designs

Article
Control of Hydraulic Pulse System Based on the PLC
and State Machine Programming †
Juraj Pančík 1, * and Pavel Maxera 2
1 Institute of Forensic Engineering, Brno University of Technology, Purkyňova, 464/118, Brno 61200,
Czech Republic
2 Institute of Forensic Engineering, Brno University of Technology, Purkyňova, 464/118, Brno 61200,
Czech Republic; pavel.maxera@usi.vutbr.cz
* Correspondence: juraj.pancik@gmail.com; Tel.: +421-908-963-289
† This paper is an extended version of paper published in the International Conference Applied Electronics
2015, University of West Bohemia, Pilsen, Czech Republic, pp. 175–180, ISBN 978-80-261-0386-8.




Received: 17 September 2018; Accepted: 14 November 2018; Published: 20 November 2018


Abstract: In this paper, we deal with a simple embedded electronic system for an industrial
pneumatic–hydraulic system, based on a low-cost programmable logic controller (PLC) and industrial
electronic parts with 24 V logic. The developed system is a hydraulic pulse system and generates a
series of high-pressure hydraulic pulses with up to a max. 200 bar output pressure level and with
up to a max. 2 Hz output hydraulic pulses frequency. In this paper we are describing requirements,
the concept of the embedded control system in a diagram, security features and its industrial
network connectivity (CAN bus, MODBUS). In description of the software solution we describe the
implementation of the program threads approach in this low-cost PLC. The PLC programming with
threads generate two layers of services—physical and application layer, and as a result, the threads
create the main control state machine. In conclusion, we describe the calibration method of the system
and the calibration curves. For further study we offer readers the full programming code written in
sequential function charts to be used as PLC language. The cost of the described industrial networked
control system with industry standard optoelectronic insulated interfaces and certified industrial
safety relay does not exceed €1000 Euros.

Keywords: PLC programming; hydraulic pulse system; state machine programming

1. Introduction
Our built-in embedded system for the pneumatic–hydraulic pulse system is based on the use of a
modern low-cost programmable logic controller (PLC). A modern PLC allows you to program parallel
running programs (threads), each of them being programmed for PLC programmers well-known
ladder diagrams or as functional block diagrams [1,2]. In our work, we prepared for the PLC robust,
external error-free control program, so as to control the series high pressure hydraulic pulses based at
one PLC. Each thread represents a separate task and independent state of system. Parallel running
threads cooperate with each other and this set of independent threads creates a unique reactive control
state machine [3,4].

2. Requirements for Pneumatic–Hydraulic Pulse System

Since we have limited space in this contribution, we are only trying to describe the requirements
for the overall machine and requirements for creating a specific series of impulses.
The system controls up to four independent series, each of them defined by four adjustable
parameters; the number of pulses (N), the maximum hydraulic pressure (p), the hydraulic pulse

Designs 2018, 2, 48; doi:10.3390/designs2040048 www.mdpi.com/journal/designs

Designs 2018,2,2,48
Designs2018, x 22 of 10
11

duration (T1) and the duration of the pause between pulses (T0). Each WAGON of this TRAIN has
duration (T1) and the
four passengers: N, duration
p, T1, T2,of the
see pause
Figurebetween
1, wherepulses (T0). Each
WAGONs WAGON
build of this “PNEUMATIC–
a so-called TRAIN has four
passengers: N, p, T1, T2, see Figure 1, where WAGONs build a so-called “PNEUMATIC–HYDRAULIC
HYDRAULIC PULSE TRAIN”. The pneumatic–hydraulic pulse train can cyclically repeat its defined
PULSE TRAIN”.
circle path by theThe pneumatic–hydraulic
number of times which ispulse train
set in the can cyclically
TRAIN SESSIONrepeat its defined
number. The circle
number pathof
by the number of times which is set in the TRAIN SESSION number. The number
WAGONs may be set by the user from 1 to 4. The embedded control system allows each user to of WAGONs mayset
be
theset by theofuser
output from 1 to 4.
the hydraulic The embedded
pressure control
in bars within thesystem
range allows eachthe
0–200 bar, user to set the
number output of
of WAGONS,
the
andhydraulic
number of pressure in barsof
cyclic reruns within the range
the train’s path.0–200
The bar, the system
control numbermustof WAGONS,
allow systemand number of
calibration
cyclic reruns of the train’s path. The control system must allow system calibration (dependence
(dependence of the output hydraulic pressure in units of [bar] at the user's desired hydraulic pressure of the
output
in [ADU] hydraulic pressure
units (ADU unit =inAnalog
units ofDigital
[bar] at the user’s
Unit)). It must desired
ensurehydraulic pressure
the generation in [ADU]
of system andunits
error
(ADU unit
messages. = Analog Digital Unit)). It must ensure the generation of system and error messages.

N No.2
WAGO Count 2
re 2, Pr WA
Pressu 0,T1 es GO
su
T re N N
3 o
T0 , Co .3
,T1 un
t3
t1
,T o 1
T0 1, C No.
1 un
re N
su O
es AG

TIME of
Pr W

Pre
PULSATION

WA re 4, C
ssu T0,T1
GO
N N unt 4
Th
co e ac

o.4
o
un
t, p tual
r e s s ta
su tus
tim re, of
e o tim hyd
f p e o rau
au f p l
se uls ic pu
(T1 e (
) T0 lse :
)a
nd

The hydrauic pulse train

Figure1.1.Pneumatic–hydraulic
Figure Pneumatic–hydraulicpulse
pulsetrain-schematic
train-schematic represents
represents of cyclic
of cyclic repeating
repeating sequence
sequence pulses
pulses for
for hydraulic
hydraulic pulse
pulse system
system as cyclic
as cyclic paths
paths of train
of train withwith
fourfour wagons,
wagons, eacheach
withwith
four four passengers.
passengers.

3.
3. Hardware
Hardware Solution
Solution

3.1. Pneumatic–Hydraulic Parts

3.1. Pneumatic–Hydraulic Parts
The schematic diagram of the developed pneumatic–hydraulic system with PLC based control
The schematic diagram of the developed pneumatic–hydraulic system with PLC based control
system is shown in Figure 2 and a photo of the prototype is shown in Figure 3. The proportional
system is shown in Figure 2 and a photo of the prototype is shown in Figure 3. The proportional
pneumatic valve regulates input air pressure. Regulated air is then fed into pneumatic four-way
pneumatic valve regulates input air pressure. Regulated air is then fed into pneumatic four-way valve
valve circuit and it controls the two-position pneumatic pump. This pneumatic circuit controls the
circuit and it controls the two-position pneumatic pump. This pneumatic circuit controls the two-
two-direction movement of the hydraulic cylinder with, resulting amplified hydraulic pressure as its
direction movement of the hydraulic cylinder with, resulting amplified hydraulic pressure as its
output [5].
output [5].
Designs 2018, 2, 48 3 of 10
Designs 2018, 2, x 3 of 11

Pneumatic and hydraulic unit

USER control unit
INPUT Pressure air source Liquid presence sensor Safety Relay
:

Hydraulic tank
SWITCH :
AUTO-0-MANUAL
Hydraulic pressure
BUTTON : START Air presence sensor EMERGENCY indicator (meter) WIKA

BUTTON: PULSE BUTTON

OUTPUT Hydraulic flow
Pneumatic proporcional valve
BUTTON : RESET Pneumatic pump Hydraulic pump

BUTTON : EMERGENCY
Hydraulic pressure
POTENTIOMETER : sensor ATE PS 60
air pressure in manual control
mode Linear displacement
sensor

Opto relay

Q1, DIGITAL OUTPUT : PULSE

U1, ANALOG INPUT: ManualSet
Cover equipment
interface
modules removing sensor
I1, DIGITAL input: MANUAL

I4, DIGITAL input: RESET

I3, DIGITAL input: PULSE
I2, DIGITAL input: AUTO

Hydr.press.sensor(0..5V)
Q0, DIGITAL OUTPUT:
Optorelay pneumatic

I0, DIGITAL input:

U0, ANALOG INPUT:
ANALOG OUTPUT:

I7, DIGITAL input:

I6, DIGITAL input:
I5, DIGITAL input:
Realy

pneumatic valve

DIST_ERR

ERROR
LIQ_ERR
AIR_ERR

pump
PHOENIX Nanoline USB
PHOENIX Nanoline base unit controller, PHOENIX Nanoline I/O PHOENIX Nanoline RS- communication module,
24 V DC input power, 6 digital inputs,4 expansion module, 2 analog 232 communication
NPN transistor outputs inputs, 2 analog outputs, module, PHOENIX Nanoline
Ethernet module

USB communication

communication

protocol server
programming or
communication

over MODBUS

over internet
over MODBUS

Customer

protocol
protocol
RS232
CAN communication
with proprietary protocol
PHOENIX Nanoline operator panel
LCD display and keypad CAN bus OLIMEX, uController
module Atmel AVR-
CAN )

USB bus
ETHERNET

Figure 2. Schematic diagram of the developed pneumatic–hydraulic system.

Figure 2. Schematic diagram of the developed pneumatic–hydraulic system.
Designs 2018, 2, 48 4 of 10
Designs 2018, 2, x 4 of 11

Figure 3. The photo of the functional prototype of the pneumatic–hydraulic pulse system.
Figure 3. The photo of the functional prototype of the pneumatic–hydraulic pulse system.

3.2. PLC Based Control System

The embedded control system was implemented on a cheap programmable logic controller type
(PLC) Nanoline from Phoenix Contact [6] and on on additional
additional PLC’s
PLC’s modules
modules (analog
(analog input–output
module, LCD display and keypad user interface module, USB, RS232 and Ethernet Ethernet communication
module). The PLC works with industrial logic levels and they both have two levels 0 and 24 V; PLC’s PLC's
analog outputs are in the range
range 0–10 V, and PLC’s
PLC's analog inputs
inputs are
are in
in range
range 0–5
0–5 V. The used PLC
Nanoline is built around an ARM 32 processor and its operating system allows for the running of
several independent
independent program
program threads
threads simultaneously. The The run
run of each thread is conditional on the
value of the hardware input signal or by the program
program setting
setting of
of value
value of
of the
the internal
internal program
program flag.
flag.
This interesting ability of the PLC’s operating system creates a challenge for us to generate a master
program for control of hydraulic
hydraulic pulses
pulses based
based on
on states
states machines
machines

3.3. User Interface Elements

HMI (human–machine interface) of the pneumatic–hydraulic
(human–machine interface) pneumatic–hydraulic pulsepulse system
system consists
consists of of keypad,
keypad,
display (4
LCD display rows××
(4rows 2020 characters)
characters) andand
fewfew switches.
switches. The The manual
manual switch
switch strains
strains betweenbetween two
two basic
basic modes
modes of equipment
of equipment (MANUAL(MANUAL mode modeandand AUTO
AUTO mode),
mode), thepotentiometer
the potentiometerserves
servesforfor manual
adjustment of output hydraulic pressure, the button allows for starting the series hydraulic pulsation
(PULSE
(PULSE mode),
mode),another
anotherbutton serves
button to stop
serves to the
stoppulses (the RESET
the pulses (the button),
RESET the security
button), (orsecurity
the emergency)
(or
button serves to turn off the power of the appliance (EMERGENCY). The required values
emergency) button serves to turn off the power of the appliance (EMERGENCY). The required values for WAGON
andWAGON
for TRAIN parameters
and TRAINand the choosing
parameters and theof other equipment
choosing of othermodes (e.g., modes
equipment calibration
(e.g.,of the system)
calibration of
are entered
the system) from the PLC
are entered build
from thekeypad.
PLC build keypad.

3.4. Electrical
3.4. Electrical Parts
Parts of
of System
System
Electrical parts
Electrical parts of
of system
system consist
consist aa 24
24 VVpower
powersupply,
supply, aa safety
safetyrelay,
relay, electrical
electrical and
and optical
optical relays,
relays,
switches, terminals and wires as is seen in Figures 2 and
switches, terminals and wires as is seen in Figures 2 and 3. 3.
Designs 2018, 2, 48 5 of 10

3.5. Safety Measures

The basis of ensuring the safety operation of high pressure pneumatic–hydraulic pulse system
is the certified safety relay [7]. The safety relay can detect system errors that switch off the power
for the whole electrical power part of the equipment (but not for control PLC). Key safety sensors
are connected in the series. In the case of detection of problems by dedicated sensors with any
media (hardware signals AIR or LIQUID) or detection of mechanical problems (hardware signals as
DISTANCE ERROR or COVER EMERGENCY SWITCH), the series of connected sensor’s contacts is
interrupted, the safety relay responds and sets the signal ERROR and switches off the power for the
hydraulic–pneumatic pulse system in order to automatically reduce the output hydraulic pressure
to minimum. The mechanical error with name DISTANCE ERROR is generated by a mechanical
contact switch mounted near the hydraulic cylinder and serves to indicate an attempt to generate
high hydraulic pressure. To ensure of the safe operation of the high pressure pneumatic–hydraulic
pulse system, we used a certified safety relay. The safety relay can, in the case of detecting the system
errors, switch off the power for the whole electrical power part of the equipment (except of power for
control PLC).

3.6. Network Connectivity of the Pneumatic–Hydraulic System

Network connectivity of our control system is ensured with the PLC expansion Ethernet
communication module [8]. This expansion module allows for external control of all program elements
in the PLC program (e.g., PLC’s signals, flags, registers ...) via industrial standard MODBUS protocol
(via TCP-IP protocols). For our special purpose, where the pneumatic–hydraulic pulse system is a part
of a test bench, we have developed the communication embedded server—a converter between the
CAN bus (CAN is used by test bench’s protocol) and RS232 (as physical base for MODBUS protocol).
The CAN converter consists of the hardware module OLIMEX occupied with 8bit ATMEL AVR-CAN
microcontroller [9]. The developed protocol and BUS converter allows us to control and monitor
pneumatic–hydraulic pulses system, even though the CAN bus.

4. Software Solution

4.1. Basic PLC Functions

The programming approaches for modern PLC are described in standards and books, for example
by the authors of [10,11]. The ladder diagram or graphic function block diagram programming
approach is still the focus of PLC’s programmers. The IEC 61131-3 (IEC 1131-3: The International
Programmable Controller Language Standard) is the third part (of 10) of the open international
standard IEC 61131 for programmable logic controllers and was first published in December 1993 by
the IEC [6]. The current (third) edition was published in February 2013. Part 3 of IEC 61131 deals with
the basic software architecture and programming languages of the control program within the PLC.
It defines two graphical and two textual programming language standards:
• Ladder diagram (LD), graphical
• Function block diagram (FBD), graphical
• Structured text (ST), textual
• Instruction list (IL), textual (deprecated in 3rd edition of the standard)
• Sequential function chart (SFC), has elements to organize programs for sequential and
parallel control processing (IEC 1131-3: The International Programmable Controller Language
Standard and)
The modern low-cost PLC based on powerful ARM architecture such as Nanoline from Phoenix
Contact allows for the running of several program threads. It gives to the PLC programmer the
possibility to program the main control program without creating one long and complicated PLC
program. Each independent PLC program thread can be initiated by hardware signal(s) (the PLC use
Designs 2018, 2, 48 6 of 10

24 V logic at input) or by internal programming flag with boolean data type (it can be set by another
PLC program thread). Each PLC program thread can be programmed with ladder diagram or graphic
functional block diagram programming approach and the PLC programmer may not to know about
the concurrent program techniques or about the use of special concurrent program library for PLC.

4.2. List of Hardware Inputs and Outputs for PLC

The list of all digital and analog inputs and outputs used in the project is in the Table 1.
Each hardware input signal (ERROR, WAIT, MANUAL, AUTO, PULSE and RESET) is processed
in the PLC by individual program thread (see Table 2). These signals are grouped in the so-called
physical layer. Some hardware signal inputs are used for indicating the error’s cause in the safety
power shutdown of the pneumatic–hydraulic system via safety relay (Figure 2).

Table 1. List of programmable logic controller (PLC) hardware inputs and outputs and their responsible
processing layer.
Name of Signal Signal is Processed in the
n. Description of Physical Signal
Hardware Signal Direction/Digital/Analog Independent Thread
1 ERROR I0-input Physical layer 4_ERROR From safety relay
2 MANUAL I1-input Physical layer 1_MANUAL User input, manual control
3 AUTO I2-input Physical layer 2_AUTO User input, pulse gen.
4 PULSE I3-input Physical layer 3_PULSE User input, start of pulsing
5 RESET I4-input Physical layer 5_RESET User input, stop of pulsing
Application layer
6 AIR_ERROR I5-input From pressure air tank switch
4_State_Func
Application layer
7 LIQUID_ERROR I6-input From hydraulic tank switch
4_State_Func
Application layer
8 DISTANCE_ERROR I7-input From distance contact switch
4_State_Func
Application layer
9 PNEU_PUMP Q0-output 1_State_Func and For pneumatic pump control
3_State_Func
Application layer
10 PULSE_RELAY Q1-output For pulse control generation
3_State_Func
11 HYDR_PRES_SENSOR AI0-input All application layers From hydraulic pressure sensor
Application layer
12 MANUAL_PRES_SET AI1-input From user man. potentiometer
1_State_Func
Application layer
13 PNEUMATIC_VALVE AU0-output 1_State_Func and For proportional valve control
3_State_Func

Table 2. List of implemented physical layer threads.

Name of Signal Condition for Program Switches the Conditionally can Description of
n.
Thread Perform of the Thread Flag to ON Set also Program Thread
PNEU_PUMP(OFF) Safety relay output
1 4_ERROR Signal ERROR = ON State_FLAGS_4_ERROR
PULSE_RELAY(OFF) processing
2 0_WAIT Signal ERROR = ON State_FLAGS_0_WAIT Wait state
Signal MANUAL = ON User input, manual
3 1_MANUAL State_FLAGS_1_MAN State_FLAGS_0_WAIT
AND ERROR = OFF control mode
Signal AUTO = ON User input, pulse
4 2_AUTO State_FLAGS_2_AUTO State_FLAGS_0_WAIT
AND ERROR = OFF generation mode
Signal PULSE = ON User input, start of
5 3_PULSE State_FLAGS_3_PULSE State_FLAGS_0_WAIT
AND ERROR = OFF pulsing
Signal RESET = ON User input, stop of
6 5_RESET State_FLAGS_2_AUTO START_BUTT_ON
AND ERROR = OFF pulsing

4.3. Physical Layer Threads

Threads of the physical layer (Table 2) run in the PLC’s operating system after their initializing
by hardware input signals. The physical layer ensures processing of hardware signals and as a result,
this layer sets outputs flags, which are processed in the application layer. These output flags manage
transitions between states in the master control state machine (literally by start or by stop of the
respective threads in the application layer). These program threads also process aforementioned inputs
hardware signals and set of hardware output signals by aligning the required settling time or also,
the next set of parameters of elements of pneumatic or hydraulic hardware (e.g., delay of relays, setting
time of input valve, etc.).
Designs 2018, 2, 48 7 of 10

4.4. Application Layer Threads

The running of the application layer thread (listed in Table 3) begin by changes of program
flags (one or two flags, then in AND or in OR mutual combination) which are received from the
physical layer. Some threads in application layer create of individual states in the master control state
diagram (Figure 3). In addition, these threads enable the realization of sub states. For example, thread
2_State_Func can call of sub state 6_State_Func. This thread serves for the manual input of parameters
in the hydraulic pulse train. Next threads also underpin subroutine for user input interaction such the
22_State_Func. This sub state provides the possibility of the manual input of calibration constants.

Table 3. List of application layer threads.

Flag Condition for Perform of Description of Program Thread, see Figure 4 Master
n. Name of Thread
the Thread Control State Diagram for Hydraulic Pulse System
State_FLAGS_0_WAIT = ON WAIT STATE, Initialization of calibration constants, zeroing of the ATE
1 0_State_Func
AND ERROR = OFF pressure sensor
State_FLAGS_1_MANUAL = ON MANUAL STATE, manual control of output hydraulic pressure via
2 1_State_Func
AND ERROR = OFF manual potentiometer
AUTO STATE, setting of parameters for hydraulic pulse train: WAGON
State_FLAGS_2_AUTO = ON
3 2_State_Func parameters numbers of TRAIN WAGON and number of TRAIN SEASSON,
AND ERROR = OFF
manual calibration constants inputs (sub state: 22_State_Func)
PULSE STATE, performing of hydraulic pulsation according of parameter
State_FLAGS_3_PULSE = ON
4 3_State_Func settings, after finish of pulsing goes automatic to AUTO MODE
AND ERROR = OFF
(FLAGS_2_AUTO = ON, FLAGS_3_PULSE = OFF)
5 4_State_Func State_FLAGS_4_ERROR ERROR STATE, Safety relay determined, determination of the error source
Sub state of PULSE STATE, measurement of the maximum of the hydraulic
6 5_State_Func State_FLAGS_5 pulse peak during PULSE MODE (during the pause time and during the
pulse time)
Sub state of AUTO STATE, user setting of parameters for four TRAIN (T0, T1,
7 6_State_Func State_FLAGS_21_QSET
COUNT, PRESSURE)
Sub state of PULSE STATE, actual modification of parameters after one
8 7_State_Func State_FLAGS_7
TRAIN SESSION

4.5. Description of the Master Control State Machine

The main control state machine (Figure 4) for hydraulic pulse system consists of 7 separate threads
running in the application layer, each thread represents the individual state of pneumatic–hydraulic
pulsing system and is described in Table 3. Transitions between states in the application layer is
controlled by the program flags and they are isolated from the hardware inputs signals (Table 1)
processed by the physical layer (Table 2). This solution allows for the reliable function of high-pressure
hydraulic pulse system, with reliable answers to user inputs or to the error status. We observed the
reliable automatically generated ends of each hydraulic train pulsation cycle.

4.6. Auxiliary Functions

The control of pulses sequences according to saved parameters in the hydraulic pulse train ensures
thread 7_State_Func in the application layer, which is called from the state PULSE (3_State_Func).
The thread 6_State_Func ensures the users inputs for controlling of the actual content of the hydraulic
pulse train and is called from AUTO STATE (2_State_Func).

4.7. Calibration of the System

The thread 6_State_Func in the application layer ensures the manual input of calibration constants
from the user. The reason for the calibration can be described as follows: user works at input or at
output with pressure units in [bar], but the PLC works with an internal representation of pressure in
ADU units (12 bit). The user can perform the calibration process in MANUAL STATE which means
static mode (no pulse condition, manually controlled output hydraulic pressure). The user obtains,
during the calibration procedure, two calibration curves. The first calibration curve is dependence
between the output hydraulic pressure (measured with portable calibrated hand-held hydraulic
pressure measurement equipment from WIKA [10]) and the output voltage in 12bit ADU (measured via
PLC itself) from the sensor output hydraulic pressure ATE PS60. ATE PS60 is a commercial produced
hydraulic pressure sensor used in the cars, the manufacturer is ATE. In our case, in calibration process
Designs 2018, 2, 48 8 of 10

we obtained a linear relationship, which leads to the linear Equation (1) derived by regression analysis
from the graph of the measured values:

PW IKA [bar ] = AATE PS60 × PATE PS60 [ ADU ] + BATE PS60 (1)

By the calibration-determined value of the constant AATE PS60 for pressure sensor ATE PS60 is
0.1021 [bar/ADU] and the value of the constant BATE PS60 is equal to 4.8074 [bar] (Figure 5).
Designs 2018, 2, x 8 of 11

Figure4.4.Master
Figure Mastercontrol
control state
state diagram
diagram for hydraulic
for hydraulic pulsepulse
systemsystem consists
consists of 7 separate
of 7 separate threads
threads running
running in the application layer, each thread represents the individual state of pneumatic–hydraulic
in the application layer, each thread represents the individual state of pneumatic–hydraulic pulsing
pulsingand
system system and is described
is described in Table 3.in Table 3.

The secondofdependence
4.5. Description is the static
the Master Control State transfer
Machine function of the entire pneumatic–hydraulic system.
This is the curve which represents output hydraulic pressure (in bar unit, measured by WIKA
The main control state machine (Figure 4) for hydraulic pulse system consists of 7 separate
equipment [12]) at the values of the input control voltage for proportional pneumatic valve (measured
threads running in the application layer, each thread represents the individual state of pneumatic–
in ADU units via PLC A/D extension module). Measurement leads to the next linear equation:
hydraulic pulsing system and is described in Table 3. Transitions between states in the application
layer is controlled by PWthe IKA
program
[bar ]flags and they
= ASYS are isolated from
× PSetInputValve the ]hardware
[ ADU + BSYS inputs signals (Table (2)
1) processed by the physical layer (Table 2). This solution allows for the reliable function of high-
pressure
where thehydraulic
value of pulse system,Awith
the constant SYS isreliable answers to and
0.053 [bar/ADU] user the
inputs or of
value to the
the constant
error status.
BSYSWe
is
observed
0.0626 the(Figure
[bar] reliable
6).automatically generated(1)
Both linear Equations ends
andof(2)each hydraulic
provide train
of four pulsation
calibration cycle. which
constants,
user can enter in to the control system (in the thread 6_State_Func). Then, after the static calibration of
4.7. Auxiliary
pneumatic Functions
hydraulic pulse system, the user input entered value are in bar units obtained at the output
of pneumatic–hydraulic system,
The control of pulses as is required
sequences in both
according states—MANUAL
to saved parameters inand
thePULSE STATE.
hydraulic pulse train
ensures thread 7_State_Func in the application layer, which is called from the state PULSE
(3_State_Func). The thread 6_State_Func ensures the users inputs for controlling of the actual content
of the hydraulic pulse train and is called from AUTO STATE (2_State_Func).

4.8. Calibration of the System

The thread 6_State_Func in the application layer ensures the manual input of calibration
constants from the user. The reason for the calibration can be described as follows: user works at
input or at output with pressure units in [bar], but the PLC works with an internal representation of
pressure in ADU units (12 bit). The user can perform the calibration process in MANUAL STATE
 𝑃𝑊𝐼𝐾𝐴 [𝑏𝑎𝑟] = 𝐴𝑆𝑌𝑆 × 𝑃𝑆𝑒𝑡𝐼𝑛𝑝𝑢𝑡𝑉𝑎𝑙𝑣𝑒 [𝐴𝐷𝑈] + 𝐵𝑆𝑌𝑆 (2)
where the value of the constant ASYS is 0.053 [bar/ADU] and the value of the constant BSYS is 0.0626
[bar] (Figure 6). Both linear Equations (1) and (2) provide of four calibration constants, which user
can enter in to the control system (in the thread 6_State_Func). Then, after the static calibration of
Designs 2018, 2,hydraulic
pneumatic 48 pulse system, the user input entered value are in bar units obtained at9 ofthe
10
output of pneumatic–hydraulic system, as is required in both states—MANUAL and PULSE STATE.

𝑃𝑊𝐼𝐾𝐴 [𝑏𝑎𝑟] = 𝐴𝐴𝑇𝐸 𝑃𝑆60 × 𝑃𝐴𝑇𝐸 𝑃𝑆60 [𝐴𝐷𝑈] + 𝐵𝐴𝑇𝐸 𝑃𝑆60

200

150
[bar]
WIKA [bar]

100
PP WIKA

y = 0.1021x + 4.8074
50 R² = 1

0
0 200 400 600 800 1000 1200 1400 1600 1800
P ATE PS60 [ADU]

Figure 5.5.Measured
Figure Measuredpressure
pressure system
system transfer
transfer curve
curve for pressure
for pressure sensorsensor ATEdependence
ATE PS60, PS60, dependence
between
between sensor
pressure pressure sensor
ATE PS60ATE PS60
output output
voltage in voltage in ADU
ADU (Analog (Analog
Digital Digital
Unit) units Unit) units and
and pressure in pressure
bar from
in bar from
portable portable measurement
measurement device WIKA device
CPH WIKA CPH
6200 (see 6200 (see
Equation Equation (1)).
(1)).

250

200
[bar]
WIKA [bar]

150
PP WIKA

100

50
y = 0.053x - 0.0626
0
0 500 1000 1500 2000 2500 3000 3500 4000 4500
P SetInputValve [ADU]

Figure 6. Measured
Figure 6. Measuredtransfer
transfercurve
curvebetween
between output
output of pneumatic–hydraulic
of pneumatic–hydraulic system
system pressure
pressure in barinunits
bar
units and control voltage for proportional pneumatic valve as input of system in ADU units (see
and control voltage for proportional pneumatic valve as input of system in ADU units (see Equation (2)).
Equation (2)).
5. Discussion
The pneumatic–hydraulic system developed by us is one part in an industrial test bench.
Our possible benefits are in the introduction of co-operating layers (physical layers and application
layers) on a low-cost PLC platform (without the need for high-level programming like C++). This may
be our possible contribution to the education of young technicians. All necessary software solutions
(running at “nanoNavigator” IDE (Integrated Development Environment) from Phoenix Contact [13])
are provided by authors for study purposes as Supplementary Materials (Source code S1). Mutually
communicating threads can be studied in the software simulator provided by nanoNavigator IDE and
is not necessary to study or program with buy any PLC hardware.

6. Conclusions
We developed an embedded control for pneumatic–hydraulic system which produces a series of
high-pressure hydraulic pulses (up 200 bar). The pneumatic–hydraulic system can be calibrated, it is
networked in industrial networks (MODBUS over TCP/P and CAN bus) and generates accurately
hydraulic pulses (time and pressures characteristics). The system proved to be reliable. This hydraulic
impulse unit is a part of a test machine and it can be used in the industry for hydraulic parts dynamic
testing by series of pulses with maximal frequency pulses 2 Hz. From the point of view of software
Designs 2018, 2, 48 10 of 10

architecture, the embedded control system is based on a low-cost PLC architecture and control program
is a set of parallel program threads. Each programming thread can be identified as one state in a master
control state diagram. The PLC multi-thread program is not designed as one large and opaque linear
program, but rather as a group of mutually communicating PLCs programs, which ultimately forms
one master control state diagram. The cost of the described industrial networked control system with
industry standard optoelectronic insulated interfaces and certified industrial safety relay does not
exceed €1000 Euros.

Supplementary Materials: The following are available online at http://www.mdpi.com/2411-9660/2/4/48/s1,

Source code S1: PLC software project (NanoNavigator IDE).
Author Contributions: Conceptualization, J.P.; Data curation, P.M.; Methodology, J.P. and P.M.; Software, J.P.;
Validation, J.P. and P.M.; Writing – original draft, J.P.; Writing – review & editing, J.P.
Funding: This research received no external funding.
Conflicts of Interest: The authors declare no conflict of interest.

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