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Implementation of automatic PLC code from MATLAB simulation model using

B&R automation target for simulink

Conference Paper · January 2013

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 Implementation of automatic PLC code from MATLAB simulation
model using B&R automation target for simulink

Rupali Salunke a*, Pratap Vikhe b, Trupti Sarode c

a
Indira College of Engineering and Management, E&TC Department, Parandwadi, Pune,India .
b
Pravara Rural Engineering College, Instrumentation &Control Department, Loni,India.
c
B&R Industrial Automation Pvt Ltd,Pune,India.

Abstract

In this research work, auto generation of PLC code is explained. This work is carried out in real time. Mathematical Model created in
MATLAB/Simulink gets automatically translated in C code using Real-Time workshop and later PLC Control implementation is done by
using B&R Automation Target for Simulink software that can generate PLC code and HMI screens. The algorithm developed to connect
simulation model and PLC-Automation Studio is elaborated. To show applicability of methodology, color mixing process model is
described. Seamless integration into an Automation Studio project work makes the development process perfect guaranteeing maximum
performance of the generated source code.

Keywords: Mixing process, Coloration control, B&R Automation Studio, HMI.

1. Introduction

In the modern industrial manufacturing, PLC device is 1.1. Model-Based Automation

well-adopted to a range of almost all types of automation
tasks. The level of automation is determined by a PLC In the field of industrial automation Model-Based
program. The processes can be modeled and controlled development methods are becoming increasingly more
through the set of instructions to PLC. Thus PLC-program significant. In case of numerical and complex control-
becomes underlying component for modern manufacturing. oriented applications, the concept of the Model-Based
Inefficiency in generating the controlling code in the design is used to realistically capture the numerical
manufacturing plant may cause huge down time and ramp- behaviour and interactively improves model parameters
up times [1]. Hence, auto generation of PLC program using until the needed behaviour is reached.
rapid modeling and compiling tools to generate IEC
standard PLC program is an efficient method to reduce the 1.2. MATLAB In Control Technology
PLC development time.
Automatic generation of PLC code has been done MATLAB/Simulink provides many advantages
several times before as for example in [5], [8], who especially for developers work with the classical control
generated ladder code or PLC code generation for industrial technology [3]. The simulation of models already during
robot cells [6]. model creation is an outstanding advantage which saves a
Software Engineers at NASA Kennedy Space developed lot of time and thus helps to save costs. Hence, all models
a process and prototype software tool that automatically can be validated already during creation. Complex control-
translates a high level specification of safety critical oriented tasks, which can normally be performed in the
application software into ladder logic that executes on a control technology by using cost-intensive expansions, can
PLC [7].

* Corresponding author. E-mail: rvkokate@gmail.com

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be created, tested and used by applying mathematical programming efforts are reduced to a minimum and in
models. many cases actually not required.
MATLAB Simulink includes B&R Toolbox in simulation
environment provides interface blocks, which handles
1.3. B&R Automation Target for Simulink communication between the automatically generated
program unit and the rest of the components of the
The realization of MATLAB/Simulink models starts with Automation Studio project.
the automatic code generation. With this product “B&R In this paper the Section II explains Methodology,
Automation Target for Simulink” B&R Industrial Section III deals with detailed algorithm for integrating
Automation provides a tool with highest level of integration simulink model and B&R target PLC Section IV gives
with model based design software Math works. This tool verification & validation of results. Section V is conclusion
allows testing and implementing MATLAB/Simulink and finally future work with an acknowledgement.
models on the PLC hardware. Thus, the manual

Fig.1. Block Diagram for Automatic Generation of PLC Code

2. Methodology
The algorithm written in this paper for generating
The module created in Simulink is automatically automatic PLC code is elaborated in steps to follow.
translated using Real-Time Workshop and Real-Time
Workshop Embedded Coder (optional) into the optimal
language for the B&R target system 3.1. Step I-Developing Process Model in MATLAB
The block diagram described in this paper employs, Simulink
designing of mathematical model using formulas. Later,
implementation of mathematical model of Color Mixing The Color Mixing Process studied here was also studied
process using MATLAB Simulink is build with the help extensively by [1], [2] and [3].The Mathematical model of
of simulink library blocks. The next step is to be carried mixing process is developed in MATLAB Simulink
out in an Automation Studio environment. In this we have environment. COLOR mixing plant consists of a mixing
to build model with the help of B&R blocks which are tank in which colors are mixed from the two auxiliaries In
available in B&R toolbox in a simulink library. After order to find an adequate control for the mixing process;
doing configuration settings we are able to translate the corresponding mathematical model is developed. The
simulink models into a PLC code on a click of button. mathematical model for one tank is considered, knowing
Above in the Fig1, the sequence of code generation is that the all three tanks have the same one. The model
given for Color Mixing Process. The execution of developed for color mixing process is as shown in Fig2.
extended parameter is based on the algorithm defined in These equations were modeled using MATLAB/
the subsequent sections. Simulink as illustrated in Fig2. The control system for the
fluid mixer is designed in order to maintain the coloration
of the output at the desired set-point and the level in the
3. Algorithm for Integrating Simulink Model with mixer in the neighboring of its set-point, not allowing it to
B&R Automation Studio be empty or to overflow. The output flow is considered
as a disturbance.
The Color Mixing Process is on-line implemented
using PLC and has been written in a specific language 3.2. Step II- Using B&R Automation Studio Toolbox;
Automation Studio of B&R PLC [4]. For understanding Creating Simulink Model which Translates Automatically
the control process written in AS C language the into C-Code
corresponding sequence control for a tank is described.
The model shown in Fig.3 is Color Mixing Process Model

391
 of the system for the configuration of the interface
between Simulink and Automation Studio.

1. Fundamental sample time: The fundamental sample

time of the Simulink model must be equal to the selected
task class cycle of the PLC i.e. B&R.
The sample time is always entered in seconds. The
error will get generated if the fundamental sample time
specified in Simulink does not match the duration of the
cyclic task class for the automaticallygenerated task in
Automation Studio, the task will be suspended.
2. Automation Studio Project Path: The path of project
created in Automation Studion.Base directory of the
Fig. 2 Color Mixing Process Model developed in Automation Studio project containing the automatically
MATLAB/Simulink generated task.
created with the help of B&R blocks which is main part 3. Automation Studio Task Name: Specify Name of the
of the project. These all block variables will get reflected automatically generated task which will get generated
in automation studio in local/global variables files. In this automatically.
model we have observed the Set Point given through 4. Checkbox Settings: Tick a checkbox to add task to
environment Control block and the output which is hardware configuration: Automatically add the generated
controlled height can be seen at scope directly. This task to the current hardware configuration of the
output can also be seen in watch window in AS. Also we Automation Studio project.
can have trace of this parameter. 5. Automation Studio configuration name: Check name of
the current Automation Studio configuration in AS and
3.3. Step III-Applying configuration Settings to Color specify same here.
Mixing Model MATLAB Simulink 6. Automation Studio PLC name: Name of the current
Automation Studio PLC in AS.
The Model created in MATLAB Simulink should have
following project settings to allow automatic integration

Fig. 3 Color Mixing Process Implemented in B&R Automatic Studio.

392
3.4. Step IV: Adding B&R Automation Studio Libraries Simulink. Within fraction of second’s message will
appear in the MATLAB command window indicating that
In order to be able to run the automatically generated the code generation has been done successfully. Then the
source code on the B&R target two B&R Automation automatically generated source code is compiled in
Studio libraries are required in the project: Add Automation Studio and transferred to the target system.
‘brsystem’& ‘sys_lib’ from exiting libraries. The simulink model from Matlab has been successfully
transferred into C language source code in Automation
3.5. Step V: Integration of Project: Automatic Code Studio as shown in fig 4. With the ‘automatic transfer’
Generation & Project Download option being enabled the generated program is included
into the Automation Studio project, the entire project is
After completing all above settings start the Automatic compiled and then transferred to the target system
Code Generation by using the menu item Tools Real- automatically.
Time Workshop. Build Model using (Ctrl+B) or using the
corresponding button on the toolbar in MATLAB

Fig. 4 Screen shot of Automatically Generated PLC code in C language.

the Automation Studio diagnostic tools like ‘Watch’ and

3.6. Physical view: Hardware Assignment ‘Trace’ the correct operation of the controller can are
verified.
To run the simulink model in real time connect
hardware to it through AS. The assignment of the 3.8. Trends (Real Time / Historical)
generated task to your hardware configuration can be
done automatically by selecting the option ‘Add task to Trends are very useful with PID Controller. You can
hardware configuration’. view the curve used to reach a certain set point. Study of
certain values will result in optimizing your process, and
it will certainly make if much more efficient.

3.9. Creating HMI in Automation Studio

Based on the designed PLC sequential control an

adequate HMI (human machine interface) has been
Fig. 5 Screen shot of Watch Window designed and implemented in Automation Studio for real
time control purposes.
3.7. Debugging: B&R Automation Studio Watch HMI gives the ability to the operator, and the user to
view the plant in real time. Add to that the ability to have
The result of the Automatic Code Generation can be alarm management that can warn the operator of a
easily verified by opening the B&R Automation Studio problem. It can even log and print all the alarms in real
Watch window after the download to the target. The result time, which can help the developer to improve the
can be seen in Fig.5 in Watch window function. Through production and efficiency. .

393
 4. Verification & Validation of the Results

The PLC code has been generated according to the

standards. The generated project does not contain any
function blocks or data blocks other than the ones needed
and used for the Color Mixing Process project. The PID
controller gets tuned with the same parameters which are
used in MATLAB simulink.
These PID settings which were entered in Matlab
Simulink remain exactly same in Automaton Studio.
The generated HMI shows the real time output values and
traces for easy analysis & understanding of the process.

5. Conclusion
Fig. 6 Output Traced in B&R Automation Studio
This paper demonstrated a method for automatically
generating PLC code and controlling the process through
simulation model. The methodology combines the high
level simulation and lower level PLC controlled devices
thus improves the fidelity between high level system
model and lower level. It reducing PLC code generation
time, as a result, can reduce the designing and
implementation time for PLC controlled manufacturing
industries. The strength of the scheme is that this
mechanism develops the HMI which the operators find
very easy to operate. Model-Based Design, together with
automatic code generation creates shorter and more cost
efficient design workflows. Also adds many advantages to
mixing process: high quality control, adequate set points
can be on-line numerically fixed.

Acknowledgement

The authors would like to express their gratitude to B&R

Automation Industrial Pvt. Ltd. for sponsoring this work
as well as providing the valuable guidance and support to
Fig. 7 Visualization- HMI Created in AS: Real Time Output
make it possible to experiment it practically.
The entire color mixing plant operates with the
designed HMI.The auxiliary tank levels are monitored,
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