IAES International Journal of Artificial Intelligence (IJ-AI)

Vol. 13, No. 1, March 2024, pp. 133~142

ISSN: 2252-8938, DOI: 10.11591/ijai.v13.i1.pp133-142  133

Design and simulation of remote monitoring of the intelligent

automatic control system in the production line

Amal Ibrahim Nasser, Ammar Ali Sahrab, Hasan M. Kadhim

Department of Electrical Engineering, College of Engineering, Mustansiriyah University, Baghdad, Iraq

Article Info ABSTRACT

Article history: In this research, we will introduce implementation requirements of a remote
wireless control and monitoring unit of industrial production lines
Received Feb 3, 2023 automatically controlled using programmable logic controller (PLC). PLC is
Revised May 12, 2023 capable of collecting different types of data and converting them into
Accepted May 21, 2023 electrical signals that can be controlled by the industrial network using
supervisory control and data acquisition (SCADA) systems. SCADA will be
installed in the main server inside the control unit. The PLC will be used as a
Keywords: decision maker of the received signals for the industrial lines that comes
from a group of detectors (sensors/transducers). The output of the PLC
Actuator processor will trigger the engines, according to a specific industrial process
Programmable logic controller management program. The processed data could be transferred through
Sensor wireless or wired method. The wireless approach will be shown in this
Supervisory control and data study, along with two other ways to implement it.
acquisition
This is an open access article under the CC BY-SA license.
Zigbee

Corresponding Author:
Amal Ibrahim Nasser
Department of Electrical Engineering, College of Engineering, Mustansiriyah University
Baghdad, Iraq
Email: [email protected]

1. INTRODUCTION
Automation has taken a vital role in industrial systems. To speed up industrial operations, almost all
industries perform operations remotely through supervisory control and data acquisition (SCADA) systems
[1], [2]. Every industry aims to achieve a significant increase in productivity by decrease operational cost and
tolerance fault [3]. SCADA system is a centralized platform that controls and monitors entire zones, or a
compound of systems covering larger zones. Control decision are executed automatically using a
programmable logic controller (PLC). Local controls are traditionally limited to only the supervisory
intervention and/or principle overriding.
Production and industrial lines are primarily of a conventional design, which is not of a high
technology standard. How to transform such lines into high technology lines, which are produced utilizing a
built-in monitoring system, is challenging. Our method aims to advance such lines by implementing cutting-
edge technology to make industrial process safer, quicker, and more affordable. The developers and
researchers must be aware of the current status of the different stages of work for making an acceptable
implementation decision. They need to disseminate various sorts of sensors/transducers throughout the
industrial decision-making line in order to learn more about this issue [4], [5]. PLC should also be capable of
understanding the signals arriving from sensors/transducers and issue orders to players in accordance with the
software that is specifically created to carry out the required operation. There are typically two ways for
transferring signals from the sensors/transducers to the controller and the other way around wired or
wirelessly. Each method has benefits and drawbacks. The benefit of adopting wireless technology is the ease
with which a new production or industrial line may be added to the system. It is also simple to install and
upgrade, and has a lower cost than wire technology.

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134  ISSN: 2252-8938

2. DESIGN REQUIREMENTS
To maintain appropriate operation and usefulness, control systems depend on a variety of parts and
equipment drivers. This section gives a general overview of the three main components that are typically
used in control systems: sensors/transducers, control units (such as programmable logic controllers PLCs),
and actuators. These components will be discussed in the next paragraphs, along with thorough explanations
of each one's roles and responsibilities:
a. Sensors/transducers: Although different industrial lines, they also need the same set of different
sensors/transducers in shapes but have the same principles of work [6], [7]. Application fields of the
sensors/transducers are: Acoustic, vibration, sound, electric current, magnetic, electric potential, radio,
transportation, automotive, chemical, environment, moisture, humidity, weather, subatomic particles,
ionizing radiation, navigation, angle, position, distance, speed, acceleration, displacement, flow, fluid
velocity, force, pressure, density, level, thermal, temperature, heat, light, optical, photons, imaging,
touch, and proximity. Basically, All the above sensors are categorized into digital and analog sensors.
However, there are specific category of sensors are frequently utilized for major automation
applications.
b. Actuators: In control systems that operate machinery and industrial processes, actuators are crucial
drivers [8]. They include a variety of industrial parts/components; such as heaters, lights, sirens/horns,
position/speed control drivers, solenoids, motors, cylinders, and valves. The movement, regulation, and
signaling needed in many industrial applications are made possible by these actuators' precision control
and manipulation capabilities. By transforming electrical energy into mechanical motion, producing
linear or rotational force, controlling fluid flow, producing heat, and providing visual indicators, they
are essential for attaining desired results. Basically, the actuators could be categorized into the
following categories: The electric actuators (such as motors and solenoids), the fluid pressure (hydraulic
actuators), and the air pressure (pneumatic actuators).
c. PLC: Depending on the main power supply of the PLC, PLCs are categorized into main two categories,
External and built-in internal main power supply. There are many types of programable logic controllers
(PLCs), which are found in electronic word stores those contain various software and hardware versions
[9]. PLCs could be selected depending on the following electrical, environmental, chemical and
mechanical specifications:
− Compatibility with the project's controls, machines and control devices.
− The surroundings and working conditions, like noise, temperature, dust, and humidity, among others.
− PLC functions utilized. As some companies, provide a few extra features and built-in peripherals (e.g.,
counters and timers) in specific version(s).
− Number of sensors/transducers, engines, and types.
− Future expansion capability.
− SCADA program compatible with PLC.
− Communication ability with other types PLC or HMI.
This paper system will be the ADVANTIC ADAM series, because it has the compatibility with other parts
and components. The series covers the requirements of this paper research.

3. ADVANTIC PRODUCTION ADAM SERIES PLC

Thanks to developments in computer-based technology, ADVANTEC's computer-based
programmable control tools are now widely used in a variety of industrial automation applications. The
ADAM Series, shown in Figure 1(a) and (b), is one noteworthy product line that comprises of intelligent
sensor-to-computer interface modules with integrated microprocessors. These modules make it possible for
sensors/transducers and computers to communicate seamlessly, offering an effective and clever control
option in industrial automation settings. A straightforward set of RS-485 protocol-transmitted commands in
ASCII format is used to remotely control the system components. The series provide data comparison, D/A
and A/D conversions, isolation, signal conditioning, digital communications, and ranging. For controlling
relays and TTL devices, a few modules have digital I/O lines. In some variants, ADAM series controllers,
additionally support native libraries and compact-size Ethernet ports. FTP Server, HTTP Server functionality,
and integrated functionality are all features that support these Ethernet ports. Multiple serials port is
available, which enable the ADAM/ ADVANTEC series controllers to make excellent choices for industrial
control applications and communications facilities for these applications. For the needs of many applications,
standard I/O design offers considerable flexibility. The ADAM series controllers, additionally support the
manufacturer libraries with extensive Modbus functionality, such as libraries [2]. ADVANTEC firm supports
this series of PLC with the essential software and hardware requirements in automation field.

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(a) (b)

Figure 1. The ADAM series (a) Wireless ADA and (b) Wired ADAM

3.1. Software configuration and calibration

Once a command has been sent from the host computer, the ADAM analog input unit could be
configured to take a variety of input voltage ranges, RTD input, or thermal input. Every setting for the unit's
configuration, such as the I/O address, HI and LO alarms, connection speed, and calibration parameter
settings. Either menu-based program or configuring command set in the commands of calibration could be
used for remote setup. The calibration parameters and configuration are kept by the units by storing them in
the non-volatile EEPROM chips in case of power outages. Calibration and setting process is important for the
correct procedure of the automation and industrial applications. This process takes into account the hardware
capability of this series. In addition to the hardware, software could be used to accomplish that process [10].

3.2. Hardware configuration

− Watchdog timer: Function of watchdog timer resets the ADAM in an automatic manner in a case when
the system malfunctions. Therefore, the maintenance is simplified.
− Power requirements: The modules accept any power supply unit in the range of +10 to +30 VDC even
though they have been made to give unregulated power at a standard voltage of 24 VDC. The immediate
ripple voltage must be kept in the range of +10 to +30 VDC, and the power supply ripple must be kept to
a maximum of 5 V from peak to peak.
− Connectivity and programming: With the use of RS485 transmission standards, ADAM could be
connected to any terminals and computers. Because it offers low-noise sensor readings, RS-485 could be
installed much closer to the source. With the use of ADAM RS485 repeater that increases maximal
communication distance to 4,000ft, up to 256ADAM modules could be connected to RS485 multi-drop
network. Through ADAM-452x module (RS-232 to RS-422/485 converter), the host computer's COM
port is linked to the RS-485 network. The ADAM RS485 repeater utilizes logical RTS signal in order to
control repeater's direction, which increases network throughput. DATA+ and DATA-, the only 2 wires
required for RS485 network, are low-cost shielded twisted pair [4]. ADAM modules could be
programmed in virtually any high-level language because all connections to and from the module are made
in ASCII [2].
− Protection against the environment: The protection offered by the package is crucial since software
controls every configuration. This packaging's plastic outer cover could be utilized to withstand moisture,
corrosive, and vibration. ADAMs are able to function at a range of humidity and temperatures levels,
from 0 to 70 °C and 0 to 95% (non-condensing), thanks to their low power consumption. Because of its
small size and SMT technology, it may be used in any industrial setting.
− Wireless LAN: some ADAMs offers a wireless LAN connected to the network. The majority of WLAN
access points use IEEE802.11b as its wireless LAN interface instead of RJ-45 Ethernet ports in their
hardware design, which is based on the ADAM series of modules. With the use of HMI or SCADA
software, ADAM could support Modbus, UDP, and TCP protocols like other ADAM modules. For
critical and real responses, UDP includes built-in event playback and data stream functionalities [1], [4].
Therefore, it is the best option for settings with expensive wiring requirements or wiring limitations.

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4. CONTROL METHODOLOGY
The design of automatic control systems in manufacturing lines must be optimized through the use
of SCADA systems. These systems are a prerequisite for effective monitoring and management of industrial
processes. In the context of automatic control system design for production lines, the current research focuses
on two data gathering and transmission approaches that were used to improve the functioning of the SCADA
system.

4.1. Supervisory control and data acquisition (SCADA)

A computer system that has been called SCADA is used in order to collect and analyze real-time
data [11], [12]. It is utilized for monitoring and controlling an equipment or plant in sectors such as energy,
transportation, water and waste management, and the telecommunications industry. The main station is
notified of any defects in industrial lines, like pipeline leaks, by the SCADA system, which after that
transmits information back to some central location [13]. The main station after those conducts required
control and analysis (specifying whether the leak is critical). SCADA systems could be rather
straightforward, like viewing environmental conditions. In order to enable direct interaction between the
human element and the control system, an industrial process control system must have a GUI [14], [15].
Which will be reached through connecting a PC in control room to PLC in order to monitor and manage the
connected equipment. A sample monitor screen is shown in Figure 2. Additional benefits of SCADA systems
include:
− Decreases operational cost.
− Offers instant knowledge regarding system performance.
− Enhances system performance and efficiency.
− Enhances the equipment’ life.
− Facilitate compliance with the regulatory agencies via creating an automated report.
− Decreases expensive repairs.
− Decreases the number of hours worked (labor costs)
− Needed for service or troubleshooting.
− Free staff for conducting other significant tasks.

4.2. Monitor room

Provide The monitor room's design focuses on two main areas:
− The control room's structural adequacy to survive any catastrophic events.
− The design of control rooms and placement of panels in order to guarantee the plant's efficient
ergonomic operation in both emergency and normal situations.
Control rooms for large plants are separate and located in buildings separate from the treatment
plant they serve. Building control rooms (or control panels) could be positioned close to small or medium-
sized plants to better manage their plant. A sample of monitor rooms is shown in Figure 3. No matter the
location, control rooms need to be suitable for maintaining factory control and must be built to guarantee that
its occupants are within acceptable limits [15]. Various events might limit the control room work, these are:
− Pressure bursts.
− Expanded boiling steam vapor bursts (BLEVEs).
− Vapor explosions (VCEs).
− Fire, including billiard fires, flash fires, jet fires, and fireballs.
− Emissions of toxic gases.
− Exothermic reactions.
Along with the SCADA computer, a simulation of the industrial lines that is enhanced with lights
that display the status of sensors and actuators might be included in the suggested control room. Each data
entry and output would be branched as a result of this integration, better grabbing the PC Human Machine
Interface's attention. By include this simulation, the work process would be visually represented, enabling
operators to track the status of sensors and actuators in real-time, improving their comprehension and
decision-making skills.

4.3. Collecting and transmitting data

According to the idea of data collection and transmitting to and from the control room, we have two
ways for implementing PLCs on our industrial line:
− The first way: Data will be collected and converted straight to a wireless signal with the use of ADAM
6050W and ADAM 6060W. The access point is after that used for receiving the data in the control
room, as can be seen in Figure 4(a). Using the same power source as ADAM modules, the sensors will

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save energy. The common wire (0V) should be connected to the same point in the case when power
source is not sufficient to supply load's requirement. Additional sources of the power could be utilized.
In the case when the power range is within the allowed range, the sensors' digital outputs are directly
connected to ADAM module's DI (i.e., digital input) ports. The relay files will subsequently be
connected to the digital data output (DO) of ADAM in order to receive the necessary actions through
their contacts. Since there is not a wireless ADAM module that deals with analog data specifically,
there is no need to utilize input and/or output analog data while using this option. Since they support
IEEE802.11b, ADAM-6051W, ADAM-6050-W, and ADAM-6060-W could connect to majority of
wireless LAN access points. The ADAM-6051W, ADAM-6050-W, and ADAM-6060-W support
Modbus/UDP and TCP protocols much like other ADAM-6000 modules. Through Modbus/TCP,
HMI/SCADA could connect to ADAM modules. For real and critical responses, the UDP protocol
includes pre-built event playback and data stream features.
− The second way: Systems that need the usage of analog data for output and/or input employ this option.
The following method is used for transferring such signals from industrial line to control room because
there is not a wireless ADAM module that can handle analog data. With the use of ADAM 5000 (or any
other modules), data will be collected and after that transformed to an Ethernet signal. Additionally, the
signal is transmitted wirelessly with the use of ADAM 4571W or ADAM 4570W. An access point
could be used to receive this data in the control room, as can be seen in Figure 4(b). Cost-effective data
porters between the RS232/422/485 and 802.11b WLAN interfaces are the ADAM-4571-W and
ADAM-4570. It offers a quick and inexpensive solution for connecting any RS232/422/485 device to an
802.11-b wireless LAN. The ADAM-4571W and ADAM-4570W are cost-efficient in the case when
continue using existing software and hardware since they are transparent and functionally effective. For
thousands of the RS-232/422/485 devices that cannot connect to network, the ADAM-4571W and
ADAM-4570W offer remote management and data access functionalities.

Figure 2. Monitor screen sample Figure 3. Monitoring room sample

(a) (b)

Figure 4. Data collection and transmission (a) the first way and (b) the second way

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4.4. IEEE 802.15.4 wireless protocol

In computer networks and telecommunications, a protocol is a group of the guidelines, which
specify the way that data is transferred. Institute of Electrical and Electronics Engineers is known by
abbreviation IEEE. This non-profit is focused on advancing technology, including electronic and electrical
devices [16], [17]. Local networks and medium-sized networks are among the network operations
technologies covered by the IEEE division known as the 802 Group. Group 15 focuses mainly on wireless
networking technologies, such as Bluetooth and the 802.15.1 workgroup everywhere. A set of specifications
called ZigBee has been based upon the IEEE 802.15.4 wireless protocol. In order to obtain pollen, various
bees zigzag randomly between flowers, hence the name "ZigBee." This is reminiscent of the networked,
imperceptible connections found in a completely wireless environment. ZigBee Alliance, which is a global
organization with approximately 150 members, oversees the standard itself. ZigBee is intended to enable
extremely effective communication between small packet devices, whereas Bluetooth concentrates on
connectivity between large packet user devices, like phones, computers, and significant peripherals. In
comparison with significantly faster 1.0 Mbps Bluetooth-based 2.4 GHz ISM line that is widely accessible,
ZigBee devices can operate at speeds of up to 250 kbps. ZigBee was created to satisfy the growing demand
for wireless networks that can connect numerous low-power devices. With small transmitters on each device
on the ground, ZigBee is employed in the industry to automate the future generation and allow
communication between the devices to some central devise. This improved connection level enables precise
remote processing and monitoring. The maximum operating range for ZigBee devices is specified to be 250
feet (76 meters), which is significantly more than what Bluetooth-capable devices can use [18], [19].
Therefore, the following ZigBee protocol features could be summarized [20],
− Low duty cycle - offers long battery life
− Low latency
− Support for several network topologies: dynamic, static mesh and star
− Collision avoidance
− 128bit AES encryption - provides secure connection amongst the devices
− Up to 65,000 nodes on a network
− Clear channel evaluation
− indication link quality
− Supports for the packet freshness and guaranteed time slots.
− Retries and acknowledgements.

5. RESULTS AND DISCUSSION

The cycling assembly will be run on the production line using the automation method to speed up,
make the process safer, and keep it under control up until the very end. The simulation depicts an industrial
line with switch and sensor status lights throughout the operation, as seen in Figure 5. Feeder traffic will be
monitored, monitored and controlled. We should now examine the signal input and output in accordance with
these requirements in order to use the PLC and integrate it into the system.
a. Input signals:
− Three digital signals for the carrier movements.
− Ten digital signals for operator orders.
− Five digital signals for product sites.
b. Output signals:
− One digital signal to conveyor motor operation.
− Fifteen digital signals for clarification lamps.
− Sixteen digital output signals and 18 digital input signals.
Those specifications state that the design depicted in Figure 6 will require three ADAM6060W
modules. The ADAM-6060-W can be defined as high-density I/O module with an integrated IEEE 802.11-b
WLAN interface for seamless Ethernet connectivity, as we previously explained. Additionally, the ADAM-
6060-W provides six relay outputs and six digital input channels (DI). It supports contacts with the contact
rating values of DC 30V, 1A and AC 120V, 0.5A. For critical handling, all digital input channels support
input latch functionality. Those DI channels could be utilized as frequency input channels and 3 kHz counter
channels. The digital output channels support pulse output along with the intelligent DI features [21]–[23].
c. ADAM-6060W Specifications:
− Communications: IEEE802.11-b WLAN
− Supports Protocols: Modbus/TCP, UDP, TCP/IP, ICMP, HTTP, and ARP

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d. Digital Inputs:
− Channels: 12
− Dry Contacts: Logic lvl0: Close to the Ground; Logic lvl1: Open
− Wet Contact: Logic lvl0: 0 ~ 3VDC Logic lvl1: 10 ~ 30VDC
− Support 3kHz counter input (32bit + 1bit)
− Support 3kHz frequency inputs
e. Relay Outputs:
− Channels: 6
− Contact rating (Resistive): AC: 120V, 0.5A DC: 30V, 1A
− Relay on time: 7ms
− Relay off time: 3ms
− Breakdown voltage: 500VAC (50/60Hz)
− Total switching time: 10ms
− Maximum Switching Rate: 20 operations/min. (at rated load)
− Insulation Resistance: 1GΩ minimal at 500VDC
− Supports pulse output (max 3Hz)
− Isolation Protection: 2000VDC
− Built-in Watchdog Timer
− Power Input: Unregulated 10 ~ 30VDC
− Power Consumption: 2W, 24VDC
− Power Reversal Protection
− Storage Humidity: 5~95% RH (non-condensing)
− Operating Humidity: 5~95% RH (non-condensing)
− Storage Temperature: -20 °C~80 °C

Figure 5. Simulation for the industrial line

Figure 6. ADAM-6060W wiring

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− Operating Temperature: -10 °C~60 °C

As shown in Figure 7, a LADDER program can now be used to program the PLC (ADAM 6060).
The SCADA program is used to supervise and monitor input and output signals from the control room since
it is connected close to the industrial line as shown in Figure 8 [24], [25]. Through this integration, the PLC's
activities may be controlled and monitored centrally, allowing for effective management of the industrial
line's operations and promoting prompt decision-making based on real-time information.

Figure 7. Ladder program for PLC

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Figure 8. SCADA design typical project

6. CONCLUSION AND RECOMMENDATION

With the aid of cutting-edge technology, typical industrial processes will be improved in terms of
cost-effectiveness, speed, and safety. A significant aspect of achieving these goals is the integration of
control systems and Internet connectivity. Control systems can be used to monitor and control industrial
operations in real time, ensuring compliance with safety regulations and enabling prompt modifications.
Furthermore, having access to the Internet allows for remote monitoring and control from any location,
which improves flexibility and responsiveness. The main goal of this research is to employ these
technologies to improve industrial processes, leading to safer operations, quicker output, and lower prices.

ACKNOWLEDGEMENTS
The researchers thank the Electrical Engineering Department; Engineering College, Mustansiriyah
University/Baghdad/Iraq “www.uomustansiriyah.edu.iq”/Iraqi MoHEandSR; for their supports.

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BIOGRAPHIES OF AUTHORS

Amal Ibrahim Nasser received the BSc. degree in electrical engineering from
the University of Baghdad, Iraq on 1994, the MSc. degree in Electrical Engineering/Electronic
and Telecommunications/Mustansiriyah University in 2000., and the Ph.D. degree in
control/control and computers/University of Technology Engineering in Baghdad, Iraq in
2007. Currently "Lecturer Dr." at the College of Engineering, Mustansiriya University, Iraq,
Baghdad. Interested in the field of scientific research for automatic control systems and
intelligence systems and their simulation in Matlab programs. She can be contacted at email:
[email protected].

Ammar Ali Sahrab received his BSc. degree in Electrical Engineering

(Honours) from Mustansiriyah University, College of Engineering, Baghdad, Iraq, in 1997.
He obtained his MSc. degree in Electronics and Communications Engineering from
Mustansiriyah University, College of Engineering, Baghdad, Iraq, in 2000. He obtained his
Ph.D. degree in Electronics, Telecommunications and Information Theory from University
"Politehnica" of Bucharest, The Faculty of Electronics, Telecommunications and Information
Technology, Bucharest, Romania, in 2016. He currently holds the position of Associate
Professor in the department of Electrical Engineering at Mustansiriyah University. His
research interests include Mobile Communications, IoT based on microcontroller, Antennas
Design and Implementation. He can be contacted at email: [email protected].

Hasan M. Kadhim is an Assistant Professor in the Electrical Engineering

Department, College of Engineering, Mustansiriyah University; Baghdad, Iraq. He received
his BSc., MSc., and Ph.D. degrees in Electrical Engineering from Baghdad University,
Mustansiriyah University, and Newcastle University in 1985, 2000, and 2017, respectively.
His research field is Source Separation, Machine Learning, Artificial Intelligence, Speaker
Diarization, TMS320-Family DSP Processor, FPGA, PLC, and Verilog-HDL language. He
can be contacted at email: [email protected].

Int J Artif Intell, Vol. 13, No. 1, March 2024: 133-142