Diseño e implementación de los sistemas de instrumentación, comunicaciones y control de un sistema multi-tanque

Abstract

The advent of the new paradigm of the fourth industrial revolution, called Industry 4.0, seeks the interconnection between different plants and productive sectors in order to improve their efficiency. An essential requirement of this evolution is the interoperability between technologies from different suppliers and manufacturers to coexist efficiently within industrial processes. The variety of proprietary solutions existing in the market turns the interoperability between systems and devices a challenge, due to the heterogeneity produced by such amount of technology belonging to different suppliers, in addition to the high investment required to acquire these systems and devices. Therefore, small and medium-sized industrial companies need to look for low-cost solutions that cover the interoperability and interconnection between the devices and the production plants.

This work proposes the design and implementation of instrumentation, industrial communications and control systems of a two-tank water system through low-cost programmable logic controllers (PLCs) and compatible with an Open Platform Communications Unified Architecture (OPC-UA) open source server. The OPC-UA server allows the integration of the plant with a Supervisory Control and Data Acquisition (SCADA) system. The purpose is to explore embedded low-cost platforms such as PiXtend and M-Duino to generate communication functions, safeguarding interoperability between devices, preprocessing of variables and control schemes within an industrial environment. The architecture of the instrumentation and communication system proposed in this paper is based on a fieldbus network implementing the Modbus protocol. The proposed control schemes are based on Proportional Integral Derivative controllers (PID controllers) and Fuzzy Gain Scheduling controller (FGS-PID), with detection and diagnosis of failures capabilities by using Extended Kalman Filter (EKF) to estimate the states of the system.