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大学生毕业设计外文文献.pdf
IEEE TRANSACTIONS ON ENERGY CONVERSION, VOL. 19, NO. 3, SEPTEMBER 2004
469
Design and Implementation of PLC-Based
Monitoring Control System for Induction Motor
Maria G. Ioannides, Senior Member, IEEE
Abstract—The implementation of a monitoring and control
system for the induction motor based on programmable logic con-
troller (PLC) technology is described. Also, the implementation of
the hardware and software for speed control and protection with
the results obtained from tests on induction motor performance
is provided. The PLC correlates the operational parameters to
the speed requested by the user and monitors the system during
normal operation and under trip conditions. Tests of the induction
motor system driven by inverter and controlled by PLC prove a
higher accuracy in speed regulation as compared to a conventional
V f control system. The efficiency of PLC control is increased
at high speeds up to 95% of the synchronous speed. Thus, PLC
proves themselves as a very versatile and effective tool in industrial
control of electric drives.
Index Terms—Computer-controlled systems,
monitoring, electric drives,
logic
programmable
drives, voltage control.
computerized
induction motors, motion control,
(PLCs), variable-frequency
controllers
I. INTRODUCTION
S INCE technology for motion control of electric drives be-
came available, the use of programmable logic controllers
(PLCs) with power electronics in electric machines applications
has been introduced in the manufacturing automation [1], [2].
This use offers advantages such as lower voltage drop when
turned on and the ability to control motors and other equip-
ment with a virtually unity power factor [3]. Many factories
use PLCs in automation processes to diminish production cost
and to increase quality and reliability [4]–[9]. Other applica-
tions include machine tools with improved precision comput-
erized numerical control (CNC) due to the use of PLCs [10].
To obtain accurate industrial electric drive systems, it is nec-
essary to use PLCs interfaced with power converters, personal
computers, and other electric equipment [11]–[13]. Neverthe-
less, this makes the equipment more sophisticated, complex, and
expensive [14], [15].
Few papers were published concerning dc machines con-
trolled by PLCs. They report both the implementation of the
fuzzy method for speed control of a dc motor/generator set
using a PLC to change the armature voltage [16], and the
incorporation of an adaptive controller based on the self-tuning
regulator technology into an existing industrial PLC [17]. Also,
other types of machines were interfaced with PLCs. Thereby,
an industrial PLC was used for controlling stepper motors
Manuscript received December 2, 2002. Paper no. TEC-00004-2002. This
work was supported by the National Technical University of Athens.
The author is with the Faculty of Electrical and Computer Engineering of
the National Technical University of Athens, Athens 15773, Greece (e-mail:
mioannid@ece.ntua.gr).
Digital Object Identifier 10.1109/TEC.2003.822303
in a five-axis rotor position, direction and speed, reducing
the number of circuit components, lowering the cost, and
enhancing reliability [18]. For switched reluctance motors as
a possible alternative to adjustable speed ac and dc drives, a
single chip logic controller for controlling torque and speed
uses a PLC to implement the digital logic coupled with a power
controller [19]. Other reported application concerns a linear
induction motor for passenger elevators with a PLC achieving
the control of the drive system and the data acquisition [20].
To monitor power quality and identify the disturbances that
disrupt production of an electric plant, two PLCs were used to
determine the sensitivity of the equipment [21].
Only few papers were published in the field of induction
motors with PLCs. A power factor controller for a three-phase
induction motor utilizes PLC to improve the power factor and
to keep its voltage to frequency ratio constant under the whole
control conditions [3]. The vector control integrated circuit
uses a complex programmable logic device (CPLD) and integer
arithmetic for the voltage or current regulation of three-phase
pulse-width modulation (PWM) inverters [22].
Many applications of induction motors require besides the
motor control functionality, the handling of several specific
analog and digital I/O signals, home signals,
trip signals,
on/off/reverse commands. In such cases, a control unit in-
volving a PLC must be added to the system structure. This
paper presents a PLC-based monitoring and control system
for a three-phase induction motor. It describes the design and
implementation of the configured hardware and software. The
test results obtained on induction motor performance show
improved efficiency and increased accuracy in variable-load
constant-speed-controlled operation. Thus, the PLC correlates
and controls the operational parameters to the speed set point
requested by the user and monitors the induction motor system
during normal operation and under trip conditions.
II. PLC AS SYSTEM CONTROLLER
A PLC is a microprocessor-based control system, designed
for automation processes in industrial environments. It uses a
programmable memory for the internal storage of user-orien-
tated instructions for implementing specific functions such as
arithmetic, counting, logic, sequencing, and timing [23], [24].
A PLC can be programmed to sense, activate, and control in-
dustrial equipment and, therefore, incorporates a number of I/O
points, which allow electrical signals to be interfaced. Input de-
vices and output devices of the process are connected to the
PLC and the control program is entered into the PLC memory
(Fig. 1).
0885-8969/04$20.00 © 2004 IEEE
470
IEEE TRANSACTIONS ON ENERGY CONVERSION, VOL. 19, NO. 3, SEPTEMBER 2004
Fig. 1. Control action of a PLC.
In our application, it controls through analog and digital in-
puts and outputs the varying load-constant speed operation of
an induction motor. Also, the PLC continuously monitors the
inputs and activates the outputs according to the control pro-
gram. This PLC system is of modular type composed of spe-
cific hardware building blocks (modules), which plug directly
into a proprietary bus: a central processor unit (CPU), a power
supply unit, input-output modules I/O, and a program terminal.
Such a modular approach has the advantage that the initial con-
figuration can be expanded for other future applications such as
multimachine systems or computer linking.
III. CONTROL SYSTEM OF INDUCTION MOTOR
In Fig. 2, the block diagram of the experimental system is
illustrated. The following configurations can be obtained from
this setup.
a) A closed-loop control system for constant speed opera-
tion, configured with speed feedback and load current
feedback. The induction motor drives a variable load, is
fed by an inverter, and the PLC controls the inverter
output.
b) An open-loop control system for variable speed operation.
The induction motor drives a variable load and is fed by
control mode. The PLC is
an inverter in constant
inactivated.
c) The standard variable speed operation. The induction
motor drives a variable load and is fed by a constant
voltage-constant frequency standard three-phase supply.
The open-loop configuration b) can be obtained from the
closed-loop configuration a) by removing the speed and load
feedback. On the other hand, operation c) results if the entire
control system is bypassed.
IV. HARDWARE DESCRIPTION
Fig. 2. Electrical diagram of experimental system.
The control system is implemented and tested for a wound
rotor induction motor, having the technical specifications given
in Table I. The induction motor drives a dc generator, which sup-
load. The three-phase power supply is con-
plies a variable
nected to a three-phase main switch and then to a three-phase
thermal overload relay, which provides protection against cur-
rent overloads. The relay output is connected to the rectifier,
which rectifies the three-phase voltage and gives a dc input to
the insulated gate bipolar transistor (IGBT) inverter. Its tech-
nical specifications [25] are summarized in Table II. The IGBT
INDUCTION MOTOR TECHNICAL SPECIFICATIONS
TABLE I
IOANNIDES: DESIGN AND IMPLEMENTATION OF PLC-BASED MONITORING CONTROL SYSTEM FOR INDUCTION MOTOR
471
TABLE II
INVERTER TECHNICAL SPECIFICATIONS
inverter converts the dc voltage input to three-phase voltage
output, which is supplied to the stator of the induction motor.
On the other hand, the inverter is interfaced to the PLC-based
controller.
This controller is implemented on a PLC modular system
[5], [26]–[28]. The PLC architecture refers to its internal hard-
ware and software. As a microprocessor-based system, the PLC
system hardware is designed and built up with the following
modules [29]–[37]:
central processor unit (CPU);
discrete output module (DOM);
discrete input module (DIM);
analog outputs module (AOM)
analog inputs module (AIM)
power supply.
Other details of the PLC configuration are shown in Tables III
and IV.
A speed sensor is used for the speed feedback, a current
sensor is used for the load current feedback, and a second
current sensor is connected to the stator circuits [32]. Thus,
the two feedback loops of the closed-loop system are setup by
using the load current sensor, the speed sensor, and the AIM.
A tachogenerator (permanent magnet dc motor) is used for
speed sensing. The induction machine drives its shaft mechani-
cally and an output voltage is produced, the magnitude of which
is proportional to the speed of rotation. Polarity depends on the
direction of rotation. The voltage signal from the tachogener-
ator must match the specified voltage range of the AIM (0–5 V
dc and 200-k internal resistance). Other PLC external control
circuits are designed using a low-voltage supply of 24 V dc.
For the manual control, the scheme is equipped with start,
stop, and trip push buttons, as well as with a forward and back-
ward direction selector switch. As shown in Fig. 2, all of the
described components: a main switch, an automatic three-phase
switch, an automatic single phase switch, a three-phase thermal
overload relay, a load automatic switch, signal lamps (forward,
backward, start, stop, trip), push buttons (start, stop, trip), a se-
lector switch (for the forward/backward direction of rotation), a
speed selector, a gain selector, as well as the PLC modules and
the rectifier-inverter are installed in a control panel. The pro-
gram is downloaded into the PLC from a personal computer PC
and an RS232 serial interface.
V. SOFTWARE DESCRIPTION
PLC’s programming is based on the logic demands of input
devices and the programs implemented are predominantly log-
Fig. 3. Flowchart of the main program.
TABLE III
PLC CONFIGURATION
ical rather than numerical computational algorithms. Most of
the programmed operations work on a straightforward two-state
“on or off” basis and these alternate possibilities correspond to
“true or false” (logical form) and “1 or 0” (binary form), respec-
tively. Thus, PLCs offer a flexible programmable alternative to
electrical circuit relay-based control systems built using analog
devices.
The programming method used is the ladder diagram
method. The PLC system provides a design environment in the
form of software tools running on a host computer terminal
which allows ladder diagrams to be developed, verified, tested,
and diagnosed. First, the high-level program is written in ladder
diagrams, [33], [34]. Then, the ladder diagram is converted
into binary instruction codes so that they can be stored in
random-access memory (RAM) or erasable programmable
read-only memory (EPROM). Each successive instruction is
decoded and executed by the CPU. The function of the CPU
is to control the operation of memory and I/O devices and to
process data according to the program. Each input and output
connection point on a PLC has an address used to identify
the I/O bit. The method for the direct representation of data
associated with the inputs, outputs, and memory is based on the
fact that the PLC memory is organized into three regions: input
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IEEE TRANSACTIONS ON ENERGY CONVERSION, VOL. 19, NO. 3, SEPTEMBER 2004
TABLE IV
PLC MODULES AND I/O DESIGNATION
image memory (I), output image memory (Q), and internal
memory (M). Any memory location is referenced directly using
%I, %Q, and %M (Table III).
The PLC program uses a cyclic scan in the main program loop
such that periodic checks are made to the input variables (Fig. 3).
The program loop starts by scanning the inputs to the system
and storing their states in fixed memory locations (input image
memory I). The ladder program is then executed rung-by-rung.
Scanning the program and solving the logic of the various ladder
rungs determine the output states. The updated output states are
stored in fixed memory locations (output image memory Q).
The output values held in memory are then used to set and reset
the physical outputs of the PLC simultaneously at the end of the
program scan. For the given PLC, the time taken to complete
one cycle or the scan time is 0, 18 ms/K (for 1000 steps) and
with a maximum program capacity of 1000 steps.
The development system comprises a host computer (PC)
connected via an RS232 port to the target PLC. The host
computer provides the software environment to perform file
editing, storage, printing, and program operation monitoring.
The process of developing the program to run on the PLC
consists of: using an editor to draw the source ladder program,
converting the source program to binary object code which
will run on the PLC’s microprocessor and downloading the
object code from the PC to the PLC system via the serial
communication port. The PLC system is online when it is in
active control of the machine and monitors any data to check
for correct operation.
A. PLC Speed Control Software
In Fig. 4, the flowchart of the speed control software is illus-
trated. The software regulates the speed and monitors the con-
stant speed control regardless of torque variation. The inverter
being the power supply for the motor executes this while, at the
same time, it is controlled by PLC’s software. The inverter alone
cannot keep the speed constant without the control loop with
feedback and PLC.
From the control panel, the operator selects the speed setpoint
and the forward/backward direction of rotation. Then, by
Fig. 4. Flowchart of speed control software.
pushing the manual start pushbutton, the motor begins the ro-
tation. If the stop button is pushed, then the rotation stops. The
corresponding input signals are interfaced to the DIM and the
output signals to the DOM as shown in Table IV.
The AIM receives the trip signal
from the stator current
sensor, the speed feedback signal from the tachogenerator, and
the
signal from the control panel. In this way, the PLC reads
the requested speed and the actual speed of the motor. The dif-
ference between the requested speed by the operator and the ac-
tual speed of the motor gives the error signal. If the error signal
is not zero, but positive or negative, then the PLC according to
the computations carried out by the CPU decreases or increases
the
of the inverter and, as a result, the speed of the motor
is corrected.
IOANNIDES: DESIGN AND IMPLEMENTATION OF PLC-BASED MONITORING CONTROL SYSTEM FOR INDUCTION MOTOR
473
During motor operation, it is not possible to reverse its direc-
tion of rotation by changing the switch position. Before direc-
tion reversal, the stop button must be pushed.
For motor protection against overloading currents during
the following commands were pro-
starting and loading,
grammed into the software.
i) Forward/backward signal is input to DIM.
, the load current
ii) Speed setpoint signal
, the stator
, and the speed feedback signal are input to
current
AIM.
iii) At no load
than 20% or
, if the speed set point is lower
r/min, the motor will not start.
iv) At an increased load over 0, 4 N m (40% of rated
, and a speed setpoint lower than 40%
r/min, the motor will not start.
torque),
or
v) If the load is increased more than 1, 0 N m (rated torque)
and if the speed set point exceeds 100% or
r/min, the motor enters the cutoff procedure.
vi) In all other situations, the motor enters in the speed con-
trol mode and the speed control software is executed as
described in Subsection A.
C. Cutoff and Restart Motor Software
In Fig. 6, the flowchart of this software is shown.
In overloading situations, the motor is cut off and the trip
lamp (yellow) is lit. The operator must release the thermal
relays and then must turn off the trip lamp by pushing trip
or stop button. The thermal relays are set to the motor rated
current 1, 5 A. Following this, the motor can be started
again.
The motor can be cut off by the operator pushing the stop
button: the display of the actual speed is set to zero, the
start lamp (green) turns off, and the stop lamp (red) turns
on and remains lit for 3 s.
The load must be disconnected immediately after the
motor cuts off and before the drive system is restarted.
The motor will not start before 3 s after cutoff even if the
start button is pushed.
VI. RESULTS
The system was tested during operation with varying loads
including tests on induction motor speed control performance
and tests for trip situations. The PLC monitors the motor oper-
ation and correlates the parameters according to the software.
At the beginning, for reference purposes, the performance of
induction motor supplied from a standard 380 V, 50-Hz network
was measured. Then, the experimental control system was op-
erated between no load and full load (1, 0 N m) in the two
different modes described in Section III:
a) induction motor fed by the inverter and with PLC control;
b) induction motor fed by the inverter.
The range of load torque and of speed corresponds to the de-
sign of the PLC hardware and software as described in the pre-
vious sections.
The speed versus torque characteristics were studied in the
range 500–1500 r/min and is illustrated in Fig. 7. The results
Fig. 5. Flowchart of monitor and protection software.
The implemented control is of proportional and integral (PI)
type (i.e., the error signal is multiplied by gain
, integrated,
and added to the requested speed). As a result, the control signal
is sent to the DOM and connected to the digital input of the
inverter to control
variations. At the beginning, the operator
by using a rotary resistor mounted on the
selects the gain
control panel (gain adjust) and the AIM receives its voltage drop
as controller gain signal (0–10 V).
The requested speed
is selected using a rotary resistor
and the AIM reads this signal. Its value is sent to the AOM and
displayed at the control panel (speed set point display). Another
display of the control panel shows the actual speed computed
from the speed feedback signal. A third display shows the load
torque computed from the load current signal in Newton-meters
(N m). Their corresponding signals are output to the AOM
(Table IV).
B. Monitor and Protection Software
In Fig. 5, the flowchart of this software is shown.
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IEEE TRANSACTIONS ON ENERGY CONVERSION, VOL. 19, NO. 3, SEPTEMBER 2004
Fig. 6. Flowchart of cutoff/restart motor software.
show that configuration b) operates with varying speed-varying
.
load torque characteristics for different speed setpoints
Configuration a) operates with constant-speed-varying load
torque characteristics in the speed range 0–1400 r/min and
0–100% loads. However, in the range of speeds higher than
1400 r/min and loads higher than 70%, the system operates
with varying-speed-varying-load and the constant speed was
r/min both con-
not possible to be kept. Thus, for
figurations a) and b) have a similar torque-speed response. This
fact shows that PI control for constant speed as implemented
by the software with PLC is effective at speeds lower than 93%
of the synchronous.
The efficiency for different values of
was also studied. In
Fig. 8, the efficiency is shown normalized, using as base value
or 1 p.u. the efficiency of the induction motor supplied from the
standard network. As depicted in Fig. 8, the results show that
configuration a) in all cases has a higher efficiency than con-
figuration b). Also, at operation with loads higher than 70%,
, meaning that the ob-
the normalized efficiency is
tained efficiency with PLC control is higher than the efficiency
of induction motor operated from the standard 380-V, 50-Hz
network without the control of PLC and without the inverter. Ac-
cording to this figure, the efficiency of PLC-controlled system is
increased up to 10–12% compared to the standard motor opera-
Fig. 7. Experimental speed–torque characteristics with PLC and inverter.
tion. From a theoretical point of view, if we neglect magnetizing
current, an approximate value for the efficiency is
is the slip and
where
are the stator and rotor winding
resistances, respectively. As can be seen from Fig. 7, the PLC-
controlled system a) works with very low slip values, almost
zero. In all speed and load torque conditions, the configuration
a) has a smaller slip than configuration b), thus the higher values
of efficiency can be justified and especially at high speeds and
frequencies. At lower frequencies, the magnetic flux increases
and, thus, there is an increase in magnetizing current resulting
in increased losses.
Fig. 9 shows the stator voltage versus stator frequency
characteristics of the inverter with PLC control for the same
range of speeds and torques as in Fig. 7. For each one of
the speed–torque characteristics from Fig. 7, the relationship
between stator voltage and stator frequency is constant. How-
ever, this relationship, which corresponds to the motor flux,
increases with the decrease of frequency from 8, 3 at 50 Hz up
to 11, 25 at 12 Hz, as shown in Fig. 10. Thus, as can be seen
from Fig. 7, where the available torque decreases from 100%
at 50 Hz up to 60% at 20 Hz, when both voltage and frequency
decrease, there is an increase in magnetic flux with a decrease
of maximum available torque.
The regulator gain
is plotted in Fig. 11 for all speed and
torque ranges. The results show that it presents an almost linear
IOANNIDES: DESIGN AND IMPLEMENTATION OF PLC-BASED MONITORING CONTROL SYSTEM FOR INDUCTION MOTOR
475
Fig. 10. Rate for stator voltage/stator frequency.
Fig. 8. Efficiency of controlled system with and without PLC per unit of
efficiency of standard supplied motor.
Fig. 9.
control.
Stator voltage versus frequency characteristics of an inverter with PLC
variation with
between characteristics.
for varying loads, with small displacements
This system presents a similar dynamic response as the
speed control. Its transient per-
closed-loop system with
formance is limited due to oscillations on torque [32] and this
behavior restricts the application of this system to processes
that only require slow speed variation.
Fig. 11. Control characteristics of PLC.
VII. CONCLUSION
Successful experimental results were obtained from the pre-
viously described scheme indicating that the PLC can be used
in automated systems with an induction motor. The monitoring
control system of the induction motor driven by inverter and
controlled by PLC proves its high accuracy in speed regulation
at constant-speed-variable-load operation.
The effectiveness of the PLC-based control software is satis-
factory up to 96% of the synchronous speed. The obtained ef-
ficiency by using PLC control is increased as compared to the
open-loop configuration of the induction motor fed by an in-
verter. Specifically, at high speeds and loads, the efficiency of
PLC-controlled system is increased up to 10–12% as compared
476
IEEE TRANSACTIONS ON ENERGY CONVERSION, VOL. 19, NO. 3, SEPTEMBER 2004
to the configuration of the induction motor supplied from a stan-
dard network.
Despite the simplicity of the speed control method used, this
system presents:
constant speed for changes in load torque;
full torque available over a wider speed range;
very good accuracy in closed-loop speed control scheme;
higher efficiency;
overload protection.
Thus, the PLC proved to be a versatile and efficient control
tool in industrial electric drives applications.
ACKNOWLEDGMENT
The author gratefully acknowledges the financial support of
the National Technical University of Athens for the buildup
of the experimental system and the laboratory tests and
measurements.
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[35] M. G.
Ioannides and I. M. Katiniotis, Laboratory of Electric
Drives. Athens, Greece: Editions National Tech. Univ., 2000.
[36] L. Hristofovou and K. Hatzipetvou, “System with PLC for the control
of asynchronous motor,” Diploma work, National Tech. Univ., Athens,
Greece, 1998.
[37] M. G. Ioannides, P. J. Papadopoulos, and J. A. Tegopoulos, “Digital tech-
niques for AC voltage regulation,” in Proc. 6th Int. Conf. Power Elec-
tronics Motion Control, Budapest, Hungary, 1990, pp. 975–979.
Maria G. Ioannides (S’85–M’86–SM’90) gradu-
ated from the Electrical Engineering Department
of the National Technical University of Athens
(NTUA), Athens, Greece.
Currently, she is Professor of Electric Drives
at NTUA. Her research interests include control
of electric machines, renewable energy systems,
small and special electric motors, new materials
for electromagnetic devices and electric motors,
effect of ELF-EMFs on human beings, and on the
environment, human risk factors, and protection in
the electric power industry. She is the author of many journal papers, papers
in conference proceedings, books, patents, technical reports, and editorials.
She was scientifically responsible and principal investigator in many research
projects funded by the Greek government, European Community, and the US.
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