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(English) Ardbox: Water treatment plant – Control tank level

(English) Ardbox: Water treatment plant – Control tank level

This posts presents an application developed with Industrial Shields Ardbox Relay 7.0. In the facilities of a water treatment plant, retrofitting of the existing automated system was required. The control system is responsible to maintain the tank level of water within defined limits. The level can be forced to increase/decrease operating  an available outflow pump.

Industrial Shields Ardbox Relay was adopted as the central unit of the control system and it has been has been running flawlessly for several months, providing a flexible, customizable and pricewise solution.

 

Some of the components integrating the whole system are:

CapturaWaterTreatmentSystem_03

(1) /(3) Light tower beacon

The main function of the tower beacon is to visually alert if the level alarmis triggered. Code example.

(2) Pump

Some of the  software structures and fucntions required for the operation of the pump are:

Encoder

Timer examples and ISTimer library

Control of stepper motor

Captura2

Contact us at industrialshields@industrialshields.com if you have any questions or  want more information of the application.

 

Solar Monitoring System with Ardbox

Solar Monitoring System with Ardbox

Solar panels are popular because they are able to give us energy from light. When the light hits the panel solar conductor, the energy is translated into moving and electrons, creating current. In this newsletter we´ll make a simple monitoring system that you can develop for your home with Open Source Hardware.

Hardware

Hardware selection depend a lot of your solar panel and its specs (output voltage, power). For this project, we will consider that we have a 5.2 kW solar panel which provides between 0-10V. The required hardware for the project is:

  1. Ardbox PLC.
  2. A Panel PC.
  3. Allegro ACS712: ACS712 chip allows DC and AC current measurement.  The value read from the sensor is proportional to current measured on the sensing terminals. Datasheet can be downloaded here.
  4. A Solar panel! We will use this one from Sparkfun.
  5. A Solar Inverter, which converts the variable direct current (DC) output of a photovoltaic (PV) solar panel into a utility frequency alternating current (AC).
  6. Wires and resistors (for the voltage divider).

On the other hand, to measure Voltage we will use a voltage divider circuit. As the ARDUINO analog pin input voltage is restricted to 5, the output voltage must be less than 5V. See the schematic: Sch   Software and code

Basically, the code measures each 5 seconds current and voltage, and, with these values, calculates the power. Later, sends these three values to the Panel PC.Regarding the voltage measure, Arduino ADC converts Analog signal to corresponding digital approximation.Regarding the current measure, we consider the following points to take into account:

  1. Analog read produces a value of 0-1023, equating to 0v to 5
  2. In our case, Analog read 1 = (5/1024) V =4.89mv, Value = (4.89*Analog Read value)/1000
  3. But as per data sheets offset is 2.5V (When current zero you will get 2.5V from the sensor’s output).

You can download the code in the following link: 2014111_arduino_code   Going Further and key benefits Solar panels come in many varieties. When shopping a solar panel for your system, there are a few specifications you need to follow. Contact us! Do you have a process to be automated? Contact Industrialshields to buy the proper hardware and Opiron to implement the entire solution.

Control of soil humidity in an irrigation installation

Control of soil humidity in an irrigation installation

This newsletter is really interesting because control soil humidity in irrigation installations makes saving water, time and money.  Continue reading… sch0   Hardware

Hardware selection is very important when you try to develop projects where sensors, actuators and PLC´s must talk each other. For this project, with chosen the following equipment:

  • PLC: Any PLC from IndustrialShields is a good option. We have chosen the M-Duino PLC Arduino 21 I/Os Analog/Digital because we think it has different communication options to be communicated with other systems (Ethernet, RS232, I2C…).
  • Panel PC: For this project, we are going to visualize and control our installation with the HummTouch 10.1” Linux panel pc.
  • Humidity sensor: Probably, when you try to develop an application like we are trying to, the most important selection is the sensor itself. There are a lot of humidity sensors available around the market completely compatible with Arduino based hardware. We´ve chosen the SHT10 sensor from Adafruit because it includes a temperature sensor as well, it comes with an intermetal mesh encasing, which is weatherproof and because it is designed to be submersible in water.
  •  Others: A relay to activate the irrigation system, a 24Vdc power supply, a good enclosure to protect the equipment and cables are important things to keep in mind too.

Software

To develop the project, the first thing to do is to ensure that we have the proper software and libraries. As we are going to use the SHT10 sensor, we will use the SHT1x library that you can download in the following link: https://github.com/practicalarduino/SHT1x. SHT10 uses a two wire communication interface similar to I2C. As usual, we will use the Arduino IDE to develop the software. You can download it here: http://www.arduino.cc/en/Main/Software. You can see the code in the following file: 2014111_arduino_code   Key benefits   There are a lot of benefits to implement a humidity control in an irrigation system. Let´s see the most important:

  • Saves Time: Automation does the job for you, so you can go on holidays knowing that your flowers will be maintained when you come back.
  •  Saves Money: No more water wasted, automation guarantees efficiency: water is used when is needed.
  •  Improves Growth: An irrigiation system guarantees flowers waterd with proper amount of water. In a reasonable time, you will have a greener garden.

  Contact us!

Do you have a process to be automated? Contact Industrialshields to buy the proper hardware and Opiron to implement the entire solution.

Controller for your installation based on Open Source hardware

Controller for your installation based on Open Source hardware

Leaders from different companies usually agree in Water will be the oil of this century. Today, as populations increase and water supplies are stretched, we are developing more and more systems to make water at a low cost. We are going to develop a basic water treatment system based on Arduino. The water contained in the tank will be used for an irrigation system.

Equipment to be used Water treatment system consists basically of the following elements:

  • An M-Duino PLC: This controller is the heart of the system. It controls the display, generates interrupts, and controls the communication.

·        A Panel PC: Used to read and display the status of the system over the Panel Pc.

  • Turbidimeter: Water clarity is measured in nephelometric turbidity units (NTU). This measurement indicates the level of dirt particles within the water.
  • Ph Analyzer: pH is an indicator of the acid or alkaline condition ofwater. The pH scale ranges from 0-14; 7 indicates the neutral point
  • Level Sensor: The level sensor will indicate us the remaining level of water in the reservoir.

sch   Software and code In this example we will define some threshold alarms:

  • If the level in the water reservoir is less than 120 l, we will send an alarm.
  • If the turbiditmeter returns a value higher than 0.8 NTU, we will send an alarm.
  • Since the normal pH range for irrigationwater is from 6.5 to 8.4, we will send alarms whenever the value is out of the indicated range.

The PLC monitors all the time if an alarm occurs, and in that case, sends the boolean alarm of  each monitored variable: Level / Turbidity / PH to the Panel PC, where we will send print it in the screen. As in other newsletters, we use the Panel PC to read the status of the system efficiently. You can find the code to be uploaded here: 2014111_arduino_code   Key Benefits The main benefits of the Opiron purposed solution are:

  • Flexibility: This application note describes how the IndustrialShields hardware can be used to make an efficient water treatment system.
  • Freedom to modify your software: You aren’t limited to what one company believes you need.
  • East to be integrated: No matter if you already have an automation system. The Arduino hardware is easy to integrate into your system.
Contact us!

Do you have a process to be automated? Contact Opiron to implement the entire solution.and Industrialshields to buy the proper hardware.

Labeling machine automation with M-Duino PLC

Labeling machine automation with M-Duino PLC

We will make the automation of a labeling machine based on the M-Duino PLC from Industrialshields. The labeling machine will label bottles of a plant.

 

Hardware I: Equipment to be used Basically, the labeling machine system consists of:

  • An M-Duino PLC: This controller is the heart of the system. It controls the display, generates interrupts, and controls the communication.
  • A Panel PC: Used to read and display the status of the system over the Panel Pc.
  • A detection Sensor:  We will make use of optical fork sensors based on infrared (non visible) light sources because they are easy to be programmed and they allow us a manual adjustment to the sensitivity via potentiometer.     
  • A motor: The motor is used to fix a constant speed in the conveyor belt. –
  • A relay: Used to activate the labeling piston.

sch Hardware II:  System   Regarding the system, in this section we will explain the interface between the M-Duino PLC and the other elements:

  • We have one detection sensor that we will program it as a Digital Input. Each time a bottle is placed in fornt of the detector, the conveyor belt will stop and wait for label the bottle.
  • The PLC will control the motion of the conveyor belt activating a motor through a relay. This will be programmed as a Digital Output.
  • The PLC will control too the labeling piston. This system will be activated through a relay too, and therefore, programmed as a Digital Output too.
  • As we made in other newsletters, the communication between Panel PC and the M-Duino will be made with I2C.

Furthermore, the system will be able to be stopped through the Panel PC. Let´s see a picture of the system to be automated:   foto       Software and code As we explained before, the system has a Panel PC which will allow us to visualize the system status (not implemented in this code) and stop the system whenever we need. The communication between the PLC and the Panel PC will be with I2C, so we will use the Wire library (you can get more information about the library here). The system will have 3 states:

  1. STOP: When the command is received from the Panel PC. This state will enable us to make maintenance activities on the system and other related tasks.
  2. Running and Bottle detected: When a bottle is detected, the system will stop the motor and activate the labeling piston.
  3. Running: This state activates the motor.

As in other newsletters, we recommend using Tesla Scada, which is able to work on Android systems. You can download the code here: 2014111_arduino_code     Key Benefits The main benefits of the Opiron purposed solution are:

  • Open Hardware: Which reliable, cheap and expandable
  • Real time measurement: Panel PC enable users to visualize the system status and stop it easy.
  • Easy to be integrated: If you plant has already installed an automation system, M-Duino can be integrated using Ethernet.
Contact us!
Do you have a process to be automated? Contact Opiron to implement the entire solution and Industrialshields to buy the proper hardware.

 

Real time electrical consumption monitoring with M-Duino

Real time electrical consumption monitoring with M-Duino

In this Project, we will show you how to read electrical consumption using Modbus communication. Modbus is an industry standard communications protocol for electronic device Hardware I: Equipment to be used The electrical consumption monitoring system consists of:

  • An M-Duino PLC: This controller is the heart of the system. It controls the display, generates interrupts, and controls the communication.

  • A Panel PC: Used to read on the status of a counter and display the graph of monthly consumption over the Panel Pc. –         Switch: Switch will work as the interface between slaves and Master in our control network.

PanelPc

  • A Power Meter witch Modbus TCP/IP communication capabilities (as TCP is Transmission Control Protocol and IP is Internet Protocol.)
  • Wires and some programming experience J.

Hardware II:  Communication The nice feature of Panel PC we used is that it has many interfaces such as Ethernet, USB  and I²C as well. We´ve expressly chosen Ethernet because our PLC  and our I2C panel have this Ethernet connecitivity. See the following picture to understand it: sch2   Software and code Arduino sketch essentially uses the Modbus TCP library for Arduino  (see the Arduino installer tutorial here).  Some important things to take care when we use this library:

  1. Insert the modbus_update function in the loop, because. takes care of the received modbus commands and will modify the registers accordingly in case of writing or reading requests.
  2. Declare an integer array (named holdingRegs) that stores the modbus registers.
  3. We recommend to review modbus tcp basics at http://www.simplymodbus.ca/

After that, just start sending values to the panel PC through USB  I2C communication. You can find the code to be uploaded to the PLC here: 2014111_arduino_code   You need to download  libraries:

And what about the software to install in our Panel PC to start visualizing graphs? In this case, we recommend to use Tesla Scada, wich is able to work on Android systems . The panel pc will start receiving data and print out data in graphs! Key Benefits The main benefits of the Opiron purposed solution are:

  • Time Saving: Forget to go to view and write values in notebooks, your control system will do this job for you.
  • Real time measurement: System provides reliable data quickly.
  • Digital data analysis: If you can measure it, you can improve it!
Contact us!
Do you have a process to be automated? Contact Opiron to implement the entire solution and Industrialshields to buy the proper hardware.
Ardbox PLC Arduino based and VFD (inverter) with USB communication

Ardbox PLC Arduino based and VFD (inverter) with USB communication

Resumen

Los controladores o drivers de los variadores de frecuencia (conocidos por sus siglas en inglés VFD´s), son muy populares en la industria porqué pueden ajustar el par y la velocidad de un motor eléctrico AC a través de la variación del voltaje de entrada del motor y de la frecuencia. El punto de funcionamiento puede ser enviado desde un PLC y, por lo tanto, desde un ordenador. Esto es justamente lo que vamos a explicar en este post: como enviar el punto de trabajo a un VFD usando un ordenador conectado a un PLC Ardbox de Industrialshields. Freq Ardbox 1 Hardware usado y consideraciones

Antes de empezar a trabajar vamos a considerar varios puntos:

  • El VFD tiene una entrada analógica donde se puede enviar el punto de trabajo. Por lo tanto la comunicación entre el VFD y el PLC será 4-20 mA.
  • El entorno de programación de Arduino tiene integrado de serie un lector i grabador que hace mucho más fácil desarrollar y depurar tu código Arduino. Este punto es importante si tomamos en consideración que vamos a usar las herramientas Arduino para hacerlo todo más fácil.

Software y código

Para comunicar nuestro PLC Ardbox con el ordenador vamos a usar la comunicación serie. La comunicación serie tan sólo significa que sólo un bit de información es enviado a la vez. Hoy en día la mayoría de ordenadores no tienen puertos serie, pero usan un driver USB-to-serial para enviar y recibir comunicación serie a través del USB. Por lo tanto, básicamente, dentro del loop() vamos a comprobar si algún dato serie ha llegado con la función Serial.available(). Si algún dato ha llegado y está disponible, lo almacenaremos en una variable llamada setpoint, la cual vamos a usar para enviar al VFD como salida output. Puedes descargarte el software a continuación:

2014111_arduino_codeVentajas principales

Las principales ventajas de la solución propuesta son:

  • Fácil: Fácil es la primera palabra que os viene a la cabeza cuando pensamos en esta aplicación. Fácil de instalar, fácil de programar y fácil de enviar ordenes al VFD!!!
  • Open Source: Porqué open source significa flexibilidad en términos de libertad de elegir, modificar e integrar tu sistema con otros más complejos, a la vez que és robusto y fiable.
  • Útil: Este proyecto es útil porqué los VFDs están en todos los sitios. Puedes veer un ejemplo de aplicación con VFDs en nuesto blog blog.
Ponte en contacto con nosotros!!!

Tiene un proceso para ser automatizado. Póngase en contacto con Industrialshields para implementar la solución completa y para comprar el hardware adecuado.

IoT in industry improves reliability equipment. Arduino as PLC application.

IoT in industry improves reliability equipment. Arduino as PLC application.

Resumen

IoT and Plc MDuino

Hoy en día, los fabricantes tienen que mantener las fábricas en funcionamiento 24×7, y, con el fin de asegurarlo, los equipos deben ser fiables debido a que un fallo puede costar millones de euros y un alto impacto en la capacidad de enviar el producto a los clientes. ¿Cómo puede la IoT ayudar a aumentar el uso de los equipo de producción y minimizar el tiempo improductivo no planificado de la fábrica? Supervisando los equipos de la fábrica, de forma rápida, proporcionando a los ingenieros de mantenimiento los pertinentes mensajes de error detallado en tiempo real. En este post mostraremos un ejemplo de cómo puede ayudar la IoT en un entorno industrial.

 

Proycto, Hardware y Arqutectura 

En este proyecto, Opiron Electronics  conecta un M-Duino PLC de IndustrialShields a la plataforma Xively IoT. En este ejemplo se va a mostrar una característica de monitorización en línea para un proceso de fábrica, lo que permitirá a los ingenieros de mantenimiento y operadores visualizar los datos de fábrica usando Internet y acceder a los mismos a través de los teléfonos inteligentes o tabletas. En este caso no vamos a implementar una solución de automatización completa, ya que no es el alcance de este post. Desde el punto de vista del hardware, la arquitectura que vamos a aplicar será como muestra la siguiente figura:

Picture Architecture


Primeros pasos

Antes de nada debemos asegurar que tenemos una cuenta Xively. Si aún no la tenemos podemos registrarnos para obtener una cuenta gratuita aquí. En segundo lugar, seleccionamos los datos que deseamos visualizar. IoT no va a sustituir a los sistemas SCADA; tenemos que pensarlo como una extensión, por lo que es importante seleccionar los datos críticos que tendremos en la nube. En nuestro ejemplo vamos a utilizar una temperatura.


Software y código

Como de costumbre, vamos a utilizar el IDE de Arduino para programar nuestro PLC. Por otra parte, para este proyecto vamos a utilizar la biblioteca Xively para Arduino que se puede descargar aquí. Necesitaremos la biblioteca de cliente HTTP, también, disponible aquí. El boceto subirá un flujo de datos a la plataforma Xively. Xively genera gráficos basados en los datos que nos proporcione, pero se pueden crear triggers y notificaciones para tener capacidades de alerta para nuestra aplicación. En cuanto al código M-Duino PLC, que se puede descargar aquí:
2014111_arduino_code Principales ventajas

Los principales beneficios de la solución  propuesta son:

  1. El control online reduce drasticamente los costes de mantenimiento y el tiempo de inactividad.
  2. Conectado: Los ingenieros de mantenimiento pueden mantenerse conectado al equipo y proceso, lo que significa que unos tiempos de reparación más rápida y una mejora de la fiabilidad.
  3. Basdo en Hardware libre: Desde el punto de vista de hardware y software, esta característica significa gran flexibilidad, gran disponibilidad de recursos en el Internet en caso de fallos o cambiar implementaciones, etc.
img_home
Industrial Shields harware
Ponte en contacto con nosotros!!!

Tiene un proceso para ser automatizado. Póngase en contacto con Industrialshields para implementar la solución completa y para comprar el hardware adecuado.

Chloride Dosing System

Chloride Dosing System

Resumen

La fabricación de agua potable es un proceso de diferentes etapas. El último paso se llama desinfección, i su finalidad es destruir los microorganismos en el agua. Para lograrlo, existen los sistemas de inyección de cloro. Esta técnica se llama dosificación. La dosificación es la técnica para controlar la adición de una sustancia a un líquido que fluye o gas. Los sistemas de dosificación están diseñados para lograr el nivel de dosificación requerido por el mantenimiento de la señal de control como una proporción de la tasa de flujo de fluido. En este post vamos a desarrollar un sistema de dosificación de cloro basado en Arduino.

Equipo a utilizar
Los equipos de control de dosificación constan básicamente de los siguientes elementos:

  • Un controlador, en este caso vamos a utilizar un M-Duino PLC.

  • Un medidor de flujo.

  • Una bomba dosificadora.

  • Un sensor de nivel de dosificación.


    nanodac-dosingcontrol

La siguiente figura muestra la disposición general del sistema de control de dosificación: La concentración de dosis medida por el sensor de nivel de dosificación se utiliza para detener la bomba si hay una alta concentración en el tanque. El medidor de flujo proporciona la entrada del bucle de control, que está conectado a la bomba (como salida).

Software y código

En este ejemplo, el nivel de dosificación y medidor de flujo se configuran como una entrada analógica 0-10V. La bomba funciona con un controlador de frecuencia. Como tenemos que desarrollar un lazo de control, hemos creado un controlador PID vinculado a la entrada especificada, la producción y el valor de consigna. Puede encontrar el código usado en el link que hay a continuación:
2014111_arduino_codePrincipales ventajas

Los principales beneficios de la solución propuesta por Opiron e Industrial shields son:

  • Flexibilidad: Com se puede ver, el hardware basado en código abierto se puede utilizar para controlar el nivel de dosificación de un sistema de cloro. Sin embargo, esta misma arquitectura puede ser usado con cualquier líquido o gas usando el algoritmo PID.
  • Libertad para modificar el software: con este tipo de software no estamos limitados al uso hardware y software propietario.
  • Fácil ser integrado: No importa si ya dispone de un sistema de automatización. El hardware Arduino es fácil de integrar en su sistema ..
  • East to be integrated: No matter if you already have an automation system. The Arduino hardware is easy to integrate into your system..
Ponte en contacto con nosotros!!!

Tiene un proceso para ser automatizado. Póngase en contacto con Industrialshields para implementar la solución completa y para comprar el hardware adecuado.