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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
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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
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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.
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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.
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Bayindi , R.; Ce ince iz, Y. A wa e pumping con ol sys em wi h a p og ammable logic con olle (PLC) and indus ial wi eless
modules o indus ial plan s—An expe imen al se up. ISA T ans. 2011,50, 321–328. [C ossRe ] [PubMed]
5.
Jaiswal, S.; Ballal, M.S. FDST-based PQ e en de ec ion and ene gy me e ing implemen a ion on FPGA-in- he-loop and NI-
LabVIEW. IET Sci. Meas. Technol. 2017,11, 453–463. [C ossRe ]
6.
Chak abo y, K.; Choudhu y, M.; Das, S.; Paul, S. De elopmen o PLC-SCADA based con ol s a egy o wa e s o age in a ank
o a semi-au oma ed plan . J. Ins um. 2020,15, T04007. [C ossRe ]
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Ioannides, M. Design and Implemen a ion o PLC-Based Moni o ing Con ol Sys em o Induc ion Mo o . IEEE T ans. Ene gy
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