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TransducerandPLCinthewatercontrolsystemapplicationsM.BaniYounisandG.FreyJuniorprofessorshipAgentenbasedAutomationUniversityofKaiserslautemP.0.Box3049,D-67653Kaiserslautem,Germany1.IntroductionCurrently,thewaterlevelcontrolinalargepartoftheelectricalpumpsarenottowinggearshiftsystem,nogearshiftmostoftheelectricalenergyconsumedinthewatersupplytothefrequentchangesinthepumpsstopped.Thisnotonlymakestheelectricalworkininefficientzones,cutshorttheusefullifeofelectricalandelectricalequipmentforthefrequentfailuretostopthehighrate,leadingtoseriouswasteofwaterresources,systemmaintenance,repairslargerworkload.Withhighlivingwaterandindustrialwatergraduallyincreased,thetraditionalcontrolmethodsthatareoutdated.Originallyusedforartificialwaterlevelcontrol,waterlevelduetothelackofaccuratepositioninghourmonitoring,itisdifficulttoaccuratelycontrolthepumpshavestopped;Usingbuoysormechanicalcontroldevicessuchaswatersupplysituationhasmadesomechanges,butbecauseofmechanicalfailuremoredevices,poorreliabilitytomaintenancewillfacegreattrouble.Frequencyconversiontechnology,withitssuperiorityintheareaofenergyefficiencyandHengyapressurecontrolsystemcanbesolvedbytheexistenceoftheaboveproblems.ConsiderselectingChanpianjiorPlcandtransducercombinationatthecoreofthesystemcanachieveabettercontrolresults.Butinsoftwaredesign,PlcprogrammingofmorethanShanpianjiconcise,andvisual;Fromthehardwareinterfaceconsiderations,Shanpianjicircuitslightlycomplex;Fromtheeconomicconsiderations,thePlcprocessesaremature,costandsmallPlcShanpianjialittle,becausethesystemparameterstobeadjustedinaccordancewiththesituationontheground,Plcsoftware,thetimeparametersadjustmentssimpler,somoreconducivetoafter-salepersonnel.ProgrammableLogicControllers(PLCs)areaspecialtypeofcomputersthatareusedinindustrialandsafetycriticalapplications.ThepurposeofaPLCistocontrolaparticularprocess,oracollectionofprocesses,byproducingelectricalcontrolsignalsinresponsetoelectricalprocess-relatedinputssignals.ThesystemscontrolledbyPLCsvarytremendously,withapplicationsinmanufacturing,chemicalprocesscontrol,machining,transportation,powerdistribution,andmanyotherfields.Automationapplicationscanrangeincomplexityfromasimplepaneltooperatethelightsandmotorizedwindowshadesinaconferenceroomtocompletelyautomatedmanufacturinglines.Withthewideningoftheirapplicationhorizon，PLCprogramsarebeingsubjecttoincreasedcomplexityandhighqualitydemandsespeciallyforsafety-criticalapplications.ThegrowingcomplexityoftheapplicationswithinthecomplianceoflimiteddevelopmenttimeaswellasthereusabilityofexistingsoftwareorPLCmodulesrequiresaformalapproachtobedeveloped[I].Ensuringthehighqualitydemandsrequiresverificationandvalidationproceduresaswellasanalysisandsimulationofexistingsystemstobecarriedout[2].OneoftheimportantfieldsfortheformalizationofPLCprogramsthathavebeengrowingupinrecenttimeisReverse-engineering[3].ReverseEngineeringisaprocessofevaluatingsomethingtounderstandhowitworksinordertoduplicateorenhanceit.WhilethereuseofPLCcodesisbeingestablishedasatoolforcombatingthecomplexityofPLCprograms,ReverseEngineeringissupposedtoreceiveincreasedimportanceinthecomingyearsespeciallyifexitinghardwarehastobereplacedbynewhardwarewithdifferentprogrammingenvironmentsTransducerinthewatersysteminconjunctionwiththeintroductionofsmallPlctechnologynotonlychangethetraditionaluseofwatercontrolvalves,andinenergyconservation,Hengyacontrol,areverygoodresults,thepaperintroducedatransducer--PLCcontroltechnologyinthepumpcontrolapplications.2.Systemcontroltheoryandcomposition1.constantpressurewatersystembasicworkingprincipleSystemusesAutomaticFrequencyControlregulationorpumpmotorspeed.Plusorminuspump.ItisprimarilybytheFrequencyControlSystem.PIDregulator,pressuresensors,liquidlevelsensorpowercontrolcircuitsandotherconponents.Hostuserscontrolsystemorcontrolboardlightover-the-countertransactions,buttons,switchtounderstandandcontrolsystenoperation,BasedonthePIDcontrolmode,theoperatorinterfacesettingsinwaterpressure,PLCtopressuresettingsandmeasuredvalucsforthedeviationPIDoperationandregulationofdistributionthroughinverterpumpspeed,sothatwaterpressurewasmaintainedatthesetvalue.2.SystenhanlwareconfigurationThesystemusesSiernensS7-200PLCanditsconfigurationsoftwareconstituteaconstantWinCCV6.0Waterpressurecontrolsystem,waterpressuremonitoringprocess.IndustroalEthernctcontrollerforPLCandtheoperatorstationcomputercommunicationbetwweentheRemoteI/OnetworkforthePLCandtheoperatorstationcompulercommunicationbetwweentheRemoteI/OnetworkforthePLCcontrollerandinverter,thesoftstarterofcommunicationbetwweenequipment.PLCcontrollermainlyusedtomonitorandcontrolwaterandelectricitysystems.For1#-4#pressurizedpumpconverterusingtheABBAcs510-01-031A4inverter,HMIoperatostationselectionDELLconputers,conputer,IndustrialEthernetservercardSiemensconmmunicationscompanyCP1612.3.SoftwaredesignofSystenThecontrolsystemsoftwarecompanySiemensPCS7V5.2package.STEPV5.2PLCcontroller.HMImonitoringsystemusedWinCCV6.0version.HMIserverandoperatingstationareusingtheWindows2000operatingsystemtohaveanopenpro