International Journal on Future Revolution in Computer Science & Communication Engineering ISSN: 2454-4248

Volume: 4 Issue: 4 325 – 330

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Temperature Control using PLC and LabVIEW Integration
Sachin S. Nerkar
Assistant Professor, Instrumentation Engineering,
Government College of Engineering, Jalgaon.
Maharashtra, India
e-mail:sachinnerkar@rediffmail.com

Abstract— Remotely controlled applications over a wide area have been commonly used in the industries today. In most of the industries direct
temperature measurement is not possible. Most of the processes for various applications require control action by using Programmable Logic
Controller (PLC) or LabVIEW. In this paper we are monitoring and controlling the process by establishing communication between PLC and
LabVIEW. This can be done by Ethernet module of PLC and used for remote control of process. Nowadays PLC can not only control by its
original software but also by third party software such as LabVIEW. The model developed and mentioned in this paper uses LabVIEW software
which provides programming, monitoring, logging and human machine interface for the temperature control of process. It is easy to integrate
different hardware simultaneously which exploits the multitasking and multiprocessing environment of LabVIEW in order to achieve the control
objective.
Keywords- Programmable Logic Controller, LabVIEW, Human machine interface.
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I. INTRODUCTION Proper monitoring of process can maintain operations

at an optimal level by identifying and
The modern sensing technology and control methods are
correcting problems before they turn into significant system fa
under continuously updating due to innovation, where the real-
ilures.SCADA systems have made substantial progress over
time temperature control is demanding higher accuracy and
the recent years in terms of functionality, scalability and
faster response more than the earlier systems. Temperature
performance. The MODBUS protocol is employed while
control is widely used in production and industrial control
communication among the multilayer SCADA architecture.
processes in all aspects of controlling quality and maintaining
quantity of production and market demands. II. PLC TO LABVIEW INTEGRATION
The PLC based Industrial Temperature Control System: Design Both process and equipments manufacturers are
and Implementation. [3] under the pressure, to maximize efficiency, reduce downtime,
Programmable logic controller (PLC) have eased the and improve yield. Manufacturers recognize that the key to
engineering design and lessen materials required, it is because making these improvements is timely and accurate flow,
the entire design is implemented in software programming logging, recording and analyzing the information. However,
paradigm. PLC has been commonly used in the industry, information development is complicated task because of mix
including controlling induction motor inverter fed variable of hardware and software that exists in plants and the
drive system. Design distance control machinery is now limitation of traditional systems. We can incorporate
possible, even by using Ethernet as the communication device LabVIEW into the existing system to add measurements and
between the computer and the PLC. [1] analysis to our processes to gather complex data and convert it
The convenience part of PLC is the accessibility and into useful information. Additionally, through the openness of
controllability by other software. The communication between LabVIEW we can connect and provide the information where
LabVIEW and PLC is established in different methods. it is needed, whether that is in a database, available on a web
Modbus technology is one of them. We are proposing here based dashboard, or provided into the existing plant control
Modbus Ethernet protocol based communication of PLC with hardware. We can even use LabVIEW to close feedback loops
the LabVIEW and process equipments in this paper. and perform complex control operations using the provided
Modbus TCP and Modbus Serial are two of the most information. [5]
commonly used industrial protocols/networks on the market.
NI LabVIEW 11.0 introduced native Modbus TCP and A personal computer (PC), with National Instrument
Modbus Serial support on any Ethernet or serial port with two LabVIEW Version 2011 is used to develop the HMI layer.
LabVIEW add-on modules: LabVIEW Real-Time and LabVIEW VI can implement HMI functionalities such as
LabVIEW DSC. Either of these modules allows creating a sense the level, ON/OFF of Motor and Solenoid Valve etc. It
Modbus TCP or Modbus Serial I/O server through a graphical gives us opportunity to show how Modbus solve this
configuration assistant. With just a few clicks of the mouse, compatibility problem. The Modbus protocol is utilized [5]
one can create a Modbus Master or Slave and specify the for data exchange between supervision control layer and RTU
different registers to read and write.[4] layer. LabVIEW works like a Master and PLC as Slave. The
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IJFRCSCE | April 2018, Available @ http://www.ijfrcsce.org
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International Journal on Future Revolution in Computer Science & Communication Engineering ISSN: 2454-4248
Volume: 4 Issue: 4 325 – 330
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automation system is developed based on LabVIEW, though  Any Modbus supported PLC (eg. Schnedier)
the serial communication, issuing commands to the PLC. PLC
will work on the control system, real-time access and store
A. Creating a Modbus Master I/O Server
various sensor signals after receiving the control command
from the PC. It was easy to develop an automated system In this section, a LabVIEW interface to the Modbus
using PLC and LabVIEW via Modbus. National Instruments addresses called an I/O Server is created. The I/O Server
provides a Modbus Library for LabVIEW that is design to automatically updates LabVIEW with the current values. [9]
facilitate communication to a device that can use a Modbus 1. In the Getting Started window of LabVIEW,
protocol.[6][8]
Click File» New Project.
A. Requirements for integration This opens a new LabVIEW Project.
1. LabVIEW capable for interface with High-Speed
2. If the Context Help window is not visible, press Ctrl +
Measurements from a Broad Range of Sensors.
H to display the window. Keep this window open for
2. LabVIEW capable for Sharing Data between PLCs and
helpful information about items under your cursor.
other Automation Devices.
3. LabVIEW for Developing Graphical User Interfaces. 3. In the LabVIEW Project window, right-click My
Computer and select New»I/O Server, as shown in Figure

Figure 1: User Interface Development with LabVIEW

B. Communication Procedure
The LabVIEW Data logging and Supervisory Control
(DSC) Module is used in this tutorial. This module includes Figure 2: For creating a New I/O Server through the
tools for logging data to a networked historical database, real- LabVIEW Project
time and historical trending, managing alarms and events,
networking LabVIEW Real-Time targets and Modbus devices 3. Select Modbus in the Create New I/O Server Window
into one complete system, and adding security to user and click Continue.
interfaces. With these features, LabVIEW becomes a powerful 4. Select Modbus Ethernet from the Model drop down
HMI/SCADA package for industrial control applications.[9] menu.
5. Enter the IP Address of your target Modbus Slave in
III. HARDWARE, SOFTWARE DESIGN the IP address field. In this example we are running
REQUIREMENTS AND PROCEDURE the Modbus Slave on the same computer as the
master, so we use the local host IP address, 127.0.0.1.
 Windows 7/Vista/XP/Server 2003 R2/Server 2008 R2
 NI LabVIEW Full Development System and 6. Select OK. A library is automatically created in your
LabVIEW DSC Project Explorer window to manage the I/O Server.

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IJFRCSCE | April 2018, Available @ http://www.ijfrcsce.org
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International Journal on Future Revolution in Computer Science & Communication Engineering ISSN: 2454-4248
Volume: 4 Issue: 4 325 – 330
_______________________________________________________________________________________________
7. Save the project as Modbus Demo Project and the 4. In the Project Explorer right click on 000001 and
library as Modbus Demo Library by selecting select Rename. Rename the variable to Coil1.

File»Save All from the project explorer window. You now have access to Modbus data natively in LabVIEW through
the shared variables.

B. Bind Shared Variables to Modbus Addresses Through the

C. Viewing Shared Variables with Distributed System
I/O Server
Manager
1. Right-click the newly created Modbus Demo Library and
From the Project Explorer window, select Tools»
select Create Bound Variables…
Distributed System Manager. This opens a window that you
2. In the Create Bound Variables window, expand the tree can use to manage your shared variables in various ways
down to the Modbus1 in order to select the desired (view, deploy, undeploy, etc.).
address range.

Figure 3: for configuring Modbus Master I/O server

3. Then select 000001-065535, and click on Add

Figure 5: Viewing Coil1's value in Distributed System
Range. Leave the default of Data Item as 000001
Manager
and Number of items as 1. Hit OK.
In the Tree pane of the Variable Manager, expand the
local host item under the My Systems category. Locate and
expand the Modbus Demo Library library, and select Coil1 to
display Auto View on the right hand side of the window.[10]
You can now toggle the Boolean push button your
front panel and see the result in Distributed System Manager
like in Figure 5.

IV. PROCESS MONITORING AND CONTROL

We can integrate any Modbus communication

supported PLC to LabVIEW in this setup I have used the
Figure 4 Select Modbus Addresses to Bind to Shared Variables Schneider Electric PLC and also used its analog card.

1. Your configuration window should now have variable Here a process of simple reactor tank measurement
000001 in the Added variables section. and control operation is considered. In this process all
2. Click OK. This creates a shared variable that is bound to necessary control signals are generated by PLC, but
the Modbus address and loads it into the Multiple Variable monitoring, Logging and recording the whole process from
Editor. LabVIEW.[5]
3. In the Multiple Variable Editor, select Done. This adds the Sequence of Operation:
new shared variables to the library that was created earlier.

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IJFRCSCE | April 2018, Available @ http://www.ijfrcsce.org
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International Journal on Future Revolution in Computer Science & Communication Engineering ISSN: 2454-4248
Volume: 4 Issue: 4 325 – 330
_______________________________________________________________________________________________
1. When start button is pressed the analog value from R
to V converter of RTD will be displayed in the form
of bit register in PLC
2. In this condition Heater will be on.
3. As given set point is reached the bit value is reset and
Heater is turned off.
4. Now if temp goes below set point bit value is set and
heater is turned on this process is continuous and a
continuous control and monitoring of temperature is
achieved.

V. SCHNEIDER PLC PROGRAMMING

Analog value coming from the RTD (output resistance is
converted into analog voltage by R to V converter) AI 0 is
Figure 7: Modbus block in Schneider PLC.
displayed in the input display and calibrating bit value in the
PLC is showing in the PLC Program. As analog input value In LabVIEW there is a Modbus demo library in which there is
reach to set point i.e. bit value 1860 at 88 degree centigrade a wide range coils (data registers) are available. The data
the heater is gets off. If the temperature of water gets reduced registers of range 000001-065535. From this range we can use
below 1860 bit value the Heater will be on. [10] the following range of data in LabVIEW as shown in figure8.
Useful range of coils is
000001-400001
A1L000001, A100001L1
A300001L1, A400001L1, AD300001
Now this coil’s having the Boolean output this is
converted in to binary by using the Boolean to binary
converter as shown in block diagram of figure 9. These binary
outputs then we have to convert into bit values by using
multipliers constants and also this final will get the
temperature indications shown in block diagram of coding in
figure 8.

Figure 6: PLC program of temperature control process

The PLC program also contains the Modbus Serial Slave box
which can communicate the PLC with Labview by using
Ethernet TCP/RTU as shown in below figure.

Fig. 8: Modbus Library and coil’s used for communication

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IJFRCSCE | April 2018, Available @ http://www.ijfrcsce.org
_______________________________________________________________________________________
International Journal on Future Revolution in Computer Science & Communication Engineering ISSN: 2454-4248
Volume: 4 Issue: 4 325 – 330
_______________________________________________________________________________________________
VI. LABVIEW PROGRAMMING The figure 10 shows the Block diagram of the Temperature
LabVIEW is a powerful and versatile analysis and control and monitoring system. The block diagram contains
instrumentation software system for measurement and the graphical source code of a LabVIEW program.
automation. It is used for communicating with devices such as
process instruments, PLCs, smart sensors, or single-loop
controllers. LabVIEW offers a variety of reliable and easy-to-
use tools to meet any of the communication needs. LabVIEW
supports Object linking and Embedding (OLE) for Process
Control (OPC) for information exchange among disparate
automation devices. LabVIEW includes compatibility with
OPC Data Access 3. OPC specification increases performance
and reliability for accessing real-time data from process
control hardware and software. With the MODBUS library for
National Instruments LabVIEW, or the built in MODBUS I/O
server in the DSC module you can use any Ethernet or serial
port as a Modbus TCP or Modbus serial master or slave. Using
the Modbus I/O server with communication gateways, you can
easily incorporate existing equipment on any industrial
network to LabVIEW application. [9]
Figure 9 shows front panel of the LabVIEW where the
temperature is measured by RTD and its analog value which is
controlled by PLC, is displayed in LabVIEW by Modbus
communication. The front panel also shows the status of Heater
whether it is on or off. If heater is on then GREEN indication
displayed and if heater is off then RED indication is displayed. Figure 10: Block diagram of LabVIEW Program
The temperature is also displayed in degree Celsius. This
shows the temperature of the process. The graph shows the VII. RESULT
changing of temperature of amplitude versus time.[10] In the industrial control process, Temperature control is a
very important especially in Interacting systems. It can have a
very good effect in quality control of products and chemical
processes Figure 9 shows, attractive
GUI based Front Panel for Temperature control application usi
ng PLC and LabVIEW integration. This Front Panel indicators
turn ON and OFF as per the process changes. This shows the
proper execution of LabVIEW program and obtains the
desired results. These ON-OFF operations are visualized on
the front panel in the form of ignition of LEDs and waveform
chart. This represents the successful communication of the PC,
PLC and Prototype setup using LabVIEW via Modbus.

VIII. CONCLUSION
The LabVIEW and PLC integration for monitoring
and controling parameter provides high-speed monitoring and
connectivity to enterprise level systems or plant. The
schneider PLC is generating actual control signal but the entire
things are monitored from the graphical user software like
LabVIEW. The design of the temerature control system is
successfully implementaed in our Labortary.
Figure 9: Front panel of LabVIEW coding for temperature
LabVIEW software enhances the performance of
monitoring and control.
systems without spending development time and enables to
handle the complexity of application. Thus the PLC can be

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International Journal on Future Revolution in Computer Science & Communication Engineering ISSN: 2454-4248
Volume: 4 Issue: 4 325 – 330
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integrated with LabVIEW for controlling several real time VIEW for Real Time Process Control”, IJESE ISSN: 2319–
applicationsin industry for effective control of parameters. 6378, Volume-1, Issue-11, September 2013.
[6] Mohamed Endi, Y. Z. Elhalwagy and Attalla hashad, “Three-
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