In this paper, a smart and centralized traffic light control and monitoring system is proposed to control the modern transportation systems and make the city safer, using programmable logic controllers (PLCs) and programmable electronic microcontroll...
Programmable Logic Controllers (PLCs) are widely used for control and automation of machines and processes, so the quality of PLC software has a direct impact on production efficiency. This paper describes a PLC program for a food production line tha...
This paper presents some of the issues related to the implementation of advanced control structures (PI controller with additional feedback, Model Predictive Controller) for drives with elastic coupling on a programmable logic controller (PLC). The p...
This paper presents a dynamic optimization solution for the data packet-based communication of programmable logic controller (PLC) visual monitoring, and the objective is to improve the communication efficiency between a supervisory computer and fiel...
This paper presents the design, development, and testing of a smart home automation system that integrates a Siemens LOGO! programmable logic controller (PLC) with an ESP32 microcontroller to enable dual-mode control—manual and voice-activated....
The security of programmable logic controllers (PLCs) that control industrial systems is becoming increasingly critical due to the ubiquity of the Internet of Things technologies and increasingly nefarious cyber-attack activity. Conventional techniqu...
The shift towards remote access and control of equipment has become more prominent, especially due to COVID-19 lockdowns. Access to physical/real equipment for practical learning remains important for engineering studies. Thus, this paper presents an...
Industrial control systems (ICSs) increasingly rely on legacy communication protocols such as ModbusTCP, which lack built-in security mechanisms and remain widely exposed to network-based attacks. This paper investigates the security limitations of a...
The growing demand for engineers with practical competencies in industrial automation requires educational approaches that effectively integrate theoretical knowledge with hands-on experience. This study proposes and evaluates a hybrid virtual–...
During adaptive laboratory evolution experiments, any unexpected interruption in data monitoring or control could lead to the loss of valuable experimental data and compromise the integrity of the entire experiment. Most homemade mini-bioreactors are...
This study presents the design and validation of an automated skip loading system for vertical shaft hoisting operations, aimed at addressing inefficiencies in current manual systems that contribute to consistent underperformance in meeting daily pro...
In this study, a double-sheet detection system for automated metal stamping is developed and modeled. This study aims to address the issue of die damage caused by overlapping workpieces (double sheeting), a significant contributor to production line...
The article discusses counters defined in the IEC 61131-3 standard. The possible implementations of standard counters function blocks in FPGAs are presented. First, counters are implemented as classical hardware-based modules. Second, counters are de...
This paper presents a proposal of a complex mechatronic system that enhances the effectivity of obtaining energy from renewable resources. The main focus is on the photovoltaic energy system, which obtains electricity from the conversion of solar rad...
This paper investigates the position drift in a stepper motor used within a part feeding system for the orientation of cylindrical components. The system employs a bowl feeder, orientation sensors, and an indexing mechanism with eight precise positio...
Networks of sensors and actuators in automated manufacturing processes are implemented using industrial fieldbuses, where automation units and supervisory systems are also connected to exchange operational information. In the context of the incoming...
Existing PLC security solutions face a fundamental conflict between stringent real-time requirements and robust protection: traditional IT security mechanisms (e.g., encryption, authentication) introduce unacceptable latency, while software-based red...
The Internet of Things (IoT) has become critical to the implementation of Industry 4.0. The successful operation of smart manufacturing depends on the ability to connect everything together. In this research, we applied the TOC (Theory of Constraints...
With the innovative advance in science and technology, manufacturing production methods have made considerable progress. However, before the production process is actually implemented, it is important to examine whether the design can meet the actual...
Bottled-beverage production systems require considerable machinery and sophisticated control systems. A malfunction in the production system can result in machine stoppages, thereby decreasing productivity and resulting in the production output not m...
We developed a real-time alert and data management framework that integrates programmable logic controllers, RS-485 industrial communication, Structured Query Language Server, Message Queuing Telemetry Transport (MQTT), and the nodemation (n8n) autom...
A programmable logic controller (PLC) executes a ladder diagram (LD) using input and output modules. An LD also has PID controller function blocks. It contains as many PID function blocks as the number of process parameters to be controlled. Adding m...
This paper presents a design of a flow meter based on a programmable logic controller (PLC). The new construction of a flow meter controlled by PLC increases the possibilities for the control and automation of fluid flow. Additionally, the didactic p...
Programmable logic controllers (PLCs) make up a substantial part of critical infrastructures (CIs) and industrial control systems (ICSs). They are programmed with a control logic that defines how to drive and operate critical processes such as nuclea...
One key role in industrial control systems (ICSs) is known as Programmable Logic Controller (PLC). However, with the development of the Internet of Things (IoT), PLCs have become exposed to an increasing number of attacks, which may cause malfunction...
Rigorous testing methods are essential for ensuring the security and reliability of industrial controller software. Fuzzing, a technique that automatically discovers software bugs, has also proven effective in finding software vulnerabilities. Unsurp...
Intelligent robotic manufacturing cells must adapt to ever-varying operating conditions, developing autonomously optimal manufacturing strategies to achieve the best quality and overall productivity. Intelligent and cognitive behaviors are realized b...
Automatic generation of Programmable Logic Controller (PLC) programs from system design models can reduce system development costs and shorten system development cycles. However, effective methods for ensuring the quality and performance of control l...
The motivation for this work arose when noticing that definitions of honeypots’ interaction level are mainly based on the information technology environment and do not reflect operational technology even if several honeypot projects approach th...
Existing field-programmable gate array (FPGA) implementations of programmable logic controllers (PLCs) still suffer from limited speed compared to high-performance industrial controllers or restricted programming flexibility, if a control algorithm i...
This article discusses edge detectors implemented in programmable logic controllers. The behaviors of different vendors’ solutions are presented with pros and cons. The trigger functions defined in the IEC 61131-3 standard were analyzed for imp...
Lifts play an important role in human transportation in multi-storage buildings, which experience continuous improvements to their architecture and structure. As a result of these improvements, the development of efficient lift systems with more prog...
As Programmable Logic Controllers (PLCs) are increasingly connected and integrated into the industrial Internet of things, cybersecurity threats to PLCs are also increasing. Adversaries can perform a denial of service (DoS) attack based on the transm...
In this paper, we deal with a simple embedded electronic system for an industrial pneumatic–hydraulic system, based on a low-cost programmable logic controller (PLC) and industrial electronic parts with 24 V logic. The developed system is a hyd...
Programmable logic controllers (PLCs) are special embedded computers that are widely used in industrial control systems. To ensure the safety of industrial control systems, it is necessary to verify the correctness of PLCs. Formal verification is con...
The Industrial Control System (ICS) is a public facility that provides services to lots of users; thus, its security has always been a critical factor in measuring its availability. Recently, a new type of attack on ICS has occurred frequently, which...
This study presents a heterogeneous PLC-based distributed controller integrating an embedded logic-monitoring blackbox for real-time failover and fault detection in industrial control environments. Industrial automation and water treatment systems he...
Industrial discrete event dynamic systems (DEDSs) are commonly modeled by means of Petri nets (PNs). PNs have the capability to model behaviors such as concurrency, synchronization, and resource sharing, compared to a step transition function chart o...
This work proposes a vendor-independent integration method for International Electrotechnical Commission (IEC) 61850 Manufacturing Message Specification (MMS) communication protocol into Programmable Logic Controller (PLC) systems that support an ope...
The mismatch between the conveying capacity of sugarcane harvesters and the feeding amount is the main cause of blockages in the conveying system. To address this issue, this paper proposes a control system that integrates machine vision technology w...
This work evaluates the use of a programmable logic controller (PLC) from Phoenix Contact’s PLCnext ecosystem as an image processing platform. PLCnext controllers provide the functions of “classical” industrial controllers, but they...
This study designed and validated a power control algorithm tailored to the unique characteristics of a 100 kW wind turbine equipped with an independent generator torque control system within the Power Conversion System (PCS). Unlike conventional pow...
The voltage control of synchronous generators, particularly under varying load conditions, remains a significant and complex challenge in the field of engineering. Although various control methods have been implemented for automatic voltage regulator...
We developed a Python-integrated closed-loop industrial safety system that bridges real-time helmet-compliance detection with immediate machine control. The custom Python application serves as critical middleware, orchestrating the complete pipeline...
This paper presents the architecture and field-programmable gate array (FPGA) implementation of a 32-bit central processing unit (CPU) dedicated to programmable logic controllers (PLCs). The CPU instruction set directly matches the instructions of th...
Brownfield industrial systems often contain programmable logic controllers (PLCs) that expose heterogeneous vendor-specific protocols but cannot directly participate in Industrial Internet of Things (IIoT) data architectures. Replacing these controll...
Across the world’s electrical substations, water-treatment plants, and manufacturing lines, a single engineer with valid credentials and a laptop can today push new control logic to a programmable logic controller (PLC) and change the physical...
An appropriate control and measurement system is one of the elements that allows for the safe and effective operation of a technological installation. Such a system may have a diverse structure that corresponds to the expectations and needs of its us...
Programmable Logic Controllers (PLCs), widely used in industrial automation, are often programmed in IEC 61131-3 Structured Text (ST), which is prone to subtle logic vulnerabilities. Traditional tools like static analysis and fuzzing struggle with th...
This paper introduces a novel approach to frequency regulation in stand-alone synchronous generators by combining particle swarm optimization (PSO) with a Fuzzy PID controller. This study compares three control methods: a programmable logic controlle...
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