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PID CLOSED-LOOP CONTROL ANALYSIS FOR
AUTOMATION WITH SIEMENS PLC USING TIA V13
Yin Yin Soe1, Pann Ei San2
Department of Electronic Engineering, Technological University (Thanlyin), Yangon (+95), Republic of the Union of Myanmar
automation plants to be maintained and supervised
Abstract
using these industry-wide standard controller [1].
This work is proposed about PID closed-loop control In automation technology, controllers are used in many
analysis for Siemens PLC using Totally Integrated different ways, for example for temperature control in
Automation (TIA) Portal V13 how to implement PLC processes. Influencing technical variables in systems
analog input projects. In industrial automation requires controlling these variables. So, PID closed-loop
technology, controllers are used in many different control system is needed for industrial automation
ways, for example for temperature control in system to get nearest output results and better
processes. Influencing technical variables in systems performance.
requires controlling these variables.so, PID control
system for analog input process to achieve high 2.OVERVIEW OF CLOSED-LOOP CONTROL SYSTEM
performance and better accuracy. In the SIMATIC
(Siemens PLC) world, the “PID_Compact” block, For an application which control the temperature of a
version 2.2, is provided for the S7-1500 CPUs for room by switching on an electric fire. The fire will heat
closed-loop process control. Siemens PLC provides the room up to the maximum temperature that is
products and solutions with industrial security possible bearing in mind the rate at which the fire heats
functions that support the secure operation of plants, the room and the rate at which is loses heat. This is
systems, machines and networks. In order to protect termed open loop control in that there is no feedback
plants, systems, machines and networks against to the fire to modify the rate at which it is heating the
cyber threats, it is necessary to implement – and room.
continuously maintain – a holistic, state-of-the-art To do this, it is needed a thermostat which can be set to
industrial security concept. Siemens’ products and switch the fire on when the room temperature is below
solutions only form one element of such a concept. the required value and switch it off when it goes above
The aim of this analysis is especially to get it. There is feedback of temperature information in this
knowledge of practical teaching with Siemens PLC system and as such it it termed closed loop control.
for BE (Electronics) students. Closed loop control of some variable, e.g. the control of
the temperature in a room, is achieved by comparing the
Keyword: Siemens PLC, TIA portal V13, PID- actual value for the variable with the desired set value
Compact, S7-1500 CPU, closed-loop control and then giving an output, such as switching on a
heater, to reduce the difference. Figure 1 illustrates this
1.INTRODUCTION by means of a block diagram. The actual value of the
In industrial automation systems and applications, PLC variable is compared with the set value and a signal
programming is very essential for many advanced obtained representing the difference or error. A
engineering programs: electronics, mechatronics, controller then takes this difference signal and gives an
industrial engineering, process industry, etc. One of the output to an actuator to give a response to correct the
main goals for the courses related to PLC programming discrepancy. Such a system is called closed-loop control.
consist on the learning of adequate control procedures
applied to different engineering fields and real
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Figure 1 Closed-Loop Control System Figure 3 USB converter (MPI port)
3.REQUIREMENTS OF THE PROPOSED WORK
1
For proposed work, the required Hardware and Software
for this learning are as follows:
• S7-1500 firmware 1.8 or higher
• Software: Totally Integrated Automation (TIA)
Portal V13 SP1 Update 9 or higher (Component
for programming the S7-1500)
• PC computer unit work as programming media
through its serial port through serial to USB Figure 4 Siemens Memory Card
converter (MPI port)
4.BASICS OF CONTROL ENGINEERING
Control engineering is a branch of engineering that
researches how to specifically influence given variables
in technical systems. The aim is to achieve and maintain
the desired value of this variable under certain
conditions. A controlled system contains the variable to
be controlled, such as the temperature of a room. To
identify the type of a system and then dynamically
control it in an optimal way, the system to be controlled
must be analyzed in detail.
One option to identify the type is to look at the step
Figure 2 S7-1500 Modules Configuration response of a controlled system. As an example, the
following figure shows the step response of a PTn
• Power Supply, PS 25W 24VDC, 6ES7 505- system (for example, temperature in a room).
0KA00-0AB0 alternatively, other power supplies The time response can be approximately defined by the
(24V DC) can also be used. following variables: Delay time Tu,Compensation time
• SIMATIC S7-1500, alternatively, other CPUs Tg, and Maximum value Xmax.
from the S7-1500 range can also be used.
• PC station, Any PC station with appropriate
software can be used. WinCC V13 SP1
Professional
• (TIA Portal V13) (Component for configuring the
visualization)
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• Create New Project
Figure 5 PTn system step response
The controller controls an actuator to bring the
controlled system to a desired state. The simplest
controllers are two-position controllers that only know
the states “ON” and “OFF” and use them to control the
controlled system via the actuator.
The frequently used PID controllers consist of three
parts:
• The P component generates an output signal
proportional to the system deviation.
• The I component integrates the system
deviation over time and, due to this integration,
affects the controlled system.
• The D component, however, responds to the
changed system deviation (time derivation of
the system deviation).
These three components of the ideal PID controller are
weighted by the coefficients proportional gain, integral
action time and derivative action time.
5.TIA PORTAL V13 SYSTEM FLOW
How to create Project and Basic information:
• Explore TIA portal
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• Configure access nodes of PLC connection.
(Download to Device)
• From “add new device” window select Controller
CPU 6ES7 511-1AK00-0AB0device, to configure.
There is a Program blocks folder in the Project tree. In
this folder, there is one program named Main [OB1].
• Configure Ethernet Connection (IP Protocol).
• Configure IO Addresses.
The following Steps for Building a Ladder Diagram are:
• Determine the No. of digital I/O
• Determine the No. of analog I/O (if needed)
• Determine if there are special functions in the
process
• Estimate program capacity depending on the
process
• Choose a suitable PLC series and prepare the
wiring diagram
• Draw flowchart or control diagram (Optional)
program the PLC using the ladder diagram
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OBs determine the structure of the user program.
System function blocks (SFB) and system functions (SFC),
SFBs and SFCs are integrated in the S7 CPU and allow
student access to some important system functions.
• Function blocks (FB)
FBs are blocks with a "memory" which student can
program theirself.
• Functions (FC)
FCs contains program routines for frequently used
functions.
• Instance data blocks (instance DB)
Instance DBs are associated with the block when an
FB/SFB is called. They are created automatically during
compilation.
• Data blocks (DB)
Figure 6 PID Control Box DBs are data areas for storing user data. In addition to
the data that are assigned to a function block, shared
data can also be defined and used by any blocks.
OBs, FBs, SFBs, FCs, and SFCs contain sections of the
program and are therefore also known as logic blocks.
The permitted number of blocks per block type and the
permitted length of the blocks are CPU-specific.
6.MODEL STRUCTURE OF THE SAMPLE PROJECT
The sample project consists of the models listed in Table
1 that are independent of each other.
The S7 program of the CPU 1511-1PN has the following
structure:
Figure 7 Data Block Call Options No Models Content of the model
1 Closed-loop • Parameterizing the PT3
control of a PT3 system simulation.
system simulation • Parameterizing and
with the aid of configuring
“PID_Compact”. “PID_Compact”.
Commissioning
“PID_Compact” with
pretuning and fine
tuning.
2 Closed-loop • Interconnecting the
control of a more individual system
complex simulations.
Figure 8 PID_Compact Function
controlled system • Commissioning
consisting of PT1, “PID_Compact” with
There are many different types of blocks which use
PDT1, lagging and pretuning and fine
within an S7 user program:
PT2 element. tuning.
• Organization blocks (OB)
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7.PID CLOSED-LOOP CONTROL SIMULATION
RESULTS
For PID control simulation, download the program to
the controller and the interface to the touch screen.
Open the program block and turn on program
monitoring by clicking the Monitoring on/off button in
the toolbar. When the monitoring mode is on, actuated
contacts, coils, or rungs turn green.
Figure 11 Solution overview
Figure 9 PID_Compact Controller System Block Diagram
Figure 12 Connection with PC station and CPU
A simple example of a control loop is the control of the
room temperature using a heater. The room
temperature is measured with a sensor and fed to a
controller. This controller compares the current room
Figure 10 Response Curve temperature to a setpoint and calculates an output value
(manipulated variable) for controlling the heater.
The automation task is to set up a control loop for
influencing physical parameters in a technical process. 7.1. Procedure Task
The control loop is to consist of the following elements:
• “PID_Compact” as the controller. The following tasks have to be performed to implement
• Simulated technical processes as the controlled the user program:
system. • Insert the PT3 system simulation into the user
program and parameterize it.
• Add the “PID_Compact” block to the user program.
• Configure the “PID_Compact” block.
• Commission the software controller with pretuning
and fine tuning.
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In the PC station of the TIA project, a visualization user
interface (WinCC Runtime) is provided that allows the
Model 1 user to use the examples.
WinCC Runtime allows the user to:
Monitor the state of the project’s scenarios
Modify individual tags of the scenarios.
In the PC station of the TIA project, a visualization user
interface (WinCC Runtime) is provided that allows the
Model 2 user to use the examples.
WinCC Runtime allows the user to:
Monitor the state of the project’s scenarios
Modify individual tags of the scenarios.
Figure 13 System Models
7.2. Parameters and formula for “PID_Compact”
After fine tuning, the following parameters are active in
the “PID_Compact” software controller:
Table 1 Symbols and parameters
Symbol Description Value Figure 14 Visualization user interface
Kp Proportional gain 10.770338 WinCC Runtime (model1)
TI Integral action time 21.10933
TD Derivative action time 5.337515 7.4. Calling and commissioning “PID_Compact”
a Proportional action weighting 0.1
b Derivative action weighting 0.2586402 Calling and commissioning show how to simulate a PT3
c Output value of the PID 0.0 controlled system with the simulation library and control
algorithm the PT3 controlled system with the “PID_Compact”
y Laplace operator - block.
s Setpoint - Fi
w Process Value -
x -
The PID algorithm of “PID_Compact” (FB1130) is based
on the following formula:
Figure 15 PID Controller Schematic diagram
The figure below shows the step response of the PT3
7.3. Monitoring the controlled system
controlled system when the input jumps from 0 50:
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industrial companies where its use is extensive. All of
them can be configured, programmed and tested with
Siemens TIA portal V13 software. The different model
can be selected from the start screen of the WinCC
Runtime system running on the “VisuPC” PC station for
future work.
9.ACKNOWLEDGMENT
Figure 16 Step response
Especially, the author special thanks to her family who
have given support and encouragement.
This simulation describes how to monitor and control
the controlled system with the aid of the provided
10.REFERENCES
visualization using WinCC Runtime Advanced.
After commissioning Scenario1, a setpoint step-change
Article/ Research Paper
from 0 50% results in the following response:
[1] Jose Luis Vazquez-Gonzalez, “An Industrial
Automation Course: Common Infrastructure for
Physical, Virtual and Remote Laboratories for PLC
Programming”, iJOE ‒ Vol. 14, No. 8, 2018, pp. 4–19.
Handbooks
[1] Müller/ Pfeiffer/ Wieser, SIMATIC S7 und SIMATIC
PCS, Publicis Publishing, Erlangen, ISBN: 978-3-89578-
340-1
Figure 17 Control response of the system [2] Hans Berger, “Automating with SIMATIC S7-1500
Configuring, Programming and Testing with STEP 7
8.DISCUSSION AND CONCLUSIONS Professional”, by Publicis Erlangen, Zweigniederlassung
der PWW GmbH, 2014.
For a better overview of the behavior of the
implemented scenarios, several options are available to Online Sources
the user:
Insight into the behavior of the control loops using the [1] Function Manual: SIMATIC S7-1200, S7-1500: PID
WinCC Runtime Advanced HMI system. Control
Detailed insight into the current status of the control https://support.industry.siemens.com/cs/ww/en/view/1
loop through the watch tables already prepared in the 08210036
CPU. [2] Download page of this entry
Analysis of PID control system using TIA portal can select https://support.industry.siemens.com/cs/ww/en/view/7
proportional, integral, derivative gain for better 9047707
response. Observation response curve in running, [3] System Manual: STEP 7 Professional V13.1
applications can be controlled how much output results https://support.industry.siemens.com/cs/ww/en/view/1
are needed for this application. For students, it is 09011420
intended how to create closed loop system for analog [4] Function Manual: SIMATIC S7-1200, S7-1500: PID
applications without real hardware PLC device. Using Control
these Siemens TIA portal software tools favorably https://support.industry.siemens.com/cs/ww/en/view/1
completes the development of skills for students and 08210036
they become familiar with software tools widely used in
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[5] System Manual: SIMATIC S7-1500 Automation
System
https://support.industry.siemens.com/cs/ww/en/view/5
9191792
[6] System Manual: WinCC Professional V13 SP1
https://support.industry.siemens.com/cs/ww/en/view/1
09096785
[7] Getting Started: SIMATIC S7-1500: Installing the
Assembly
https://support.industry.siemens.com/cs/ww/en/view/7
1704272/52316681355
[8] Application Example: „Single and Multi Loop
Controller Structures (Cascade Control) with PID_Temp”
https://support.industry.siemens.com/cs/ww/en/view/1
03526819
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