilized for the controlling of AC Motor and vice versa. The motor we used to control its parameters is Induction Motor in delta connection.

SLAVES PROGRAMMING FOR COMMUNICATION

On Modbus communication there is verity of settings of master addressing to the slave depends upon the vendor & settings of the device. Some devices only required software settings to become as a slave or as a master. For example, Fatek PLC can be set as slave or master by configuring internal software settings as slave or master. In the figure below the left most one shows the setting of fatek PLC as slave-I including Baurd Rate, Parity, Data Bits & stop bit, Reply delay time, Transmission delay time, receive timeout interval time & Protocol setting for the communication with the master. In similar pattern as mentioned above some of the slave required a program to respond with the Master. The right lowest most section of the figure is Delta PLC slave program. The program contains D1120 special purpose register for Baud rate & Parity Settings & K2 is the slave id which is assigned (moved) to the special purpose register D1121. Master PLC utilized a block named Modbus_RTU_AC500 for the addressing of each slave & data sending & receiving JOB_STAR_RTU, JOB_END_RTU, TIMEOUT_RTU, JOB_RTU & DATA_RTU are essentially used for the Modbus communication.

MASTER PROGRAMMING FOR COMMUNICATION WITH THREE SALVES

Codesys Software is utilized for the programming of master Programming with the three slaves. The master ABB PLC program contains a Modbus_RTU_AC500 block for the purpose of interfacing with other slaves. The block contains Job to assign different operations. The diagram below shows the starting few networks of the program. For complete program please see appendix A. The master ABB PLC program contains a Modbus_RTU_AC500 block for the purpose of interfacing with other slaves. The block contains Job to assign different operations. ADR blocks are the pointers which points the coming data from the slave to the defined arrays of different data types for specified operatons. The diagram above shows the starting few networks of the program. For complete program please see appendix A.

PROGRAMMING EACH PLC FOR RESPECTIVE PLANT

Each plant program must be inserted in the respective controlling slave or master PLC in their respective programming languages &softwares. ABB Master controlling Four Story Elevator station so its programming is done in its codesys software. The figure below contain the programs of plants controlling via ABB PLC & Delta &Fatek PLC as well[6]. Similary, Winproladder&WPLSoft are the softwares utilized for the programming of Level & Sorting plants controlled via Fatek& Delta PLC respectively.The diagram above shows the starting few networks of the program.

HUMAN MACHINE INTERFACE (HMI) DEVELOPMENT OFSYSTEM&INTERFACING WITH MASTER PLC USING OPC SERVER
The HMI software used as the front end of the Master PLC is SIEMENS SIMATIC WinCC Flexible 2008. The HMI software communicates with the master PLC via RS-232 on OPC server. The Figure show the steps of OPC tags taking from codesys to the WinCC Flexible software. For OPC server setting its necessary to set communication parameters of the master PLC software (Codesys). So that the HMI software WinCC take all the tags for its proper operation.

ANALYSIS (MATHEMATICAL MODELLING)

This section contains the possible mathematical modeling of Plants. The only possible mathematical modeling in our project plant is: Industrial Height wise Sorting Conveyor Station

Industrial Height wise Sorting Conveyor Station

The mathematical modeling for a conveyer belt can be best described bydrawing the conveyer belt diagram. The figure 5.1 shows a conveyer belt structure that has a object of mass m moving on it. Consider an object of mass m, moving on the conveyor belt: The total force on the belt is. F =W (1.3.1) W = mg.......(1.3.2) The mechanical torque on the conveyor belt is given by: Since So, = rF...(1.3.3) F =W = rW.. ..(1.3.4)

The torque on the conveyor belt motor is given by, Where, K = mechanical constantent = induced flux IA = armature curr = KI A..................................................................................................................(1.3.5)

The relation between mechanical & electrical power is given by, P elec.= P mech. ..(1.3.6) Since, Pelec.= EA. IA.. ..(1.3.7) Where, EA = induced EMF P mech. =

Substituting equation (1.3.7) and (1.3.8) in equation (1.3.6), we get r = E I..(1.3.8) Since, E A= K (1.3.9) = KI A. (1.3.10) = KI A...(1.3.11) The terminal voltage is related to induced EMF as VT= EA+ I ARA..(1.3.12) Substituting equation (1.3.9) in equation (1.3.12)we get V T = K + I A R A .... (1.3.13) Solving for K , we get K = (VT IA RA)/ .... (1.3.14) Substituting the value of K in equation (1.3.14) we get

= (V T I A R A) / A * IA..... (1.3.15)

Analysis
Equation (1.3.4) & (1.3.11) represent the torque. One equation represents torque due to load and other due to electrical excitation. The torque due to electrical excitation must be than the torque due to the load, in order to move the is more than the conveyor efficiency. Use the typical values of electrical parameters for the D.C. Geared motor (which are listed as under). Torque could be calculated using equation (1.3.15) We have, VT = 24 volts RT = 3.5 = 70 rpm = 0.554 newton-meter For calculating the torque using equation (1.3.4) the parameter r = 0.2 meterss m = 0.25kg W = 2.45 newton Calculating the torque using equation (1.3.4) we have, = 0.45 newton-meter The two values of torques clearly indicate that the electrical torque is quite larger than the mechanical one. So the conveyor belt motor can bear its load and efficiently run the belt.

Sensor Modeling
This section describes some of the basic and useful characteristics of the sensor. The sensor is photovoltaic switch in our system to detect height of the object. Figure 1.3.3 shows a general block of an object that passes on the conveyer belt and it also shows the width S of the object. Consider an object moving with velocity V and covering a distance S in front of the sensor, which is equal to its width. Using the distance time relationship we have, s = vt(1.3.16)

If the objects used have maximum width of 10cm, and the velocity of conveyor is not exceeding 0.5m/sec, then the minimum response time can be calculated using these two values t = 200msec So, we require a sensor that can give response in less than 200msec.

Actuator Modeling
Actuators are basically devices that converts electrical signal into mechanicalactions. The actuator in our system is designed using DC motor as actuating mechanism. The parameter that is of significant importance in our project is the time response of the shifter. Figure 5.3 shows the design of the actuator that we have chosen for our project. Since the maximum speed of the conveyor belt could be 0.5m/sec, and the face of the shifter is 10cm long, so the response time of the shifter can be evaluating using the basic relation, Here s = 0.1m v = 0.5m/ sec So, we have . This result shows that the shifter should give response in 200msec, in order to sort out the object. s = vt ...(1.3.16)

DESIGNING (Schematics & Circuits)

It is important to design the driver schematic& circuit for the three plants, 1. Driver Circuit of Four Story Elevator Control Station 2. Driver Circuit of Industrial Height wise Sorting Conveyor Station 3. Driver Circuit of Water Flow & Level Control Industrial Monitoring Station

Driver Circuit of Four Story Elevator Control Station(Modbus Master)

This shows the driver circuit of four story elevator control station.Four Story Elevator Control Station plant is a prototype of an elevator having 4 floors. The system primarily designed to explicitly illustrate the essential components of the Roped Elevator System. The four story elevator prototype contains the limit switches as the gate & Floor sensors & inner & outer call buttons and a heavy geared DC motors & four seven segment displays used to display the floor position of the elevator box. Total 17 digital I/Os are required for the operation of the plant including 12 digital inputs & 05 digital outputs. The plant is controlled via ABB master PLC having total 32 digital I/Os including 16 digital inputs & 16 digital outputs.

Driver Circuit of Industrial Height wise Sorting Conveyor Station (Modbus Slave-I)
Sorting is any process of arranging items in some sequence and/or in different sets, and accordingly, it has two common, yet distinct meanings: Ordering is arranging items of the same kind, class, nature, etc. in some orderedsequence. In our project we use no. of sensors and actuators for different defined height objects (boxes) Three sensors of OMRON which are Photoelectric (IF) sensors used Total 08 digital I/Os are required for the operation of the plant including 03 digital inputs & 05 digital outputs. The plant is controlled via Fatek PLC Slave-I having total 14 digital I/Os including 08 digital inputs & 06 digital outputs.

Driver Circuit of Water Flow & Level Control Industrial Monitoring Station (Modbus Slave-II)
Industries require a source to acquire the plants data and their monitoring on computers. Today, electronics apart from other applications is committed to designing and developing of broad range of electronic systems used in automated processes serving in an industrial environment. Liquid flow and level control is one of them that ensure safe, fault free and proper operation of process industries. PLC can be used to control liquid flow and level control. The achievement of this plant is that it has provided process industry with an easy access alternate which is cost efficient and equally reliable. In this system the important parameters of any process industry is monitored and controlled. Two 10 turn pots are used for the flow & level feedback in the control tank while a solenoidal valve is also present to drain the water from tank. The pots are calibrated such that the motorize valve & level can be input from HMI & achieve at the graduated scale. Total 03 digital outputs & two analog inputs are required for the operation of the plant. The plant is controlled via Delta PLC Slave-II having total 14 digital I/Os including 06 analog I/Os.

SimulationFor Modbus Address checking & verification of LG Variable Frequency Drive(VFD) Using ModScan32
LG Variable Frequency Drive (VFD) is used to control the parameters of AC Motor and vice versa. The motor we used to control its parameters is Induction Motor.Induction Motor is actually the AC Motor in which power is supplied to it by means of electromagnetic induction process. We used 750 watts induction motor in this project because it is easily available in our PLC Lab. And the total capacity of VFD to drive Induction Motor is 1HP (horse power)[8]. VFD used in our project is LG brand and its serial no. is SV008IG5. The basic available operating functions in VFD are: But we used only three parameters of it to drive Induction Motor: On-Off Controlling Forward-Reverse Direction Controlling

Speed Controlling

LG Variable Frequency Drive (VFD) is a field devicedirectly connected to the master via Modbus (RTU) communication as LG VFD is Modbus supported[11].

DSP COMPONENTS (DELTA PLC SLAVE-II Controlling)

The minimum number of necessary components in a typical digital signal processing system must be: 1. A lowpass analog antialiasing prefilter that bandlimits the signal to be sampled to within the Nyquist interval. 2. An A/D converter (sampler and quantizer). 3. A digital signal processor. 4. A D/A converter (staircase reconstructor), possibly preceded by an equalizing digital filter. 5. A lowpass analog anti-image postfilter to complete the job of the staircase reconstructor and further remove the spectral images introduced by the sampling process.[7] Every PLC controlling Analog inputs & outputs have almost all the DSP components stated above.As in Industrial grade system integration using Modbus communication DELTA PLC slave-II is controlling Water Flow & Level Control Industrial Monitoring Station (02 Analog Inputs & 03 digital outputs). EX2/SX2 sampling time of analog/digital conversation. Default: 2. Unit: 1ms. Sampling time will be regarded as 2ms if D11182. Where D1118 is the special purpose register. The maximum error of sampling time, Whentheerror affects the output, please fix the scan time. TS = - (1 scan time + 1ms) ~ + (1 scan time).(1.5.1)

PLC provides digital input filters to avoid interference. The response time (n) of X0 ~ X7 inputfilters can be adjusted by REFF instruction. The instruction sets the value specified in n to D1020 (X0 ~ X7 input filter time) directly. The internal processor of the Delta PLC is the digital signal processor which processes the information & produce its outputs according to the programming. Antialiasing Pre-filter & Post filter are builten at the input & output of the PLC for bandlimits the signal to be sampled to within the Nyquist interval &possibly preceded by an equalizing digital filter.

SOLUTION REALIZED (DEVELOPED)

There are four subsystems and final solution is the combination of all these four subsystems as follows: 1. 2. 3. 4. 5. Modbus Master(Subsystem-I) Modbus Slave-I(Subsystem-II) Modbus Slave-II (Subsystem-III) Modbus Slave-III(Subsystem-IV) Final Solution

Modbus Master (Subsystem-I)

The Subsystem-I is controlling Four Story Elevator Control Station plant which is a prototype of an elevator having 4 floors. The system primarily designed to explicitly illustrate the essential components of the Roped Elevator System. This sort of an exercise is extremely helpful in understanding the concept s of a complete Control system and has been designed in a simple yet realistic manner. The exercise aim for the accurate controlling of the elevator buckets height digitally with a PLC. The exercise carefully and wisely divided into different task to cover the practical implementation as well as the theoretical aspects of the project.

Modbus Slave-I (Subsystem-II)

The Subsystem-II is controlling Sorting Plant. Sorting is any process of arranging items in some sequence and/or in different sets, and accordingly, it has two common, yet distinct meanings. In our project we use no. of sensors and actuators for different defined height objects (boxes) Three sensors of OMRON which are Photoelectric (IF) sensors used. Three actuators are used to sort different height objects to their respective destination One Conveyer belt is used for taking object in forward direction A sensor (also called detector) is a device that measures a physical quantity and converts it into a signal which can be read by an observer or by an instrument. Three photo sensors are used of Omron brand in which they are located in different. Total 08 digital I/Os are required for the operation of the plant including 03 digital inputs & 05 digital outputs. The plant is controlled via Fatek PLC Slave-I having total 14 digital I/Os including 08 digital inputs & 06 digital outputs.

Modbus Slave-II (Subsystem-III)

The Subsystem-II iscontrolling Flow & Level Control Plant.Industries require a source to acquire the plants data and their monitoring on computers. Today, electronics apart from other applications is committed to designing and developing of broad range of electronic systems used in automated processes serving in an industrial environment. Liquid flow and level control is one of them that ensure safe, fault free and proper operation of process industries. PLC can be used to control liquid flow and level control.

Two 10 turn pots are used for the flow & level feedback in the control tank while a solenoidal valve is also present to drain the water from tank. The pots are calibrated such that the motorize valve & level can be input from HMI & achieve at the graduated scale. Total 03 digital outputs & two analog inputs are required for the operation of the plant. The plant is controlled via Delta PLC Slave-II having total 14 digital I/Os including 06 analog I/Os.

Modbus Slave-III (Subsystem-IV)

Subsystem-IV is LG Variable Frequency Drive (VFD) is used to control the parameters of AC Motor and vice versa. The motor we used to control its parameters is Induction Motor. Induction Motor is actually the AC Motor in which power is supplied to it by means of electromagnetic induction process. We used 750 watts induction motor in this project because it is easily available in our PLC Lab. And the total capacity of VFD to drive Induction Motor is 1HP (horse power). VFD used in our project is LG brand and its serial no. is SV008IG5[10]. But we used only three parameters of it to drive Induction Motor: On-Off Controlling Forward-Reverse Direction Controlling Speed Controlling LG Variable Frequency Drive (VFD) is a field devicedirectly connected to the master via Modbus (RTU) communication as LG VFD is Modbus supported and utilized for the controlling of AC Motor and vice versa. The motor we used to control its parameters is Induction Motor in delta connection.

Final Solution
All the above four substations are collectively providing the complete solution for the industrial grade system integration using Modbus Communication. The figure below shows the master subsystem and all the three slave subsystems which comprises the final communication solution of the problem of communication of different vendors of PLCs using MODBUS communication. Each PLC as a slave is controlling different plants according to the programming and controlled by the master (HMI). However, the master PLC is also controlling a plant according to the programmed subroutines. The last slave i.e. third slave is a field device which is Modbus supported thats why its directly connected with the master & controlling AC motor station. Industrial Grade System Integration using Modbus Communication consists of three different brands of PLCs and a field device. Every device & every standard utilized in the project is of industrial grade.

PRACTICAL RESULTS
Hence Practical results of every subsystem shows the successful implementation of Industrial Grade System Integration using Modbus Communication which consists of three different brands of PLCs and a field device. Every device & every standard utilized in the project is of industrial grade. Master is controlling the whole process and communicated with the entire slave by single shielded twisted pair cable following RS-485(half duplex). Each PLC as a slave is controlling different plants according to the programming and controlled by the master (HMI). However, the master PLC is also controlling a plant according to the programmed subroutines. The last slave i.e. third slave is a field device which is Modbus supported thats why its directly connected with the master & controlling AC motor station.Following are the four hardware plants controlled by master & each slave successfully: a. b. c. d. Four Story Elevator Control Station (Control via Master) Industrial Height wise Sorting Conveyor Station (Control via SlaveI) Water Flow & Level Control Industrial Monitoring Station(Control via SlaveII) Variable Frequency AC Motor Industrial Control Station (Control via SlaveIII)

DISCUSSION OF RESULTS
Hence Practical results of every subsystem show the successful implementation. Since the simulation using Modscan32 &Modsim 32 softwares are for the confirmation & satisfactory response of the slave & master PLCs. So the Simulation & Practical results of the whole system are nearly same. Thus, sech PLC as a slave is controlling different plants according to the programming and controlled by the master (HMI) successfully and can be controlled by using single HMI frontend of Siemens (SIMATIC winCC Flexible 2008). LG Variable Frequency Drive (VFD) is a field devicedirectly connected to the master via Modbus (RTU) communication as LG VFD is Modbus supported and utilized for the controlling of AC Motor and vice versa. The motor we used to control its parameters is Induction Motor in delta connection. Hence the result of each subsystem confirms the successful working & implementation of the solution.

CONCLUSION
In the modern era of revolutionized Industrial Automation and distributed controlsystem, every industry want to automate and centralize all of their projects and operating plants that can be monitored and controlled within a single room and decreasing man power. Programmable Logic Controllers, which serves as an enabling technology by providing such an interface between utility and load that could follow a communication protocol.In an operating industry a problem of interfacing and networking different brands (vendor) of PLCs with a single HMI PG/PC device has vital significance and for that purpose it needs solutions like Communication processors and other communicating devices. So covering these issues we have to find the solution. The project contains three PLCs& a field device of different vendors controlling different plants & each PLC is communicated with one master via MODBUS communication Protocol. MODBUS is an application layer messaging protocol, positioned at level 7 of the OSI model that provides client/server communication between devices connected on different types of buses or networks. Modbus controllers communicate using a master-slave technique, in which only one device (the master) can initiate a communication sequence. The sequence begins with the master issuing a request or command on the bus (a 'query'), which is received by the slaves. The slaves respond by taking appropriate action, supplying requested data to the master or informing the master that the required action could not be carried out. Different plants and setup of PLCs are used to implement automation techniqueswhich are comprised of three different PLCs and a field device as the key component by which four plants are controlled and monitor through HMI application. The featured following characteristics: Completely Automated Communication of different Vendor PLCs& Field devices. Modbus Communication implementation via RS-485(half duplex). User Friendly & Monitoring and Controlling through single HMI.

Our project meets the specified needs and provides a complete solution with the human friendly and complete HMI for Industrial automation and Networking using MODBUS communication protocol