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This paper discusses the design and implementation of a portable IoT station. Communication and data synchronization issues in several installations are addressed here, making possible a detailed analysis of the entire system during its operation. The system operator requires a synchronized data stream, combining multiple communication protocols into one single time stamp. The hardware selected for the portable IoT station complies with the International Electrotechnical Commission (IEC) industrial standards. A short discussion regarding interface customization shows how easily the hardware can be modified so that it is integrated with almost any system. A programmable logic controller enables the Node-RED to be utilized. This open-source middleware defines operations for each global variable nominated in the Modbus register. Two applications are presented and discussed in this paper; each application has a distinct methodology utilized to publish and visualize the acquired data. The portable IoT station is highly customizable, consisting of a modular structure and providing the best platform for future research and development of dedicated algorithms. This paper also demonstrates how the portable IoT station can be implemented in systems where time-based data synchronization is essential while introducing a seamless implementation and operation. [ABSTRACT FROM AUTHOR]

This work is concerned with the vulnerability of a network industrial control system to cyber-attacks, which is a critical issue nowadays. This is because an attack on a controlled process can damage or destroy it. These attacks use long short-term memory (LSTM) neural networks, which model dynamical processes. This means that the attacker may not know the physical nature of the process; an LSTM network is sufficient to mislead the process operator. Our experimental studies were conducted in an industrial control network containing a magnetic levitation process. The model training, evaluation, and structure selection are described. The chosen LSTM network very well mimicked the considered process. Finally, based on the obtained results, we formulated possible protection methods against the considered types of cyber-attack. [ABSTRACT FROM AUTHOR]

In this study, the design of a Digital-twin human-machine interface sensor (DT-HMIS) is proposed. This is a digital-twin sensor (DT-Sensor) that can meet the demands of human-machine automation collaboration in Industry 5.0. The DT-HMIS allows users/patients to add, modify, delete, query, and restore their previously memorized DT finger gesture mapping model and programmable logic controller (PLC) logic program, enabling the operation or access of the programmable controller input-output (I/O) interface and achieving the extended limb collaboration capability of users/patients. The system has two main functions: the first is gesture-encoded virtual manipulation, which indirectly accesses the PLC through the DT mapping model to complete control of electronic peripherals for extension-limbs ability by executing logic control program instructions. The second is gesture-based virtual manipulation to help non-verbal individuals create special verbal sentences through gesture commands to improve their expression ability. The design method uses primitive image processing and eight-way dual-bit signal processing algorithms to capture the movement of human finger gestures and convert them into digital signals. The system service maps control instructions by observing the digital signals of the DT-HMIS and drives motion control through mechatronics integration or speech synthesis feedback to express the operation requirements of inconvenient work or complex handheld physical tools. Based on the human-machine interface sensor of DT computer vision, it can reflect the user's command status without the need for additional wearable devices and promote interaction with the virtual world. When used for patients, the system ensures that the user's virtual control is mapped to physical device control, providing the convenience of independent operation while reducing caregiver fatigue. This study shows that the recognition accuracy can reach 99%, demonstrating practicality and application prospects. In future applications, users/patients can interact virtually with other peripheral devices through the DT-HMIS to meet their own interaction needs and promote industry progress. [ABSTRACT FROM AUTHOR]

An appropriate control and measurement system is one of the elements that allows for the safe and effective operation of a technological installation. Such a system may have a diverse structure that corresponds to the expectations and needs of its user. The devices of various manufacturers, including PLC (programmable logic controllers), can be used as a source of measurement data. This enables flexible measurement–control installations, which are adapted to the technological installations, to be built. This paper presents a system, which was created by the authors, for monitoring the temperature, pressure and flow rate of fluids. It uses the operational and IT properties of the PLC and is adapted to an existing installation on the test stand for multiphase spraying processes. In addition, as a part of the research, an application written in Python language, which allows collected data to be displayed, stored and exported, was implemented. [ABSTRACT FROM AUTHOR]

The interconnection between sensors, controllers and instruments through a communication network plays a vital role in the performance and effectiveness of a control system. Since its inception in the 90s, the Object Linking and Embedding for Process Control (OPC) protocol has provided open connectivity for monitoring and automation systems. It has been widely used in several environments such as industrial facilities, building and energy automation, engineering education and many others. This paper presents a novel OPC-based architecture to implement automation systems devoted to R&D and educational activities. The proposal is a novel conceptual framework, structured into four functional layers where the diverse components are categorized aiming to foster the systematic design and implementation of automation systems involving OPC communication. Due to the benefits of OPC, the proposed architecture provides features like open connectivity, reliability, scalability, and flexibility. Furthermore, four successful experimental applications of such an architecture, developed at the University of Extremadura (UEX), are reported. These cases are a proof of concept of the ability of this architecture to support interoperability for different domains. Namely, the automation of energy systems like a smart microgrid and photobioreactor facilities, the implementation of a network-accessible industrial laboratory and the development of an educational hardware-in-the-loop platform are described. All cases include a Programmable Logic Controller (PLC) to automate and control the plant behavior, which exchanges operative data (measurements and signals) with a multiplicity of sensors, instruments and supervisory systems under the structure of the novel OPC architecture. Finally, the main conclusions and open research directions are highlighted. [ABSTRACT FROM AUTHOR]

Digital twin (DT) is an emerging key technology that enables sophisticated interaction between physical objects and their virtual replicas, with applications in almost all engineering fields. Although it has recently gained significant attraction in both industry and academia, so far it has no unanimously adopted and established definition. One may therefore come across many definitions of what DT is and how to create it. DT can be designed for an existing process and help us to improve it. Another possible approach is to create the DT for a brand new device. In this case, it can reveal how the system would behave in given conditions or when controlled. One of purposes of a DT is to support the commissioning of devices. So far, recognized and used techniques to make the commissioning more effective are virtual commissioning and hybrid commissioning. In this article, we present a concept of hybrid virtual commissioning. This concept aims to point out the possibility to use real devices already at the stage of virtual commissioning. It is introduced in a practical case study of a robotic manipulator with machine vision controlled with a programmable logic controller in a pick-and-place application. This study presents the benefits that stem from the proposed approach and also details when it is convenient to use it. [ABSTRACT FROM AUTHOR]

Power line impedance is a very important parameter on the design of power line communications (PLC) modem architecture. Variations on the impedance of the power line affect the communications circuit performance. In order to determine impedance of the power lines, measurements were carried out in Turkey at frequencies ranging from 10 to 170 kHz, (CENELEC A,B,C,D bands). Measurements were conducted in three categories: rural, urban and the industrial power lines. Experimental results are presented in graphical form. The measured impedances were determined as 3-17 ohms, 1-17 ohms, and 1-21 ohms for rural, urban and the industrial lines, respectively. A set of the formulas between impedance and frequency are developed on the power lines using the regression analysis from the obtained empirical data. Signal attenuations on the power lines in the CENELEC band are also measured for rural, urban and industrial regions. Attenuation measurements are repeated for phase-neutral, phase-ground and the neutral-ground conductors. Signal attenuations are found to be 4-30 dB, for different power lines. To establish validity of obtained results for the design of PLC systems, the results are compared with previous investigations. The effects of some household appliances such as TV, PC, UPS, lighting and cooling systems on the impedances and the attenuations for power line communications systems are observed. Some suggestions and proposals are presented for PLC modem designers. [ABSTRACT FROM AUTHOR]

In recent years, the Industry 4.0 paradigm has accelerated the digitalization process of the industry, and it slowly diminishes the line between information technologies (IT) and operational technologies (OT). Among the advantages, this brings up the convergence issue between IT and OT, especially in the cybersecurity-related topics, including new attack vectors, threats, security imperfections, and much more. This cause raised new topics for methods focused on protecting the industrial infrastructure, including monitoring and detection systems, which should help overcome these new challenges. However, those methods require high quality and a large number of datasets with different conditions to adapt to the specific systems effectively. Unfortunately, revealing field factory setups and infrastructure would be costly and challenging due to the privacy and sensitivity causes. From the lack of data emerges the new topic of industrial testbeds, including sub-real physical laboratory environments, virtual factories, honeynets, honeypots, and other areas, which helps to deliver sufficient datasets for mentioned research and development. This paper summarizes related works in the area of industrial testbeds. Moreover, it describes best practices and lessons learned for assembling physical, simulated, virtual, and hybrid testbeds. Additionally, a comparison of the essential parameters of those testbeds is presented. Finally, the findings and provided information reveal research and development challenges, which must be surpassed. [ABSTRACT FROM AUTHOR]

This paper presents a design of a flow meter based on a programmable logic controller (PLC). The new construction of a flow meter controlled by PLC increases the possibilities for the control and automation of fluid flow. Additionally, the didactic potential of the use of simple automation in the form of a programmable logic controller was considered. A device enabling the measurement of fluid flow rate based on a PLC controller was designed, constructed, and tested. The choice of device was the Gems Sensors FT-210 series turbine flow sensor, which is characterized by low purchase and maintenance costs. The properties and the chemical resistance of polyamide-12, the material the sensor is made of, make it possible to test the flow of various types of fluids. As part of the work, an algorithm and a program controlling the device was developed based on the APB Soft software, enabling the accurate reading of the number of impulses sent by the turbine flow sensor. The results of the designed flow meter were compared with the results obtained for the Krohne VA-40 high accuracy rotameter. [ABSTRACT FROM AUTHOR]

The most common cause of diseases in swimming pools is the lack of sanitary control of water quality; water may contain microbiological and chemical contaminants. Among the people most at risk of infection are children, pregnant women, and immunocompromised people. The origin of the problem is a need to develop a system that can predict the formation of chlorine water disinfection by-products, such as trihalomethanes (THMs). THMs are volatile organic compounds from the group of alkyl halides, carcinogenic, mutagenic, teratogenic, and bioaccumulating. Long-term exposure, even to low concentrations of THM in water and air, may result in damage to the liver, kidneys, thyroid gland, or nervous system. This article focuses on analysis of the kinetics of swimming pool water reaction in analytical device reproducing its circulation on a small scale. The designed and constructed analytical device is based on the SIMATIC S7-1200 PLC driver of SIEMENS Company. The HMI KPT panel of SIEMENS Company enables monitoring the process and control individual elements of device. Value of the reaction rate constant of free chlorine decomposition gives us qualitative information about water quality, it is also strictly connected to the kinetics of the reaction. Based on the experiment results, the value of reaction rate constant was determined as a linear change of the natural logarithm of free chlorine concentration over time. The experimental value of activation energy based on the directional coefficient is equal to 76.0 [ k J × m o l − 1 ] . These results indicate that changing water temperature does not cause any changes in the reaction rate, while it still affects the value of the reaction rate constant. Using the analytical device, it is possible to constantly monitor the values of reaction rate constant and activation energy, which can be used to develop a new way to assess pool water quality. [ABSTRACT FROM AUTHOR]