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Scan time reduction of PLCs by dedicated parallel-execution multiple PID controllers using an FPGA

Dhanabalan, Gnanasekaran

Abstract

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 more process parameters slows down PLC scan time. Process parameters are measured as analog signals. The analog input module in the PLC converts these analog signals into digital signals and forwards them to the PID controller as inputs. In this research work, a field-programmable gate array (FPGA)-based multiple PID controller is proposed to retain PLC scan time at a lower value. Concurrent execution of multiple PID controllers was assured by assigning separate FPGA hardware resources for every PID controller. Digital input to the PID controller is routed by the novel idea of analog to digital conversion (ADC), performed using a digital to analog converter (DAC), comparator, and FPGA. ADC combined with dedicated PID controller logic in an FPGA for every closed-loop control system confirms concurrent execution of multiple PID controllers. The time required to execute two closed-loop controls was identified as 18.96000004 ms. This design can be used either with or without a PLC.

Full text

Ci a ion: Dhanabalan, G.; Tamil Sel i, S.; Mahdal, M. Scan Time Reduc ion o PLCs by Dedica ed Pa allel-Execu ion Mul iple PID Con olle s Using an FPGA. Senso s 2022,22, 4584. h ps://doi.o g/ 10.3390/s22124584 Academic Edi o : Mehme Rasi Yuce Recei ed: 18 May 2022 Accep ed: 15 June 2022 Published: 17 June 2022 Publishe ’s No e: MDPI s ays neu al wi h ega d o ju isdic ional claims in published maps and ins i u ional a il- ia ions. Copy igh : © 2022 by he au ho s. Licensee MDPI, Basel, Swi ze land. This a icle is an open access a icle dis ibu ed unde he e ms and condi ions o he C ea i e Commons A ibu ion (CC BY) license (h ps:// c ea i ecommons.o g/licenses/by/ 4.0/). senso s A icle Scan Time Reduc ion o PLCs by Dedica ed Pa allel-Execu ion Mul iple PID Con olle s Using an FPGA Gnanaseka an Dhanabalan 1, Sanka Tamil Sel i 1and Mi osla Mahdal 2,* 1Depa men o Elec onics and Communica ion Enginee ing, AAA College o Enginee ing and Technology, Si akasi 626123, India; [email p o ec ed] (G.D.); [email p o ec ed] (S.T.S.) 2Depa men o Con ol Sys ems and Ins umen a ion, Facul y o Mechanical Enginee ing, VSB-Technical Uni e si y o Os a a, 17. Lis opadu 2172/15, 708 00 Os a a, Czech Republic *Co espondence: mi osla [email p o ec ed] Abs ac : A p og ammable logic con olle (PLC) execu es a ladde diag am (LD) using inpu and ou pu modules. An LD also has PID con olle unc ion blocks. I con ains as many PID unc ion blocks as he numbe o p ocess pa ame e s o be con olled. Adding mo e p ocess pa ame e s slows down PLC scan ime. P ocess pa ame e s a e measu ed as analog signals. The analog inpu module in he PLC con e s hese analog signals in o digi al signals and o wa ds hem o he PID con olle as inpu s. In his esea ch wo k, a ield-p og ammable ga e a ay (FPGA)-based mul iple PID con olle is p oposed o e ain PLC scan ime a a lowe alue. Concu en execu ion o mul iple PID con olle s was assu ed by assigning sepa a e FPGA ha dwa e esou ces o e e y PID con olle . Digi al inpu o he PID con olle is ou ed by he no el idea o analog o digi al con e sion (ADC), pe o med using a digi al o analog con e e (DAC), compa a o , and FPGA. ADC combined wi h dedica ed PID con olle logic in an FPGA o e e y closed-loop con ol sys em con i ms concu en execu ion o mul iple PID con olle s. The ime equi ed o execu e wo closed-loop con ols was iden i ied as 18.96000004 ms. This design can be used ei he wi h o wi hou a PLC. Keywo ds: analog o digi al con e sion; da a acquisi ion; ield p og ammable ga e a ays; PI con ol; p og ammable logic con olle ; scan ime 1. In oduc ion The con ibu ion o a p og ammable logic con olle (PLC) in an au oma ion sys em is signi ican . I ac s as a con olle o closed-loop sys em(s) and execu es combina ional o sequen ial logic epea edly h ough he ladde diag am (LD). I is capable o handling a su icien numbe o analog and digi al signals. Howe e , adding mo e and mo e signals o i is a bu den. The PLC needs an analog inpu module (AIM), an analog ou pu module (AOM), and a p opo ional, in eg al, and de i a i e (PID) unc ion block in he LD o ealize a closed-loop con ol sys em. This ensu es ha he ou pu o he closed-loop con ol sys em is always a he desi ed alue. Whene e he PLC eads he PID unc ion block in i s LD, i e e s o he AIM o ead he analog alue conce ned wi h ha unc ion block. I gene a es a digi al ou pu a e comple ing he execu ion o he PID unc ion block and o wa ds i o he AOM. A digi al o analog con e e (DAC) in he AOM con e s his digi al ou pu in o an analog signal and ac i a es he inal con ol elemen . Adding mo e PID unc ion blocks delays he execu ion o he emaining ungs in he LD and inc eases he scan ime o he PLC. The basic eason behind his is ha he PLC, AIM, and AOM ha e p ocesso s o pe o m hei unc ions. An elabo a e li e a u e e iew was ca ied ou o unde s and how esea che s ocus on he mul iple closed-loop con ol sys ems. A model o composi ion and in en o y con ol o a con inuous e hanol–wa e nonlinea pilo dis illa ion column has been de eloped in [ 1 ]. A compu e ac s as a con olle , and he con ol ac ion is es ablished using a neu al ne wo k combined wi h he gene ic algo i hm. A no el echnique o moni o he condi ion Senso s 2022,22, 4584. h ps://doi.o g/10.3390/s22124584 h ps://www.mdpi.com/jou nal/senso s Senso s 2022,22, 4584 2 o 17 o a wind u bine gea box using an NI da a acquisi ion ca d and LabVIEW is explained in [ 2 ]. The design in oduced a new signal p ocessing echnique o moni o he condi ion o he gea box. A digi al signal p ocesso (DSP)-based speed con ol ac ion o a h ee-phase induc ion mo o using he ec o -con olled me hod has been implemen ed in [ 3 ]. The DSP p ocesso modi ies he alue o he phase cu en o a y he mo o speed. A wa e pumping sys em has been de eloped in [ 4 ]. I used a PLC and an indus ial wide a ea ne wo k (WAN) o con ol he wa e le el in he ank. The digi al implemen a ion o a as , disc e e S ockwell ans o m (FDST) o accu a e powe quali y (PQ) e en de ec ion and ene gy me e ing is discussed in [ 5 ]. The FDST algo i hm was implemen ed in an FPGA, and he PQ e en s we e analyzed using LabVIEW. The design used a 12-bi analog o digi al con e e (ADC), a ailable in he FPGA boa d, o con e he es analog signal in o digi al. A PLC-SCADA-based con ol sys em o a wa e s o age ank is discussed in [ 6 ]. I used an RSLOGIX 5000 PLC in i s design. The speed con ol o a h ee-phase induc ion mo o using a PLC has been implemen ed by [ 7 ]. The PLC main ains he speed o he induc ion mo o a he desi ed alue. An idea o de ec ing induc ion mo o aul s using FPGAs is discussed in [ 8 ]. I used a 16-bi se ial ou pu ADC o con e he acqui ed cu en signal in o a digi al signal. The design o a pa allelized mul i-PID con olle using a ield p og ammable ga e a ay (FPGA)-based mul ip ocesso is discussed in [ 9 ]. I used an enhanced PicoBlaze mic ocon olle (EPM). The design was es ed wi h ou PID con olle s ha an simul ane- ously. Howe e , his wo k did no discuss how his mul iple PID con olle handles analog signals. An example ci ed in he wo k does no equi e he con e sion o analog signals in o digi al. The e o e, i is no clea whe he his design can pe o m he concu en execu ion o mul iple PID con olle s when an analog signal is o be main ained a he desi ed se poin . Thus, he e iew indica es ha single o mul iple closed-loop con ol sys ems ha e been de eloped using a PLC, compu e , DSP, o FPGA, o a combina ion o hese pieces o equipmen . The FPGA has being iden i ied as a be e al e na i e ha can pe o m he unc ion o a p ocesso [ 10 ] in an imp o ed way. One such example is he design o he FPGA-based loa ing-poin p ocesso discussed in [ 11 ]. FPGAs can also be used in he implemen a ion o PID con olle s [ 12 , 13 ]. The design o an ul asonic local posi ioning sys em using an FPGA o obo applica ions is discussed in [ 14 ]. I used a PID con olle so ha he obo could ack he line accu a ely. Resea che s a e eage o ind an op imized solu ion o PLCs in e ms o FPGAs [ 15 ]. Resea che s ha e also s a ed o ealize PID con olle s using FPGAs, as discussed in [ 16 ]. This wo k p oposed a me hod in which mo e han one closed-loop con ol sys em will be concu en ly p ocessed by he dedica ed ha dwa e esou ces o he FPGA wi hou comp omising he scan ime o he PLC. 2. O e iew o Closed-Loop Con ol Sys em wi h PLC In he ea ly 1990s, esea che s de eloped a dedica ed ha dwa e con olle ha did no demand any so wa e. The ASIC design o a PI con olle is discussed in [ 17 ]. Realiza ion o a mul iple PID con olle using a low powe single chip has been discussed in [ 18 ]. Con en ionally, a closed-loop con ol sys em has a con olle , inal con ol elemen , and ansmi e . The con olle compa es he desi ed alue wi h he ansmi e ou pu and ac ua es he inal con ol elemen o main ain he p ocess a iable a he desi ed alue. The con olle employs a mic op ocesso /mic ocon olle [ 19 ] o ealize con olle algo i hms such as P/PI/PID. I has an inbuil ADC o con e he analog ou pu o he ansmi e signal in o digi al. A single closed-loop con ol sys em needs an ADC, a mic op ocesso as a con olle , and a DAC. This coun inc eases along wi h he numbe o closed-loop con ol sys ems. Howe e , a single mic op ocesso shall be de ined as a con olle . In a p ac ical scena io, all he ADCs and DACs a e de eloped as AIMs and AOMs, espec i ely. The p ocesso in he PLC is used o execu e he con ol algo i hm, as shown in Figu e 1. Senso s 2022,22, 4584 3 o 17 Senso s 2022, 22, x FOR PEER REVIEW 3 o 15 Figu e 1. O ganiza ion o closed-loop con ol sys em using a PLC. Bo h he AIM and he AOM mus ha e a p ocesso o ensu e p ope signal con e - sion. Thus, he AIM, AOM, and PLC ha e p ocesso s in hei a chi ec u e [20]. Because he p ocesso execu es only one ins uc ion a a ime, he PLC has o wai o he AIM o comple e i s ope a ion. The PID unc ion block in he LD is o de ed as las in he execu ion o a ladde diag am. Including PID unc ion blocks in he LD c ea es an unnecessa y delay in he execu ion o digi al signals. I he e is a de ice ha akes ca e o PID unc ion blocks, hen he bu den o he PLC can be g ea ly educed. This wo k has p oposed a solu ion o mul iple PID con olle s de eloped using an FPGA ha can be con igu ed as a mix u e o AIM, DIM, AOM, and DOM. The p esen con igu a ion o a PLC-based au oma ion sys em does no ha e he con igu a ion o AIM/AOM/DIM/DOM in a single module. 3. Design o Single and Mul iple PID Con olle s Sec ions 3.1. and 3.2. elabo a e he design o single and mul iple PID con olle s de- eloped using an FPGA. Sec ion 3.1.1 explains he design o an ADC ha ensu es concu - en con e sion o mo e han one analog signal in o digi al. As a whole, his chap e p o- ides a no el solu ion o he simul aneous p ocessing o all PID con olle s. 3.1. FPGA Design o PID Con olle A PID con olle helps o main ain he alue o a p ocess pa ame e a he desi ed alue. I equi es h ee pa ame e s, p opo ional gain, in eg al ime, and de i a i e ime, o be adjus ed o achie e be e pe o mance. In his wo k, Ve ilogHDL code has been de eloped o he PID con olle . I equi ed, he PID con olle can be easily changed in o a PI con olle by assigning he de i a i e ime as ze o in HDL (Ha dwa e Desc ip ion Language) code [21]. The s anda d equa ion o a PID con olle is gi en as: ()= ()+ () + ()  (1) In Equa ion (1), () is he e o signal, () is he con olle ou pu ,  is he p o- po ional gain,  is he in eg al ime, and  is he de i a i e ime. Because he equa ion mus be ealized by an FPGA, i is con e ed in o he o m o a di e ence equa ion [22,23], as men ioned in Equa ion (2). 󰇟󰇠= 󰇟−1 󰇠+ 󰇟󰇠+ 󰇟−1 󰇠+ 󰇟−2 󰇠 (2) whe e, = + +  Figu e 1. O ganiza ion o closed-loop con ol sys em using a PLC. Bo h he AIM and he AOM mus ha e a p ocesso o ensu e p ope signal con e sion. Thus, he AIM, AOM, and PLC ha e p ocesso s in hei a chi ec u e [ 20 ]. Because he p ocesso execu es only one ins uc ion a a ime, he PLC has o wai o he AIM o comple e i s ope a ion. The PID unc ion block in he LD is o de ed as las in he execu ion o a ladde diag am. Including PID unc ion blocks in he LD c ea es an unnecessa y delay in he execu ion o digi al signals. I he e is a de ice ha akes ca e o PID unc ion blocks, hen he bu den o he PLC can be g ea ly educed. This wo k has p oposed a solu ion o mul iple PID con olle s de eloped using an FPGA ha can be con igu ed as a mix u e o AIM, DIM, AOM, and DOM. The p esen con igu a ion o a PLC-based au oma ion sys em does no ha e he con igu a ion o AIM/AOM/DIM/DOM in a single module. 3. Design o Single and Mul iple PID Con olle s Sec ion 3.1. and Sec ion 3.2. elabo a e he design o single and mul iple PID con olle s de eloped using an FPGA. Sec ion 3.1.1 explains he design o an ADC ha ensu es concu en con e sion o mo e han one analog signal in o digi al. As a whole, his chap e p o ides a no el solu ion o he simul aneous p ocessing o all PID con olle s. 3.1. FPGA Design o PID Con olle A PID con olle helps o main ain he alue o a p ocess pa ame e a he desi ed alue. I equi es h ee pa ame e s, p opo ional gain, in eg al ime, and de i a i e ime, o be adjus ed o achie e be e pe o mance. In his wo k, Ve ilogHDL code has been de eloped o he PID con olle . I equi ed, he PID con olle can be easily changed in o a PI con olle by assigning he de i a i e ime as ze o in HDL (Ha dwa e Desc ip ion Language) code [21]. The s anda d equa ion o a PID con olle is gi en as: u( ) = kP e( ) + 1 TI Z 0 e( )d +TD de( ) d  (1) In Equa ion (1), e( ) is he e o signal, u( ) is he con olle ou pu , kP is he p opo - ional gain, TI is he in eg al ime, and TD is he de i a i e ime. Because he equa ion mus be ealized by an FPGA, i is con e ed in o he o m o a di e ence equa ion [ 22 , 23 ], as men ioned in Equa ion (2). u[k] = u[k−1]+k1e[k] + k2e[k−1]+k3e[k−2](2) Senso s 2022,22, 4584 4 o 17 whe e, k1=kp(1+ki+kd) k2=−kp(1+2kd) k3=kpkd Inpu s and ou pu s o and om he mul iple closed-loop con ol sys em a e mul iple. The execu ion becomes concu en when sepa a e ha dwa e is assigned o execu e Equa ion (2) o e e y inpu . Hence, mul iple closed-loop con ol sys ems designed using FPGAs can be isualized as eal mul iple inpu and mul iple ou pu sys ems. 3.1.1. Single Closed-Loop Con ol Sys em—P oposed In a closed-loop con ol sys em, inpu s o a PID con olle a e se o poin o he ansmi e ’s ou pu , whe ein he calcula ion o he con ol e o (di e ence o hese inpu s) is ealized in-side he con olle . The ansmi e ecei es inpu om a senso . An indus ial s anda d ansmi e gene a es ou pu in he ange o 0–5 V. The ou pu o he ansmi e is an analog signal. The in e ace ci cui ha comp ises a DAC, compa a o , and analog o digi al con e sion logic in he FPGA, as in Figu e 2, con e s he ansmi e ’s analog signal in o digi al. The wo king p inciple o successi e app oxima ion egis e (SAR) ype ADC is p e e ed in many applica ions, as men ioned in [24]. Senso s 2022, 22, x FOR PEER REVIEW 4 o 15 =− −2  =  Inpu s and ou pu s o and om he mul iple closed-loop con ol sys em a e mul iple. The execu ion becomes concu en when sepa a e ha dwa e is assigned o execu e Equa- ion (2) o e e y inpu . Hence, mul iple closed-loop con ol sys ems designed using FPGAs can be isualized as eal mul iple inpu and mul iple ou pu sys ems. 3.1.1. Single Closed-Loop Con ol Sys em—P oposed In a closed-loop con ol sys em, inpu s o a PID con olle a e se o poin o he ans- mi e ’s ou pu . The ansmi e ecei es inpu om a senso . An indus ial s anda d ansmi e gene a es ou pu in he ange o 0–5 . The ou pu o he ansmi e is an analog signal. The in e ace ci cui ha comp ises a DAC, compa a o , and analog o dig- i al con e sion logic in he FPGA, as in Figu e 2, con e s he ansmi e ’s analog signal in o digi al. The wo king p inciple o successi e app oxima ion egis e (SAR) ype ADC is p e e ed in many applica ions, as men ioned in [24] Figu e 2. FPGA design o single closed-loop con ol sys em. This wo k has p oposed a no el con e sion p ocess o analog signals in o digi al, which can be seen in Figu e 3. I was de eloped, simula ed, and e i ied using Mul isim [25]. Figu e 3. FPGA design o analog inpu module o a single channel. I unc ions on he wo king p inciple o successi e app oxima ion egis e (SAR) ype ADC. The mos signi ican bi (MSB) o he SAR egis e will be se , and he emaining bi s will be in ese condi ion. A egis e in an FPGA is decla ed as a SAR egis e . The Figu e 2. FPGA design o single closed-loop con ol sys em. This wo k has p oposed a no el con e sion p ocess o analog signals in o digi- al, which can be seen in Figu e 3. I was de eloped, simula ed, and e i ied using Mul isim [25]. Senso s 2022,22, 4584 5 o 17 Senso s 2022, 22, x FOR PEER REVIEW 4 o 15 =− −2  =  Inpu s and ou pu s o and om he mul iple closed-loop con ol sys em a e mul iple. The execu ion becomes concu en when sepa a e ha dwa e is assigned o execu e Equa- ion (2) o e e y inpu . Hence, mul iple closed-loop con ol sys ems designed using FPGAs can be isualized as eal mul iple inpu and mul iple ou pu sys ems. 3.1.1. Single Closed-Loop Con ol Sys em—P oposed In a closed-loop con ol sys em, inpu s o a PID con olle a e se o poin o he ans- mi e ’s ou pu . The ansmi e ecei es inpu om a senso . An indus ial s anda d ansmi e gene a es ou pu in he ange o 0–5 . The ou pu o he ansmi e is an analog signal. The in e ace ci cui ha comp ises a DAC, compa a o , and analog o dig- i al con e sion logic in he FPGA, as in Figu e 2, con e s he ansmi e ’s analog signal in o digi al. The wo king p inciple o successi e app oxima ion egis e (SAR) ype ADC is p e e ed in many applica ions, as men ioned in [24] Figu e 2. FPGA design o single closed-loop con ol sys em. This wo k has p oposed a no el con e sion p ocess o analog signals in o digi al, which can be seen in Figu e 3. I was de eloped, simula ed, and e i ied using Mul isim [25]. Figu e 3. FPGA design o analog inpu module o a single channel. I unc ions on he wo king p inciple o successi e app oxima ion egis e (SAR) ype ADC. The mos signi ican bi (MSB) o he SAR egis e will be se , and he emaining bi s will be in ese condi ion. A egis e in an FPGA is decla ed as a SAR egis e . The Figu e 3. FPGA design o analog inpu module o a single channel. I unc ions on he wo king p inciple o successi e app oxima ion egis e (SAR) ype ADC. The mos signi ican bi (MSB) o he SAR egis e will be se , and he emaining bi s will be in ese condi ion. A egis e in an FPGA is decla ed as a SAR egis e . The DAC con e s his SAR con en in o analog, and a compa a o compa es i wi h he analog signal ha is o be con e ed in o digi al. Because he DAC ou pu is connec ed o he non-in e ing inpu o he compa a o , he MSB will be e ained as such, p o ided he DAC ou pu is g ea e han he analog inpu signal. O he wise, i will be ese . Se ing o ese ing he SAR con en will be comple ed by he FPGA. The FPGA hen se s he consecu i e MSB bi leading owa ds he leas signi ican bi (LSB) and epea s he abo e p ocedu e. Because all he bi s ha e o be e i ied in his manne , an 8-bi ADC will equi e eigh clock pulses. The equi alen digi al ou pu o he analog signal can be iden i ied by eading he con en o he SAR egis e a he eigh h clock pulse. I can also be ead by a compu e h ough RS232 se ial da a communica ion. This helps o es ablish a da a acquisi ion sys em (DAS). The con e sion ime, τ c, o he p oposed design is compu ed based on he se ling ime o DAC0808 ( τ s), he delay ime o he compa a o ( τ cd), and he delay ime o he FPGA logic ( τ d). The digi al ou pu o he ADC in his wo k is 8-bi . Hence, τ cis calcula ed om he ollowing Equa ion (3): τc=8×(τs+τcd +τ d)(3) In gene al, o an nbi ADC, Equa ion (2) is modi ied o: τc=n×(τs+τcd +τ d)(4) whe e nindica es he numbe o clock cycles equi ed o comple e he con e sion. Thus, he gene a ed digi al ou pu is s o ed in he FPGA egis e . The PID con ol logic shown in Figu e 2accep s his egis e con en as i s p ocess a iable. The e o e, e( ) is gene a ed by sub ac ing he se poin om he alue o he p ocess a iable. PID con ol logic gene a es u( ) and o wa ds i o he inal con ol elemen (FCE). Usually, he FCE accep s analog signals. Hence, he digi al ou pu o he PID con olle is con e ed in o analog using DAC. Real- ime implemen a ion o a closed-loop con ol sys em has used DAC0808, IC741, and XC3S200 FPGA chips. The compa a o was designed using IC741. The clock signal applied o he Xilinx XC3S200 FPGA chip was 50 MHz. 3.1.2. Mul iple Closed-Loop Con ol Sys em—P oposed Con en ionally, he mic op ocesso p ocesses mul iple closed-loop con ol sys ems. Howe e , i sequen ially execu es all he closed-loop sys ems, as men ioned in Figu e 4. Senso s 2022,22, 4584 6 o 17 Senso s 2022, 22, x FOR PEER REVIEW 5 o 15 DAC con e s his SAR con en in o analog, and a compa a o compa es i wi h he analog signal ha is o be con e ed in o digi al. Because he DAC ou pu is connec ed o he non- in e ing inpu o he compa a o , he MSB will be e ained as such, p o ided he DAC ou pu is g ea e han he analog inpu signal. O he wise, i will be ese . Se ing o ese ing he SAR con en will be comple ed by he FPGA. The FPGA hen se s he consecu i e MSB bi leading owa ds he leas signi ican bi (LSB) and epea s he abo e p ocedu e. Because all he bi s ha e o be e i ied in his manne , an 8-bi ADC will equi e eigh clock pulses. The equi alen digi al ou pu o he analog signal can be iden i ied by eading he con en o he SAR egis e a he eigh h clock pulse. I can also be ead by a compu e h ough RS232 se ial da a communica ion. This helps o es ablish a da a acquisi ion sys- em (DAS). Th econ e sion ime, τc, o he p oposed design is compu ed based on he se ling ime o DAC0808 (τs), he delay ime o he compa a o (τcd), and he delay ime o he FPGA logic (τ d). The digi al ou pu o he ADC in his wo k is 8-bi . Hence, τc is calcu- la ed om he ollowing Equa ion (3):  = 8 ×  +  +  d (3) In gene al, o an  bi ADC, Equa ion (2) is modi ied o:  =  ×  +  +  d (4) whe e  indica es he numbe o clock cycles equi ed o comple e he con e sion. Thus, he gene a ed digi al ou pu is s o ed in he FPGA egis e . The PID con ol logic shown in Figu e 2 accep s his egis e con en as i s p ocess a iable. The e o e, e( ) is gene a ed by sub ac ing he se poin om he alue o he p ocess a iable. PID con ol logic gene a es u( ) and o wa ds i o he inal con ol elemen (FCE). Usually, he FCE accep s analog signals. Hence, he digi al ou pu o he PID con olle is con e ed in o analog using DAC. Real- ime implemen a ion o a closed-loop con ol sys em has used DAC0808, IC741, and XC3S200 FPGA chips. The compa a o was designed using IC741. The clock signal applied o he Xilinx XC3S200 FPGA chip was 50MHz. 3.1.2. Mul iple Closed-Loop Con ol Sys em—P oposed Con en ionally, he mic op ocesso p ocesses mul iple closed-loop con ol sys ems. Howe e , i sequen ially execu es all he closed-loop sys ems, as men ioned in Figu e 4. Figu e 4. Mul iple PID con olle equa ion o mic op ocesso . One o he majo d awbacks o his sys em is ha he p ocesso will be able o execu e i s  PID con olle equa ion a  μs, assuming he ime equi ed o execu e one PID con olle is 1 μ. The p oposed sys em was used o de eloped a mul iple PID con olle by which all PID con olle equa ions will be execu ed simul aneously, as in Figu e 5. The Figu e 4. Mul iple PID con olle equa ion o mic op ocesso . One o he majo d awbacks o his sys em is ha he p ocesso will be able o execu e i s n h PID con olle equa ion a n h µs , assuming he ime equi ed o execu e one PID con olle is 1 µs . The p oposed sys em was used o de eloped a mul iple PID con olle by which all PID con olle equa ions will be execu ed simul aneously, as in Figu e 5. The pa allel p ocessing capaci y o an FPGA discussed in [ 26 ] indica es he possibili y o ealizing mul iple PID con olle s using FPGAs. Senso s 2022, 22, x FOR PEER REVIEW 6 o 15 pa allel p ocessing capaci y o an FPGA discussed in [26] indica es he possibili y o eal- izing mul iple PID con olle s using FPGAs. Figu e 5. Mul iple PID con olle equa ion o FPGA. This is achie ed by assigning sepa a e PID con olle logic and hence sepa a e FPGA ha dwa e esou ces o each closed-loop con ol sys em. Assigning ha dwa e o each PID con olle does no demand any no el y. A pe ec mul iple closed-loop con ol sys em can be es ablished when all he PID con olle s can simul aneously access i s desi ed alue in he o m o a digi al signal. This wo k has esol ed he issue by in eg a ing he ADC con e sion p ocess wi h he PID con olle , as in Figu e 6. By compa ing Figu e 6 wi h Figu e 2, one can unde s and ha a mul iple PID closed-loop con ol sys em is es ablished wi h a compa a o , wo DACs, and PID con olle logic o e e y closed-loop con ol sys- em. Figu e 6. Closed-loop con ol sys em o wo analog signals. Figu e 6 shows he design ha can concu en ly main ain wo p ocess pa ame e s a hei desi ed alues. The concep o AIMs e ol ed when a se o DAC0808 and a compa - a o is included o e e y closed-loop con ol sys em. Simila ly, he concep o AOMs e ol ed when a DAC0808 is included in e e y closed-loop con ol sys em. In he same way, indi idual PID con ol logic is adop ed in FPGAs o e e y closed-loop con ol sys- em. Thus, he FPGA plays he ole o he PLC. I should be no ed ha Figu e 6 is e ol ed om Figu es 2 and 3. Thus, he no el y o his wo k is iden i ied in Figu e 6. I has an AIM, an AOM, and a PID con olle . The maximum numbe o closed-loop con ol sys- ems ha can be ealized in an FPGA is based on i s ha dwa e esou ces. This wo k has de eloped Ve ilogHDL code o eigh closed-loop con ol sys ems, which ha e used app oxima ely 55% o he FPGA ha dwa e esou ces. Figu e 5. Mul iple PID con olle equa ion o FPGA. This is achie ed by assigning sepa a e PID con olle logic and hence sepa a e FPGA ha dwa e esou ces o each closed-loop con ol sys em. Assigning ha dwa e o each PID con olle does no demand any no el y. A pe ec mul iple closed-loop con ol sys em can be es ablished when all he PID con olle s can simul aneously access i s desi ed alue in he o m o a digi al signal. This wo k has esol ed he issue by in eg a ing he ADC con e sion p ocess wi h he PID con olle , as in Figu e 6. By compa ing Figu e 6 wi h Figu e 2, one can unde s and ha a mul iple PID closed-loop con ol sys em is es ablished wi h a compa a o , wo DACs, and PID con olle logic o e e y closed-loop con ol sys em. Senso s 2022,22, 4584 7 o 17 Senso s 2022, 22, x FOR PEER REVIEW 6 o 15 pa allel p ocessing capaci y o an FPGA discussed in [26] indica es he possibili y o eal- izing mul iple PID con olle s using FPGAs. Figu e 5. Mul iple PID con olle equa ion o FPGA. This is achie ed by assigning sepa a e PID con olle logic and hence sepa a e FPGA ha dwa e esou ces o each closed-loop con ol sys em. Assigning ha dwa e o each PID con olle does no demand any no el y. A pe ec mul iple closed-loop con ol sys em can be es ablished when all he PID con olle s can simul aneously access i s desi ed alue in he o m o a digi al signal. This wo k has esol ed he issue by in eg a ing he ADC con e sion p ocess wi h he PID con olle , as in Figu e 6. By compa ing Figu e 6 wi h Figu e 2, one can unde s and ha a mul iple PID closed-loop con ol sys em is es ablished wi h a compa a o , wo DACs, and PID con olle logic o e e y closed-loop con ol sys- em. Figu e 6. Closed-loop con ol sys em o wo analog signals. Figu e 6 shows he design ha can concu en ly main ain wo p ocess pa ame e s a hei desi ed alues. The concep o AIMs e ol ed when a se o DAC0808 and a compa - a o is included o e e y closed-loop con ol sys em. Simila ly, he concep o AOMs e ol ed when a DAC0808 is included in e e y closed-loop con ol sys em. In he same way, indi idual PID con ol logic is adop ed in FPGAs o e e y closed-loop con ol sys- em. Thus, he FPGA plays he ole o he PLC. I should be no ed ha Figu e 6 is e ol ed om Figu es 2 and 3. Thus, he no el y o his wo k is iden i ied in Figu e 6. I has an AIM, an AOM, and a PID con olle . The maximum numbe o closed-loop con ol sys- ems ha can be ealized in an FPGA is based on i s ha dwa e esou ces. This wo k has de eloped Ve ilogHDL code o eigh closed-loop con ol sys ems, which ha e used app oxima ely 55% o he FPGA ha dwa e esou ces. Figu e 6. Closed-loop con ol sys em o wo analog signals. Figu e 6shows he design ha can concu en ly main ain wo p ocess pa ame e s a hei desi ed alues. The concep o AIMs e ol ed when a se o DAC0808 and a compa a o is included o e e y closed-loop con ol sys em. Simila ly, he concep o AOMs e ol ed when a DAC0808 is included in e e y closed-loop con ol sys em. In he same way, indi idual PID con ol logic is adop ed in FPGAs o e e y closed-loop con ol sys em. Thus, he FPGA plays he ole o he PLC. I should be no ed ha Figu e 6is e ol ed om Figu es 2and 3. Thus, he no el y o his wo k is iden i ied in Figu e 6. I has an AIM, an AOM, and a PID con olle . The maximum numbe o closed-loop con ol sys ems ha can be ealized in an FPGA is based on i s ha dwa e esou ces. This wo k has de eloped Ve ilogHDL code o eigh closed-loop con ol sys ems, which ha e used app oxima ely 55% o he FPGA ha dwa e esou ces. 3.2. Case S udy o Mul iple PID Con olle —Le el and P essu e P ocess S a ion The design o mul iple closed-loop con ol sys ems was es ed and e i ied o wo closed-loop con ol sys ems. The design depic ed in Figu e 5was used o main ain he desi ed alue o le el and p essu e o he le el and p essu e p ocess s a ions, espec i ely. 3.2.1. Le el P ocess S a ion The Labo a o y se -up o he le el and p essu e p ocess s a ion used o es he closed- loop con ol sys em is shown in Figu e 7. A pump loca ed below he s o age ank pumps wa e om he ese oi ank. I has wo ou le s. One is connec ed o a s o age ank and he o he o he ese oi . Senso s 2022,22, 4584 8 o 17 Senso s 2022, 22, x FOR PEER REVIEW 7 o 15 3.2. Case S udy o Mul iple PID Con olle —Le el and P essu e P ocess S a ion The design o mul iple closed-loop con ol sys ems was es ed and e i ied o wo closed-loop con ol sys ems. The design depic ed in Figu e 5 was used o main ain he desi ed alue o le el and p essu e o he le el and p essu e p ocess s a ions, espec i ely. 3.2.1. Le el P ocess S a ion The Labo a o y se -up o he le el and p essu e p ocess s a ion used o es he closed-loop con ol sys em is shown in Figu e 7. A pump loca ed below he s o age ank pumps wa e om he ese oi ank. I has wo ou le s. One is connec ed o a s o age ank and he o he o he ese oi . Figu e 7. Le el p ocess s a ion. The con ol al e is ins alled in be ween he pipeline o he pump and he s o age ank. A capaci ance p obe senso is used o sense he wa e le el. I s ou pu is con e ed in o 4 o 20 mA cu en signal by a le el ansmi e . The connec ion be ween he ans- mi e and he non-in e ing e minal o he compa a o is shown in Figu e 8. An indus- ial s anda d ansmi e gene a es an ou pu o 4 o 20 mA cu en signal (Suni a Sinha [27]). A esis o is connec ed in se ies wi h he 24 V DC powe supply o con e he 4 o 20 mA cu en signal in o a 1 V o 5 V ol age signal. An equi alen esis o ha adop s he con e sion o cu en signal in o ol age was iden i ied as 240 Ω. The ou pu o he FPGA is connec ed o he I/P con e e . Figu e 8. Con e sion o he ou pu cu en o he ansmi e in o ol age. A esis o connec ed in se ies wi h he DAC and I/P con e e ensu es ha he cu en lowing in he loop is in he ange o 4 o 20 mA. DAC ou pu is se as 5 V. The esis o alue is adjus ed and ound o be 130 Ω when he cu en low in he ci cui is 20 mA [28]. 3.2.2. P essu e P ocess S a ion The labo a o y se up o he p essu e p ocess s a ion in Figu e 7 has wo s o age anks o s o e comp essed ai . I is possible o s o e comp essed ai , ei he in bo h he anks o only in one ank, by ope a ing he hand al e in e linked be ween he wo anks. The maximum p essu e ha can be s o ed in he ank is 2 Kg/cm. As discussed in he le el Figu e 7. Le el p ocess s a ion. The con ol al e is ins alled in be ween he pipeline o he pump and he s o age ank. A capaci ance p obe senso is used o sense he wa e le el. I s ou pu is con e ed in o 4 o 20 mA cu en signal by a le el ansmi e . The connec ion be ween he ansmi e and he non-in e ing e minal o he compa a o is shown in Figu e 8. An indus ial s anda d ansmi e gene a es an ou pu o 4 o 20 mA cu en signal (Suni a Sinha [ 27 ]). A esis o is connec ed in se ies wi h he 24 V DC powe supply o con e he 4 o 20 mA cu en signal in o a 1 V o 5 V ol age signal. An equi alen esis o ha adop s he con e sion o cu en signal in o ol age was iden i ied as 240 Ω . The ou pu o he FPGA is connec ed o he I/P con e e . Senso s 2022, 22, x FOR PEER REVIEW 7 o 15 3.2. Case S udy o Mul iple PID Con olle —Le el and P essu e P ocess S a ion The design o mul iple closed-loop con ol sys ems was es ed and e i ied o wo closed-loop con ol sys ems. The design depic ed in Figu e 5 was used o main ain he desi ed alue o le el and p essu e o he le el and p essu e p ocess s a ions, espec i ely. 3.2.1. Le el P ocess S a ion The Labo a o y se -up o he le el and p essu e p ocess s a ion used o es he closed-loop con ol sys em is shown in Figu e 7. A pump loca ed below he s o age ank pumps wa e om he ese oi ank. I has wo ou le s. One is connec ed o a s o age ank and he o he o he ese oi . Figu e 7. Le el p ocess s a ion. The con ol al e is ins alled in be ween he pipeline o he pump and he s o age ank. A capaci ance p obe senso is used o sense he wa e le el. I s ou pu is con e ed in o 4 o 20 mA cu en signal by a le el ansmi e . The connec ion be ween he ans- mi e and he non-in e ing e minal o he compa a o is shown in Figu e 8. An indus- ial s anda d ansmi e gene a es an ou pu o 4 o 20 mA cu en signal (Suni a Sinha [27]). A esis o is connec ed in se ies wi h he 24 V DC powe supply o con e he 4 o 20 mA cu en signal in o a 1 V o 5 V ol age signal. An equi alen esis o ha adop s he con e sion o cu en signal in o ol age was iden i ied as 240 Ω. The ou pu o he FPGA is connec ed o he I/P con e e . Figu e 8. Con e sion o he ou pu cu en o he ansmi e in o ol age. A esis o connec ed in se ies wi h he DAC and I/P con e e ensu es ha he cu en lowing in he loop is in he ange o 4 o 20 mA. DAC ou pu is se as 5 V. The esis o alue is adjus ed and ound o be 130 Ω when he cu en low in he ci cui is 20 mA [28]. 3.2.2. P essu e P ocess S a ion The labo a o y se up o he p essu e p ocess s a ion in Figu e 7 has wo s o age anks o s o e comp essed ai . I is possible o s o e comp essed ai , ei he in bo h he anks o only in one ank, by ope a ing he hand al e in e linked be ween he wo anks. The maximum p essu e ha can be s o ed in he ank is 2 Kg/cm. As discussed in he le el Figu e 8. Con e sion o he ou pu cu en o he ansmi e in o ol age. A esis o connec ed in se ies wi h he DAC and I/P con e e ensu es ha he cu en lowing in he loop is in he ange o 4 o 20 mA. DAC ou pu is se as 5 V. The esis o alue is adjus ed and ound o be 130 Ω when he cu en low in he ci cui is 20 mA [ 28 ]. 3.2.2. P essu e P ocess S a ion The labo a o y se up o he p essu e p ocess s a ion in Figu e 7has wo s o age anks o s o e comp essed ai . I is possible o s o e comp essed ai , ei he in bo h he anks o only in one ank, by ope a ing he hand al e in e linked be ween he wo anks. The maximum p essu e ha can be s o ed in he ank is 2 Kg/cm2 . As discussed in he le el p ocess s a ion, esis o alues connec ed o he p essu e ansmi e and I/P con e e we e iden i ied as 240 Ωand 130 Ω, espec i ely. Senso s 2022,22, 4584 9 o 17 3.2.3. FPGA In e acing Boa d An FPGA in e ace boa d is designed o p ocess wo p ocess pa ame e s: le el and p essu e. Each pa ame e equi es wo DACs and one compa a o . One DAC and a compa a o a e used o con e he analog signal o he ansmi e ou pu in o digi al. A second DAC is used o ac i a e he I/P con e e o which he ou pu is ini ia ed om he FPGA as a con olle ou pu . Hence, he in e ace boa d has ou DAC0808 chips and wo compa a o s, which we e designed using IC741, as shown in Figu e 9. Senso s 2022, 22, x FOR PEER REVIEW 8 o 15 p ocess s a ion, esis o alues connec ed o he p essu e ansmi e and I/P con e e we e iden i ied as 240 Ω and 130 Ω, espec i ely. 3.2.3. FPGA In e acing Boa d An FPGA in e ace boa d is designed o p ocess wo p ocess pa ame e s: le el and p essu e. Each pa ame e equi es wo DACs and one compa a o . One DAC and a com- pa a o a e used o con e he analog signal o he ansmi e ou pu in o digi al. A sec- ond DAC is used o ac i a e he I/P con e e o which he ou pu is ini ia ed om he FPGA as a con olle ou pu . Hence, he in e ace boa d has ou DAC0808 chips and wo compa a o s, which we e designed using IC741, as shown in Figu e 9. Figu e 9. In e ace boa d o ADC con e sion, DAC ou pu o I/P con e e . DAC1 and DAC2 a e used o he p essu e p ocess s a ion, and DAC3 and DAC4 a e used o he le el p ocess s a ion. The ou pu s o compa a o s and inpu s o he DACs a e in eg a ed in o a single 50-pin connec o so ha he o he end o he connec o can be connec ed o he FPGA boa d (XC3S200). This boa d has one 40 pin connec o , h ee 25 pin connec o s, and one uni e sal asynch onous ecei e ansmi e (UART) connec o . Addi ionally, i has eigh swi ches and eigh ligh emi ing diodes (LEDs). 3.3. Ve ilogHDL Code—Acquisi ion, Con ol, UART The con ibu ion o FPGAs in he design o closed-loop con ol sys ems is c ucial. They a e used o con e an analog signal o ansmi e ou pu in o digi al, ini ia e con ol ac ions based on he ansmi e ou pu , and ans e necessa y da a o he compu e o moni o ing. 3.3.1. Ve ilogHDL Code—Single PID Con olle , UART FPGA implemen a ion o any design can be ca ied ou by ep esen ing a p oblem in HDL code. This is e i ied o i s p ope unc ionali y du ing simula ion. Thus, e i ied code is con e ed in o a bi ile a e syn hesis o FPGA implemen a ion. This wo k has used Ve ilogHDL code o de elop he en i e logic o he FPGA implemen a ion o mul i- ple closed-loop con ol sys ems. The essen ial elemen s o Ve ilogHDL code o a PID con olle is lis ed below. The main module  in okes he modules  and . The  module is esponsible o con e ing he analog signal in o a digi al signal based on he logic discussed in Sec ion 3.1.1. This digi al ou pu is applied as an inpu o he PID con- olle . Hence, he logic o gene a e con olle ou pu has also been included in his mod- ule. Thus, gene a ed con olle ou pu (  ) and digi al ou pu (), combined in o , a e ansmi ed o he compu e by execu ing he mod- ule . This pe o ms he unc ion o UART da a ansmission. Clock pulse ime, Figu e 9. In e ace boa d o ADC con e sion, DAC ou pu o I/P con e e . DAC1 and DAC2 a e used o he p essu e p ocess s a ion, and DAC3 and DAC4 a e used o he le el p ocess s a ion. The ou pu s o compa a o s and inpu s o he DACs a e in eg a ed in o a single 50-pin connec o so ha he o he end o he connec o can be connec ed o he FPGA boa d (XC3S200). This boa d has one 40 pin connec o , h ee 25 pin connec o s, and one uni e sal asynch onous ecei e ansmi e (UART) connec o . Addi ionally, i has eigh swi ches and eigh ligh emi ing diodes (LEDs). 3.3. Ve ilogHDL Code—Acquisi ion, Con ol, UART The con ibu ion o FPGAs in he design o closed-loop con ol sys ems is c ucial. They a e used o con e an analog signal o ansmi e ou pu in o digi al, ini ia e con ol ac ions based on he ansmi e ou pu , and ans e necessa y da a o he compu e o moni o ing. 3.3.1. Ve ilogHDL Code—Single PID Con olle , UART FPGA implemen a ion o any design can be ca ied ou by ep esen ing a p oblem in HDL code. This is e i ied o i s p ope unc ionali y du ing simula ion. Thus, e i ied code is con e ed in o a bi ile a e syn hesis o FPGA implemen a ion. This wo k has used Ve ilogHDL code o de elop he en i e logic o he FPGA implemen a ion o mul iple closed-loop con ol sys ems. The essen ial elemen s o Ve ilogHDL code o a PID con olle is lis ed below. The main module con olle in okes he modules con e and ansmi . The con e module is esponsible o con e ing he analog signal in o a digi al signal based on he logic discussed in Sec ion 3.1.1. This digi al ou pu is applied as an inpu o he PID con olle . Hence, he logic o gene a e con olle ou pu has also been included in his module. Thus, gene a ed con olle ou pu ( ou pu ocon olle ) and digi al ou pu ( da a odac ), combined in o da a , a e ansmi ed o he compu e by execu ing he module ansmi . This pe o ms he unc ion o UART da a ansmission. Clock pulse ime, clk , o he FPGA is educed o ‘clkdi ided’, which is he equi ed clock pulse o ADC con e sion. Simila ly, FPGA speed is Senso s 2022,22, 4584 16 o 17 highe execu ion speed when hese componen s a e eplaced by high-speed de ices. This p oposed design can be used independen ly o in combina ion wi h PLCs. The o al numbe o PID con olle s equi ed in an applica ion decides he numbe o FPGAs used in he design o mul iple PID con olle s. When he design is o be used wi h a PLC, he concep o ne wo king mus be included in he FPGA. This is also applicable when he e is a si ua ion in which he con en o one FPGA is o be sha ed wi h o he FPGAs. Hence, he au ho s ha e aimed o de elop mul iple PID con olle s ha suppo ne wo k communica ions in he u u e. Au ho Con ibu ions: Concep ualiza ion, G.D. and M.M.; da a cu a ion, G.D. and S.T.S.; o mal analysis, G.D. and S.T.S.; in es iga ion S.T.S.; me hodology, M.M.; so wa e, G.D. and M.M.; supe i- sion, M.M.; w i ing—o iginal d a , G.D. and S.T.S.; w i ing— e iew and edi ing, M.M. All au ho s ha e ead and ag eed o he published e sion o he manusc ip . Funding: This esea ch ecei ed no ex e nal unding. Ins i u ional Re iew Boa d S a emen : No applicable. In o med Consen S a emen : No applicable. Da a A ailabili y S a emen : No applicable. Con lic s o In e es : The au ho s decla e no con lic o in e es . Re e ences 1. De Cane e, J.F.; del Saz-O ozco, P.; Gonzalez, S.; Ga cia-Mo al, I. Dual composi ion con ol and so es ima ion o a pilo dis illa ion column using a neu ogene ic design. Compu . Chem. Eng. 2012,40, 157–170. [C ossRe ] 2. Salem, A.; Abu-Siada, A.; Islam, S. Imp o ed condi ion moni o ing echnique o wind u bine gea box and sha s ess de ec ion. IET Sci. Meas. Technol. 2017,11, 431–437. [C ossRe ] 3. Ca los, G.G.; Ju enal, R.R.; Geo gina, M.V.; Edga , R.A.; Jo ge, M.S.; Rica do, L.R. A PC-based a chi ec u e o pa ame e analysis o ec o -con olled induc ion mo o d i e. Compu . Elec . Eng. 2011,37, 858–868. 4. Bayindi , R.; Ce ince iz, Y. 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