TELKOMNIKA, Vol. 11, No. 12, December 2013, pp.

7251~7258
e-ISSN: 2087-278X
 7251

Temperature Monitoring System based on PLC

Shoucheng Ding*, Wenhui Li

College of Electrical and Information Engineering, Lanzhou University of Technology, Lanzhou 730050,
Gansu, China
*Corresponding author, e-mail: [email protected]

Abstract
The programmable logic controller (PLC) is an industrial control computer; it is the new
automatic device inherited computer, automatic control technology and communication technology.
System temperature signal detected by the temperature sensor. The temperature transmitter will be the
temperature value converted into a voltage signal of 0-10V into PLC. PLC voltage signal setting
compared to the temperature deviation after PID operation; the system will issue a temperature control
signal to reach the electric heater voltage control. So that it implements a continuous monitoring and
control of the temperature. The temperature monitoring system in the industrial field has a certain value.

Keywords: temperature monitoring, PID, control, configuration software, PLC

Copyright © 2013 Universitas Ahmad Dahlan. All rights reserved.

1. Introduction
The temperature is commonly used in the industrial production process parameters,
while closely related to people's lives. In many fields of scientific research and production
practice, the temperature control occupies a very important position, especially in metallurgy,
chemical industry, building materials, food, machinery, petroleum and other industries, has a
pivotal role. Programmable Logic Controller (PLC) is an industrial control computer; inherit
computer, automatic control technology and communication technology as one of the new
automatic device. It has strong anti-interference ability and cheap price, reliability,
programming is simple, easy to learn and use, by the project operator, like in the industrial
field, the PLC has been widely used in various areas of industrial control.
The configuration software is an automatic control system monitoring layer a software
platform and development environment. Its flexible configuration will provide users with
software tools to quickly build industrial automatic control system monitoring and general level.
Before the appearance of the configuration software, the industrial areas of the user by
hand or entrust a third party to write HMI (Human Machine Interface software), it has
developed a long time, low efficiency and poor reliability shortcomings; or buy a dedicated
industrial control systems. It usually is a closed system, the choice of small, often can not meet
the demand, and it is difficult to exchange data with the outside world, upgrade and add
functionality to be severely restricted. The emergence of the configuration software
configuration software allows users to build a system which best suits their own applications.
With the rapid increase in the level of industrial automation, computer widely used in
the industrial field, a wide range of control equipment and process monitoring devices in
industrial applications, industrial control software has been unable to meet the diverse needs of
the user. In the development of the traditional industrial control software, once the industrial
controlled object changes, it is necessary to modify the source code control system, leading to
long development cycle; industrial control software has successfully developed so that each
control different repeated low usage, it's expensive. General industrial automation
configuration software can be a good solution to the problems of traditional industrial control
software, enables users to any configuration of objects and control purposes, the completion of
the final automation control engineering [1].
This paper designed a temperature monitoring system based on Mitsubishi PLC. This
system through the analog input module capable of temperature changes in the amount of
conversion to digital into the PLC, PID controller temperature reaches the set value, it
compares the current temperature and set temperature, if beyond the set value the system will

Received July 23, 2013; Revised August 17, 2013; Accepted August 29, 2013
7252  e-ISSN: 2087-278X

alarm. At the same time, the system was adopted MCGS upper monitoring system, to achieve
human-computer integration.

2. System Hardware Block Diagram

The temperature control system hardware block diagram is shown in Figure 1. System
controlled object is a signal of the temperature, and the temperature sensor detects the
temperature of the heating tube. Through the output module, the temperature value is
converted to a digital signal fed to the PLC module. PLC to the temperature signal obtained
with the temperature settings are compared, and then get the temperature deviation after PID
operation, it will issue a control signal and the corresponding operation, such as higher than 50
degrees Celsius, and the alarm [2].

2.1. I/O Assignment

Input interface: (X0) button, start button; (X1) button, stop button.
Output interface: (Y0) start indicator; (Y1) stop light; (Y2) the normal operation of light;
(Y3) alarm indicator; (Y4) heating lamp; Y5-Y14: LED lights a segment-h segment. Y15-Y17:
LED chip select signals.

2.2. PID Control System

PID is the abbreviation of proportion, differentiation, integration, and PID controller is
the most widely used closed-loop controller. PLC analog PID control, the use of the following
methods:
(1) PID process control modules: process control module contains the A/D converter
and D/A converters, PID control procedures designed PLC manufacturers, and stored in the
module, the user use only need to set some parameters, very convenient to use, a module can
control a few road or even dozens of road closed loop. However, the relatively high value of
this module, generally used in large and medium-sized control system.
(2) PID instruction: many PLC has for PID process control module and the PID control
function instruction, for example FX2N PID instruction. They are actually used for PID control
subroutine used in conjunction with analog input / output modules, you can get a similar
process with PID control module effect, but the price is much cheaper.
(3) The edited program PID closed-loop control: Some PLC PID process control
module and the PID instruction. Although it can use the PID control instructions, but hope the
other improvements PID control algorithm. In the above case, it requires the user to the
preparation of the PID control program.
(4) closed-loop control of the inverter: Inverter does not generally have a PI controller
or PID controller. For this type of closed-loop control system of constant pressure water supply,
the feedback signal can be received feedback signal input terminal of the inverter, inverter
internal control its closed-loop control [3]. PLC through communication or switch signal to the
inverter frequency reference signal and the start and stop commands. If the feedback signal is
sent to the PLC analog input module with PLC PID closed-loop control, analog signal as a D/A
converter output inverter frequency of a given signal, the need to increase the PLC analog
input modules and analog output module, will increase the cost of hardware.

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2.3. PID Algorithm

In engineering practice, the most widely used regulator control law for the proportional,
integral, differential control, PID control for short. When not fully understand a system and the
controlled object, or can not be measured through effective means to obtain the system
parameters, the most suitable PID control technology. PID controller is based on the error of
the system, using a proportional, integral, differential, the calculated control amount is
controlled.
Proportional (P) control: proportional control is one of the most simple, the most
commonly used control mode, the controller output and input error signal proportional
relationship. When only a proportional control system output, there is a steady-state error.
Integral (I) control: integral control, the controller output and input error signal
proportional to the integral relationship. An automatic control system, steady-state error into
the steady state, this system is called steady-state error of the system. In order to eliminate the
steady state error, must refer to the integral term in the controller. The integral term for the
calculation of the error depends on the time integral of the increase over time, the integral term
increases. Thus, even when the error is small, the integral term will increase over time to
increase, he pushed the controller output is increased, so that the steady state error is further
reduced until it is equal to zero. Therefore, using proportional + integral controller can make
the system into the steady-state is no steady-state error [4, 5].
Derivative (D) control: differential control, the controller output is proportional to the
input. The automatic control system in the adjustment process to overcome the error may
oscillations and even instability. The reason is the presence of large inertial assembly or after
assembly having suppression error of the role change; the variation is always behind the error.
The solution is to inhibit the role of the error changes ahead. That is, in the control wherein the
reference only the proportional term is often not enough, the role of the proportional term only
enlarge the amplitude of the error term, and the current increase of the differential term, it can
predict the trend of change in the error. Thus, proportional + derivative control to advance so
that the role of suppression error equal to zero, or even negative, thus avoiding the serious
overshoot of the amount charged. Proportional + derivative controller can improve the dynamic
performance of the system in the mediation process [6].
PID controller can adjust the loop output, so that the system reaches a steady state.
The relationship of the deviation e, the input amount r and the output c is given by:

e(t )  r (t )  c(t ) (1)

PID control loop block diagram is shown in Figure 2.

The output of the controller is given by:

1 1 de(t )
u (t )  K p [e(t )  
Ti 0
e(t )dt  Td
dt
] (2)

In the where:
u(t)-PID loop output
Kp-Proportionality coefficient
Ti-Integral coefficient
Td-Differential coefficient
PID regulator transfer function is given by:

Temperature Monitoring System based on PLC (Shoucheng Ding)

7254  e-ISSN: 2087-278X

U (s) 1
D(s)   K p [1   Td s (3)
E (s) Ti s

Digital computer processing function relationship must be discretized continuous

function the sampling deviation cycle, and then calculate the output value. The PID
discretization law is as shown in Table 1.

Table 1. PID Discretization Law

Analog form Discrete form
e (t )  r (t )  c (t ) e( n)  r ( n)  c ( n )
de(t ) e( n)  e( n  1)
dT T

 e(i)T  T  e(i)
t n n

 e(t )dt
0
i 0 i 0

The discrete PID output equation is given by:

e(i)  T [e(n)  e(n 1)]}  u (n)  u (n)  u (n)  u

T n
Td
u(n)  K p {e(n)  p i d 0
(4)
Ti i 0

In the formula, Proportional is given by:

u p ( n )  K p e( n ) (5)

Integral term is given by:

T
 e(i)
n

ui ( n )  K p (6)
Ti i 0

Differential term is given by:

Td
ud (n)  K p [e( n)  e( n  1)] (7)
T

In the above formula, the integral term is including a first sampling period to a
cumulative value of all the errors of the current sampling cycle. Calculation, there is no need to
retain all the error term of the sampling period, and only need to retain the integral sum. It can
use the PID instruction in the PLC to control algorithm amount.
PID parameter tuning method is to determine the regulator proportion coefficient P,
integration time Ti and derivative time Td to improve the system's static and dynamic
characteristics of the system transition process to achieve the most satisfied with the quality
indicators requirements generally can by theoretical calculations to determine but the error is
too large. Currently, the most widely used engineering tuning method, as the empirical method,
the attenuation curve method, critical proportions and reaction curve method. The experience
method called trial and error method, it does not require the prior calculations and experiments,
but using a set of empirical parameters, based on operating experience, the constantly
changing parameters in accordance with the effect of the response curve for a temperature
control system, and PID parameters law is shown in Table 2.

Table 2. Temperature Control PID Experience Parameters

Controlled Integration time Derivative time
regular Proportionality
variable (minutes) (minutes)
Temperature Lag larger 20-60 3-10 0.5-3

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2.4. PID Controller Circuit

PID controller circuit is shown in Figure 3. The arithmetic circuit of the controller is a
concatenation of the two arithmetic circuits of the PD and PI. Operational amplifier A1, A2, A3,
24V single power supply, the same phase and the inverting input can not work around at 0V
input measurement signal is based on the starting 1-5V voltage to zero volts, the input circuit to
conduct voltage level shifting, the deviation level of the voltage is raised to 10V as a starting
point of the change, so the signal voltage u01, u02, u03 are to 10V starting reference. In the
amplifier A1 proportion differential circuit, the derivative action is needed to introduce or
excision.
When the differential action is not required, the switch K1 is in the disconnected
position, the amplifier A1 is proportional amplifier. Without disturbance introduced differential,
differential capacitance CD will not work through the switch K1 is connected to the voltage
divider on charging the capacitor CD. So, the need to introduce a differential effect, the switch
K1 can be readily turned "on" position, without causing a sudden jump of the output voltage u02
of the impact, i.e. without the process being controlled [7, 8].

Figure 3. PID Control Circuit Diagrams

In Figure 3, the differential gain Kd=n=10 the differential time Td = nCDRD, CD = 3.9μF,
RD= 62 kΩ-15MΩ then to Td =0.04-10min, a range of variation of the feedback voltage ratio is
1-250. In amplifier A2 proportional integral circuit, switch K2 is a integration time multiplied
switch. When placed "× 1" position, 1kΩ resistor one end open. K2 placed in the position of the
"× 10", input voltage u02 after 1/10 partial pressure connected to the integrating resistor R1.
Integral velocity slows m times, because no change in the proportion of degree, so the integral
time Ti =mR1C, consider to add to the R2 signal amplitude m times, the ultimate limits of the
integral output amplitude will drop, so in this case the integral gain is also decreased to m
times. In the circuit C1=CM=10μF, R1= 62kΩ-15MΩ, set A2=105, when m= 1, Ti =0.01-2.5min,
Ki=105.
Resistor connected to the output terminal of amplifier A2, a diode D1 and the emitter of
the transistor T1 constituting plate follower. The amplifier A3, the transistors T2 and T3 form a
voltage-current conversion of the output circuit, it PID circuit 1-5V between the change in
output voltage u03 converted to a current output of 4-20mA, 250Ω resistor R14, then the 4-20mA
converter 1 -5V voltage output. u03 based changing voltage (10V) is as a starting point, while
the SCR trigger voltage control signal is connected between the output terminal and the
ground, therefore the output circuit must also assume the task of level shifting [9].

3. System Software and Configuration Software

Software flow chart of the system consists of four parts, and they are the main
program flow chart, flow chart of temperature setting, alarm subroutine flowchart and interrupt
the program flow chart. The main program flow chart is shown in Figure 4.

Temperature Monitoring System based on PLC (Shoucheng Ding)

7256  e-ISSN: 2087-278X

With the rapid increase in the level of industrial automation, computer widely used in
the industrial field, one of the requirements of industrial automation is increasing, a wide range
of control equipment and process monitoring devices in industrial applications, making the
traditional industrial control software Unable to meet the diverse needs of the user. MCGS the
emergence of industrial control configuration software provides a new way to solve some
practical engineering, because of its ability to solve the problems of traditional industrial control
software, allowing users to any group under the control object and control purposes state,
completed the final automation control engineering. MCGS Chinese industrial automation
control configuration software is a set of 32 engineering software, stable operation in
Window95/98/Me/NT/2000 other operating systems, set animation, process control, data
acquisition, equipment control and output, data transmission network, hot standby, engineering
reports, data and curves and many other powerful functions in one, and support at home and
abroad many data acquisition on the output device, and is widely used in the petroleum,
power, chemicals, iron and steel, mining, metallurgy, machinery, textile, aerospace,
construction, materials, refrigeration, transportation, communications, food, manufacturing and
processing industry, water treatment, environmental protection, intelligent buildings,
laboratories and other engineering fields [10].
MCGS to provide users with a complete program to solve practical engineering
problems and development platform, able to complete on-site data acquisition, real-time and
historical data, alarm and security mechanisms, process control, animation, trend curve and
statements output, as well as enterprise monitoring network functions. MCGS, users do not
have the knowledge of computer programming can be developed in a short period of time
easily completed a run stable, full-featured, low maintenance and a highly specialized
computer monitoring system [11].
MCGS has a simple, good visibility, maintainability, the salient features of the high-
performance, high reliability, and has been successfully used in the petrochemical industry,
steel industry, electric power systems, water treatment, environmental monitoring, machinery
manufacturing, transportation, energy, raw materials, agricultural automation, aerospace and
other fields, the actual operation of the various field of long-term, stable and reliable system.
MCGS configuration software top five part, MCGS configuration software created
works by the master window, the device window, the user window, the real-time database and
run strategy in five parts, each part of the configuration operation to complete the work, has
different characteristics. MCGS is shown in Figure 5.

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TELKOMNIKA e-ISSN: 2087-278X  7257

Host monitoring, temperature monitoring system, it needs to create the following

variables: the start button, stop button, start light, stop light, normal indicator, stop lights, alarm
indicator and temperature display. Where in the temperature display type is numeric.
Graphical interface system ride by the graphic object is stationary, these graphic object
animation design, truly describe the state of the outside world objects change, achieve process
real-time monitoring purpose. MCGS graphics animation designs the user window graphic
objects and data objects in the real-time database to establish the correlation connection and
set the animation properties. The system is running, the appearance and state of the graphics
object, driven by the real-time collection of data objects in order to achieve the graphics
animation. MCGS the alarm processing as a data object attributes, encapsulated in data
objects from the real-time database automatically processed. When the value or state of the
data object is changed, the real-time database to determine whether an alarm or the alarm has
been generated corresponding data object has ended, and the generated alarm information to
the rest of the system, the same time, the real-time database according user configuration
settings, the alarm information is stored in the specified save the database file.
The defined alarm operation is as follows: temperature variable in the real-time
database, double-click the "temperature", select "Allow alarm processing, alarm attribute;
alarm settings, select" limit alarm, the alarm value is set to: 50 degrees; alarm Note: the
temperature exceeds the upper limit of 50 degrees when the alarm; check alarm information
automatically saved to disk properties. Real-time data reports real-time data variables for the
current time display and printing certain report format (user configuration): reflect the amount of
instantaneous, real-time data reports through the MCGS system real-time form components
configured to display real-time data statements [12, 13].
Analog devices MCGS software to generate a set of the simulation curve data,
according to the parameters set for the user commissioning works. The member can generate
standard sine wave, square wave and triangle wave; saw tooth wave signal and its amplitude
and period can be set arbitrarily.

4. Conclusion
The programmable controller has strong anti-interference ability and cheap price,
reliability, programming is simple, easy to learn and use by the project operator, like in the
industrial field. This article is designed temperature monitoring system based on Mitsubishi
PLC. PID controller allows the temperature reaches the set value, and the system compares
the current temperature and set temperature, temperature control; beyond the set value, the
system will alarm. The system has good stability, high reliability, and broad application
prospects.

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