SCADA Control System Through Servomotor with PLC Monitored

by Software Application on Automatic Rolling Door

Imam Sutrisno

, Rahmadika Akbar

, Muhammad Reza Pahlevi

, Anisa Fitri Santosa

Perwi Darmajanti

, Didik Dwi Suharso

, Ignatius Kristianto Agung Nugroho

, Muji Setiyono

Fadel Muhammad

and Muhammad Idris

Politeknik Perkapalan Negeri Surabaya, Indonesia

Politeknik Pelayaran Surabaya, Indonesia

Sekolah Tinggi Ilmu Pelayaran, Indonesia

Politeknik Pelayaran Sorong, Indonesia

Keywords: SCADA, Servomotor, PLC.

Abstract: Automation is a basic technology in the digital era especially in industrial revolution 4.0 so as a human is a

shared responsibility between the workers and engineers who are specifically authorized to maintain the

stability of the technology. For example, a rolling door in an industrial warehouse is a way to make the

distribution possible from inside to outside the room or vice versa. But the implementation of the industrial

warehouse rolling door is still operated manually. So this study aims to create a control system for the

industrial warehouse rolling door like a Supervisory Control and Data Acquisition (SCADA) and it’s

controlled automatically through Servomotor with Programmable Logic Controller (PLC) and also to monitor

the system to inform certain conditions by using a software application. The purpose making of the automatic

rolling door for industrial warehouses with monitor software application itself is to construct everything from

the loading distribution to the shipment automatically without doing it manually and also at the same moment

can be monitored every time.

1 INTRODUCTION

The increasing need for automation in every life

aspect has made a lot of industry to develop many

automatic standards and implementations. The

engineer and the workers have a challenge so that it

meets the technical requirements as regulated by each

of the tools and component manual. The vehicle

should be considered first if it fits the regulation to

pass the rolling door and made it through the room for

loading. The automatic rolling door opens when the

door controller receives an activation signal from the

sensor and activates the gear motor to drive the belt

and pulley. When no one is detected inside the

activation area, the door starts closing after a

designated period of time. An automatic rolling door

operator is a set of driving devices and controllers that

opens/closes the door. It includes components such as

a gear motor and door controller. The power to the

door operator can be turned on/off easily during the

maintenance of the door. Activation sensors are used

to activate the door's openings and closings by

sending a signal to the door operator. The software

application is connected to every component of the

automatic rolling door so it can be controlled through

Human Machine Interface (HMI) and monitored in a

device such as a personal computer or laptop. The

challenges of the applied systems using this

technology have already been reported in some early

research. And some techniques used have been

considered useful candidates for the vehicle-to-

infrastructure context. Our paper proposed the

implementation of a basic rolling door controller as a

fixed infrastructure automated by common

distribution and transition vehicles used such as pick-

up trucks or cargo trucks.

Sutrisno, I., Akbar, R., Pahlevi, M., Santosa, A., Darmajanti, P., Suharso, D., Nugroho, I., Setiyono, M., Muhammad, F. and Idris, M.

SCADA Control System Through Servomotor with PLC Monitored by Software Application on Automatic Rolling Door.

DOI: 10.5220/0011812000003575

In Proceedings of the 5th International Conference on Applied Science and Technology on Engineering Science (iCAST-ES 2022), pages 437-441

ISBN: 978-989-758-619-4; ISSN: 2975-8246

437

2 MANUSCRIPT PREPARATION

2.1 Literature Review

2.1.1 SCADA

SCADA (supervisory control and data acquisition) is

a category of software applications for controlling

industrial processes, which is the gathering of data in

real-time from remote locations in order to control

equipment and conditions. SCADA provides

organizations with the tools needed to make and

deploy data-driven decisions regarding their

industrial processes (Peter Loshin, 2021).

2.1.2 Servomotor

A servo motor is an electromechanical device that

produces torque and velocity based on the supplied

current and voltage. A servo motor works as part of a

closed loop system providing torque and velocity as

commanded by a servo controller utilizing a feedback

device to close the loop. The feedback device supplies

information such as current, velocity, or position to

the servo controller, which adjusts the motor action

depending on the commanded parameters

(Kollmorgen Experts, 2020).

2.1.3 Authors

A Programmable Logic Controller is a small

industrial computer originally designed to perform

the logic functions executed by electrical hardware

(relays, switches, and mechanical timer/counters), as

defined by The U.S. Department of Commerce

National Institute of Standards & Technology

(NIST). PLCs have evolved to control complex

processes and are used in supervisory control and data

acquisition (SCADA) systems and Distributed

Control Systems (DCS). PLCs are used in almost all

industrial processes. PLCs have user-programmable

memory for storing instructions for specific

functions, including I/O control, logic, timing,

counting, three mode (PID) control, communication,

arithmetic, and data and file processing. Unlike

SCADA and DCS, PLCs usually do not have a central

control server and HMI and, therefore, they

“primarily provide closed-loop control without direct

human involvement.”. This kind of automation

allows engineers with a limited knowledge of

computers and computing languages to operate the

systems easily, as PLCs are generally considered

intuitive (Cristina Tuser, 2022).

2.2 Research Method

In the process of making a prototype, it is necessary

to design and flow to be able to know the

development and progress of the prototype as follows

Figure 1: Flowchart.

2.2.1 Identification of Problems

To start the method, first we should know the industry

need how the efficiency must be and how practically

could be of the use of rolling doors automatically.

Measure the width of the sensor placement and also

where the control panel should be placed. And then

configure the placement of the wiring how to connect

the control panel to the object.

2.2.2 Case Study

Based on the majority of user requests, this case

requires various actuator sensors and control systems

iCAST-ES 2022 - International Conference on Applied Science and Technology on Engineering Science

438

to run automatic rolling door systems such as load

cells, relays, mini-circuit breakers, motor drivers,

power supply, PLC, and HMI.

2.2.3 Analysis

The step requires designing a series of automatic

rolling door control systems, system design, design

a set of supporting tools, control panel design, and

diagram wiring. Also, there is an analysis of non-

functional requirements. Hardware: Personal

computer (PC/Laptop), communication cable,

control panel. Software: EasyBuilder Pro

application for HMI designing and connecting HMI

to the program, PANATERM application for

monitoring the Servomotor, FPWIN GR application

for the PLC programming, and AutoCAD

application for various designing (Sutrisno, 2019).

2.2.4 Design

A hardware design from control panel.

Figure 2: Control panel wiring.

The control panel contains a 24VDC power

supply, 6A mini-circuit breaker, Panasonic PLC

FP0R, PLC CPU, and terminals. The mini-circuit

breaker to turns on the power source. The Power

supply supplies the DC current to the PLC. Terminals

to connect various wiring.

Picture of one of the HMI design windows.

The HMI is designed to make it easier to control

and monitor the object. There are many various

windows included in the HMI display like parameter

window, monitor window, input window, and many

others.

Figure 3: HMI Display.

2.2.5 Development

Hardware and software development as follows:

Determine which components to use, designing

wiring, make ladder program on PLC FP0R, creating

HMI display for operator convenience, trial run of the

entire automatic rolling door system such as checking

servomotor, PLC, and also HMI.

2.2.6 Implementation

At this stage, testing of the tool and a trial run of the

servomotor through the PANATERM application is

carried out by running for several hours to ensure that

the servomotor is safe. Checking the program if it

connected with sensor & actuator. If all the

requirement is ready and safe, the simulation can be

started. The vehicle will drive through the near edge

of the door. And if the sensor detected, the

servomotor will work which means the rolling door is

open (Sutrisno, 2014).

2.2.7 Evaluation

This evaluation stage where the author sees the

success rate of the simulation after passing the trial

and will be used to develop the next automatic rolling

door process.

2.3 Program Logic Ladder

The following figure shows the program used to

program the PLC FP0R.

Figure 4: Command button rung network.

SCADA Control System Through Servomotor with PLC Monitored by Software Application on Automatic Rolling Door

439

The created program is centered on a pushbutton from

start button, stop button, emergency button, and reset

button.

Figure 5: Indexing data rung network.

In the indexing data program, the use is for saving and

loading data when the simulation is working

including the day, time, and date. The data can be also

removed or reset to make new data. The data will be

displayed on HMI itself.

2.4 Alarm Display List

Alarm display list can be viewed in PANATERM

application. The alarm list contains various past

machine error from the servomotor so we can monitor

and know the problem what causes the error. This is

the alarm list from the recent simulation.

Model name: MDDLN45SG011

Print Date: July 27, 2022 13:44:27

Serial No: 18050079

Table 1: Now Error.

Protect Function

Error CD

Encoder communication

disconnect error

protection

21.0

Table 2: Now Warning.

Protect Function

Error CD

Encoder communication

warning

When the simulation start and the device/laptop is

connected to the control panel via a communication

cable, we can open the PANATERM application to

monitor and look at the alarm list history from the

past to the present. The monitor displays from the

now error, now warning, and past error history. With

the alarm list, we can see why and how the simulation

work or maybe there is an error so we can find the

problem from the list and find the solution to make it

work again like running a jog in a trial run.

Table 3: Past Error History.

Hist.

Protect Function

Error CD

Power Of

Time[h]

Encoder

communication

disconnect error

protection

21.0

12926

Over-load

protection

16.0

12926

Encoder

communication

disconnect error

protection

21.0

12926

Encoder

communication

disconnect error

protection

21.0

12926

Over-load

protection

16.0

12926

Over-load

protection

16.0

12926

Overload protection

16.0

12926

Over-load

protection

16.0

12926

Over-load

protection

16.0

12926

Over-load

protection

16.0

12926

Over-load

protection

16.0

12926

Encoder

communication

disconnect error

protection

21.0

12926

Over-load

protection

16.0

12926

Overload protection

16.0

12926

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440

3 CONCLUSIONS

With the simulation that has been cleared and how the

system work, the level of security and effectiveness

in an industrial warehouse can be further increased

and allows the industrial product distribution to

become fastly automatic and also can be reliable.

Because this system can facilitate the warehouse

worker and distribution transition allowed it to be

more practical in these day technology and has very

minimum of failure and work accidents. Meanwhile,

when using this system, the message can be

maintained until the situation is under control and all

of the workers are ensured. This system could be

implemented to Society 5.0. Where all working

activities can be improved effectiveness and

efficiency with the control system more precisely and

quickly than before.

REFERENCES

Loshin, Peter (2021). What is a SCADA (supervisory

control and data acquisition) and how does it work? In

https://www.techtarget.com. Accessed July 30, 2022.

Kollmorgen Experts (2020). How Servo Motors Work. In

https://www.kollmorgen.com. Accessed July 30, 2022.

Tuser, Cristina (2022). What is a Programmable Logic

Controller (PLC)? In https://www.wwdmag.com.

Accessed September 19, 2022.

Sutrisno, Imam (2019). Design of Pothole Detector Using

Gray Level Co-occurrence Matrix (GLCM) And Neural

Network (NN). IOP Conference Series: Materials

Science and Engineering.

Sutrisno, Imam (2014). Nonlinear Model-Predictive

Control Based on Quasi-ARX Radial-Basis Function-

Neural-Network. 2014 8th Asia Modelling Symposium

Sutrisno, Imam (2009), Pemrograman Komputer Dengan

Software Matlab disertai contoh dan aplikasi skripsi

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SCADA Control System Through Servomotor with PLC Monitored by Software Application on Automatic Rolling Door

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