Overview of Low Voltage Engineering Drives

Overview
of
Low Voltage Industrial Ac Drives
Nereus Fernandes

Contents
High Level Guidelines to build & operate a Drive System
•Control Schemes for Grid and Motor Converters
•Market Trends
•Motor and Drive Differentiation as per Application
•Inverter Duty Motors
•Software enabled Motor Design
•Software enabled Drive Design – Matlab Simulation & Auto-Code Gen
•Configuring a Typical Industrial Drive
•Drive Control using Industrial Communication Buses
•Servo Drive Control
•Drive Sizing and Selection Software
•Motion Control Software
•CNC, Robots, Machine Simulation
•Industrial Cyber Security

Overview
of
Software and Communication in
Low Voltage Industrial Ac Drives
Nereus Fernandes
A more suitable title would be…

Line and Motor Control Schemes
Direct Power Control
Voltage Oriented Control
Direct Torque Control
Field Oriented Control
Proven Motor Technologies and Control Schemes
– very few changes to the core technologies over the past 15-20 years
V/F Control
Diode /Thyristor
Bridge
Brake Chopper

AC Drive Brands
And many more…
Drives have become a commodity

Industrial Drive Market Trends
• Maximum utilization of existing captive-generation / mains
infrastructure
– Soft-Starters, Drives & “Control System Sequenced Start-up and
Load cycles” – are used to reduce inrush current
– Today in most Plants, trying to go back, and operate motors using
DOL or Start-Delta Starters will result in tripping of the Mains
Breakers
• Increase in Connectivity
– Drives are increasingly operated through PLC/DCS interface v/s
stand-alone
– General movement from Serial Buses to Ethernet buses
• Increased focus on Energy Efficiency and Power Quality
– General movement away from DC Drives
– Direct Drive => Elimination of Couplings like Gears, Belts, ..
– Increased use of Active Front End – PWM Rectifiers
• Increasing use of Software in design, configuration,
operation and maintenance

Differentiation by Application
• Industry is risk averse
– Proven Designs are readily accepted
– Number of successfully running installations increases
acceptance
– Global product approvals required as industry
• e.g. CE, UL, cUL, CSA, Marine Certifications, ATEX, Machinery
Safety- SIL 3 / PL e
• Only selling a Drive is not enough to enter or hold a
market
– total solution is required with PLC & SCADA programs and
also motors, gear boxes, etc…
– Complete End-Product Simulations help improve Customer
confidence in new applications and also help with
Customer Training
– Eco-system of Dealers and System Integrators to handle
scale

Hardware in Drives
• Load
• Drive Train – Couplings, gearboxes, ..
• Motor
– Encoders
• Drive Core Components
– Micro-controller
– Switches
– Switch Drivers
– Sensors
– Passive Components
• Drive Accessories
– Reactors : line, load
– Filters : du/dt, common mode, sine
– Switchgear and Protection
– Control Panels
• Controller : PLC/DCS, Motion Controller, CNC, Robot

Software in Drives
• Drive Firmware
– Core Control Techniques & Gate Pulse generation
• Simulation, C/C++ Code
– Application Features : cranes, coilers, fans, pumps, lifts,..
– Connectivity : Fieldbus, IT network
• Drive System Design
– Selection Software : Motor, Drive, Switchgear
– CAD electrical symbols, 2D, 3D models
– Simulation Models
– Multi-domain Simulation : Mechanical, Electrical, Automation
– Hardware In the Loop (HIL)
– On-line and Off-line Documentation, Sample Applications, Help Files, Help Forums..
• Drive Configuration Software
– Parameter Setting, Commissioning : ABB, Siemens
– PLC, HMI, SCADA Programming
– Motion Control, CNC
• Drive Operation and Monitoring
– IO and Fieldbus communication with : PLC, HMI, SCADA, Motion Controller,
CNC/Robot
– IT network communication : IoT - uplink, cloud, user displays
– Industrial Cyber Security

Drive & Motor Control Type
selection as per Application

V/f Open Loop Vector Closed Loop Vector

Differentiation by Application

Wind Turbine Pitch System
Pitch Motor
Pitch Axis Drive
Pitch Interface Module
Slip Rings for Power
and Data
Back-up Capacitor
• Master Pitch Control
• Battery Charge Control
• Communications
In the Hub we have Pitch Motors, Drives, Back-up Batteries that rotate and must
function in any orientation ( even inverted )

Wind Turbine Pitch System
Maintenance of systems in the Wind Turbine Hub is challenging
• Failures should be minimum, typical Component life is rated at 20 years
• Components should be compact so they can be carried up 80m+ to the nacelle

For Processes that cannot shut-down immediately on power failure but need controlled
shut-down
Cost Effective alternative to upstream UPS

Overview of Low Voltage Engineering Drives

Distributed Drive System
Combines Gear Box, Motor & Frequency Converter
Compact Solution suitable for Conveyor Applications

Motor
Fixed
Displ
Pump
Pressure Control Valve
Flow Control Valve
(w Bypass)
Filter
Orientation Control Valve
Oil Cylinder
Oil Tank
Set-points
Sensing
Control
Controller
Pressure Relief
Valve
Conventional Proportional
Hydraulic System
Constant Volume of Oil is Pumped even when there is no movement in the system
=> Power Wastage

Servo-Hydraulic System
Oil is only pumped as required
No Movement => No Oil Pumped
Power Saved
Also less heating of Oil => lower
Oil Cooling

Savings with Servo Hydraulic System
During Holding Cycles – flow is limited to compensate for oil that leaks over the seals

Electric Cylinders
Gradual movement towards All-Electric Machines

Networked drives with sequenced operation for optimized power utilization and pump
lifetime management

Drive “talks” the Application Language
Drive Operator Panel with Application specific setting and display

Cold Rolling Mills / Sheet Metal Lines
ACS880 Built-in Control software

Automation Package
• PLC Programs
• SCADA Programs
Cold Rolling Mills / Sheet Metal Lines

Support for
Wireless
Radio Control
Ensure that the motor is
fluxed-up and generating
holding torque before brake
release

Safety System monitors the condition of the Crane and takes appropriate
action by overriding the Control System to bring the Crane to a safe state

ACS880 integrated safety features
• Complies with the requirements of the
European Union Machinery Directive
2006/42/EC
• Built-in safe torque-off (STO)
• Optional integrated safety functions module
provides:
• SS1 = Safe stop 1
• SLS = Safely-limited speed
• SBC = Safe brake control
• SMS = Safe maximum speed
• SSE = Safe stop emergency
• SS2 = Safe stop 2
• SOS = Safe operating stop
• SSM = Safe speed monitor
• SAR = Safe acceleration range
• SDI = Safe direction
• POUS = Prevention of unexpected startup
• Reduces installation space and simplifies
cabling
• Connection to Safety PLC over PROFIsafe

Regenerative Drives for Flywheel Energy Storage
Regenerative Drives are the interface to Mechanical Energy Storage Systems
like Flywheels, Pumped Storage/Gravity Batteries…

Test Benches
Regenerative
Active Front
End

Direct Drive Motor
For Cooling Towers
Drive Train Reduction : Direct Drive Motor fits in place of the Gear-Box

ACS880 with
Cooling Tower Control Firmware
No need for separate heating elements in motor

Integrated Elevator Controller
The words of a typical Indian
Lift Contractor :
“This is popular & selling a
lot.. ..never heard of ABB or
Siemens”

8KHz default switching
frequency may not be
suitable for retrofits on
old ac-line motors
Drive trips every 2-3
days with Earth Fault

AC Induction Motor Technology
is more than 100 years old

Rotor Discharge
Hi-Freq Circulating
Rotor Ground
Not pure sine wave so harmonics present

Protecting Motors used with Drives
• Use Inverter Grade Motors
– Better Winding Technique
– Better Winding Insulation
– Designed for voltage peaks of >1600V and dv/dt rise times of
<0.1us
– Better Thermal Performance
– Separate Forced Cooling Fan for low speed operation
– Insulated Bearings
– Grounding Brush/Ring on Motor shaft

• Keep Motor Cables short <20m
• Better Earthing of Transformer, Drive, Motor, Drive Train using HF Ground
Straps
• Symmetric PE (Protective Earth) Shielded Motor Cabling
• For longer cables or Old/Ordinary Line Motors use
– Lower Switching Frequency ~2KHz
– Load Reactors
– Dv/dt Filters
– Sine Filters
– Regularly Grease Bearings
– Retrofit Grounding Brush/Ring on Motor/Load shaft
Protecting Motors used with Drives

Changes in the Motor Market…
Direct Power Control
Voltage Oriented Control
Direct Torque Control
Field Oriented Control
Proven Motor Technologies and Control Schemes
– very few changes to the core technologies over the past 15-20 years
Recognize this one?
V/F Control
Diode /Thyristor
Bridge
Brake Chopper

Proven stator technology with new
innovative rotor design.
• Identical Foot-prints
• Rotor has no magnets or windings
• Virtually No Rotor Loss
• Low Winding Temperature
• Increases Winding Life and Reliability
• Low temperatures => lower bearing failures
• Not Line Start – requires drive
This type has been
around since the
1920s, with some
more work done in the
1970s, but is being
actively marketed
since the last 5 years
New??
Software Simulations have
played a major role in the
refinement of both the
Motor and the Drive.

Free Tools for Motor Design :
https://www.femm.info/wiki/HomePage
https://motoranalysis.com/
https://www.jmag-international.com/express/

New Materials / Power Electronic Devices
• Wide Band-Gap (WBG) Materials
– Silicon Carbide SiC
• SiC MOSFET
• SiC Anti-Parallel Diode
– Gallium Nitride GaN
• GaN HEMT (High Electron Mobility Transistor)
• Wide Band-Gap Devices

Compact Size = PLC IO Module
GaN Transistors preferred for SMD devices
For EC (BLDC) Motor Control
Low Losses => Low Temperature Rise => Better Thermal Stability=>
Smaller Heatsink/Stack Size=> Suitable for Motor Integrated Drives, EVs
Terminals
1,2,3,4,5,6,7,8
Terminals
9,10,11
1200V, 900A
High Band Gap => Suitable for High Voltage Operation

Isolated Power Supplies to be provided for each switch

Peak Output Current of 30A
IGBT Voltage 1700V
Switching Freq 60KHz
Transformer Coupling

On-Chip Coreless Transformer - IGBT Driver

Integrated Power Module for
Small Appliance Motor Drive Applications
600V DC
3V-5V DC
MCU Side Power Side

Current Sensors
AMC3302
±50mV Shunt Input, Precision Current Sensing Isolated Amplifier
with integrated DC/DC converter
https://www.lem.com/en/hall-effect-current-sensors
https://www.lem.com/en/air-core-current-sensors
https://www.lem.com/en/fluxgate-current-sensors

B C D
E
C*
C**
Isolated and
Non-isolated
Motor Current
Feedback
Selection is dependent on the Power
and Performance – ultimately on the
cost of the drive.
Low Cost drives use the non-isolated
leg-shunts, with the control MCU also
floating in the Power Domain
https://www.analog.com/en/technical-articles/measurement-techniques-for-industrial-motion-control.html
To Isolate or not to Isolate
Isolated => safer, more reliable
Non-Isolated => cheaper

Voltage Sensors
AMC3330
±1-V Voltage Divider Input, precision
reinforced isolated amplifier with
integrated DC/DC converter

EDA – Electronic Design Automation
Multi-User Support & Collaboration
Online Resources of Component
Manufacturers provide
• Spice Models
• Symbols
• Footprints
• 3-D Models
These sites
determine if
your design is
possible and
economically
viable
– based on
the
availability of
components

Drive Control Chpisets
Motor Controller MCU trends follow the Drive market trends
•In-built Support for Communication Interfaces
•Large number of EPWM outputs to support the Motor Inverter
+ Active Front End / PFC + Multi-Motor
•Support for Safety, Security and Sector-specific Standards
•General movement from proprietary architectures to ARM
Cortex-M for executing the Control Routines
•General movement to multi-core MCUs
• Cortex-M0+Cortex-M4/M7
• Cortex-A + Cortex-M

TI – Motor Control DSP, Software and Kits

TI Digital Motor Control Library

TI – Drive Safety Reference Designs
1oo2d Architecture
with diagnostics
both independent-
hardware channels
(5 & 6) are capable of
disconnecting
the gate-driver power
supply to ensure that the
torque generating energy
to the motor can be
removed

Tool Chains - TI
RTOS & libraries for Fieldbus Communication, Graphic Displays, etc..

Tool Chains - AD

Tool Chains - Infineon

For prototyping leverage the Evaluation Boards from MCU and Switch Manufacturers

Tool Chains - Renesas

Tool Chains – Microchip

https://www.sim2tronic.com/downloads/

https://www.esi-group.com/
Good to see support for Scilab!!

Tool Chains - ST

Tool Chains - NXP

Matlab – Simulink Modelling and Code Generation
Simulation and Emulation Tools for System/Load, Motor and Drive
MUST be effectively used to save time and money in Design and
Development
Code must be written to confirm to Automotive & Safety Standards

https://in.mathworks.com/products/motor-control.html
https://www.nxp.com/design/software/automotive-software-and-tools/model-based-design-toolbox-mbdt:MBDT

Model In the Loop - Idealized Simulation
using Matlab Model Blocks

Software In the Loop
- generated C code executing on PC

Processor In the Loop
- generated C code executing on MCU
MCU outputs are sensed by Matlab
and used as inputs to the System
Models executing in Matlab on the
PC and outputs from the System
Models are fed to the MCU inputs.
Communication between Matlab/PC
and the MCU could be via the MCU
debug interface to directly get/set
the variable values in the MCU.

Hardware In the Loop
MCU+I/O Interfaces
with Emulated Motor+Load Hardware
Motor+Load Simulation Model
can be downloaded to
an Electric Motor Emulator
(refer after the next 1-2 slides)
This is followed by testing on Actual Hardware

(MCU)Hardware In the Loop (HIL)
C-code C-code
Actual MCU+Interfaces
Emulated System
Emulated System Emulated System

Enables System-Level Testing via the MCU
+ I/O Interfaces even without the actual
Power Electronics or Motor

(HIL) Electric Motor Emulator(EME)
• Mimics the 4-quadrant electrical output of a 3-
phase synchronous or induction motor/generator
under user-controlled speed, torque and
temperature conditions thereby simulating an
electric drive train
• Supports multiple motor/generator characteristics
in a single set of hardware. Scalable from 50kW
to 550kW
• Enables test under extreme operating conditions
in a safe mode without harm to the Inverter or
Test Equipment (high rate of change, overspeed,
continuous overload conditions).
https://www.dvelectronics.com/
https://www.speedgoat.com/

Reference Books & Sites
The Motor Control Site
of your selected MCU
Excellent references for Motor Drive control schemes like FOC and DTC and
Active Front-End control schemes like VOC and DPC

Drive Components
Control Unit
ZCU-11
Operator
Panel
ISU & Inverter Units

Numeric History graph
Analog
ACS880 intuitive control panel
Examples of control panel displays
• parameter setting
• Local Control – ON/OFF, Speed Inc/Dec,..
• simple monitoring
• Data logger
• Fault logger
• Internal diagnostics data
• safety set-up
• multiple backup and restore
• block programming
• point-to-point connection

ACS-AP Control Panel
USB connector
 Use control panel as a USB adapter
for PC tools
 Save data from Drive to the control
panel and take it to the PC (and vice versa
download data from PC to Drive)

RS485-networking
USB
RS485
Panels removed, 2 RJ45 connectors for chaining
the bus
Panel or other
USB/RS485
converter
ACS-AP Control Panel
Panel bus - Up to 32 drive simultaneously in the network

Start, Stop the Drive
From your cellphone

• Using the control panel
• Control locations and operating modes
• Program features
• Application macros.
• Parameters.
• Additional parameter data
• Fault tracing
• Fieldbus control through the embedded fieldbus interface
(EFB)
• Fieldbus control through a fieldbus adapter
• Control chain diagrams
- Important Document

( Generator Applications
-Inverter intrefaces with
Generator
-Supply Unit creates the
AC micro-grid )
- Parameter Groups & Control Chain Diagrams

- Parameter Groups & Control Chain Diagrams

Ramp Function Generator(RFG)
Output
Ramp Function Generator(RFG)
Enable
Operation
Enable

ACS880, Drive Composer Tool
PC tool for start-up, configuration and maintenance
• parameter setting
• Local Control – ON/OFF, Speed
Inc/Dec,..
• point-to-point connection
• simple monitoring
• networked drives
• control diagrams
• data logger(s)
• Fault logger
• Internal diagnostics data
• safety set-up
• multiple backup and restore
• block programming

ACS880, Drive Composer Tool
Graphical Configuration using Control Diagrams
© ABB Group
August 24, 2025 | Slide 118

PLC
Control of
Drive
using I/O
The Bad :
•Expensive Analog I/O
required
• 10+ wires required per Drive
The Good :
• Old and standard Interface.
Independent of Drive Make
and Model and allows easy
swapping.
Analog
Setpoints
To Drive
Digital
Feedback
From
Drive
Digital
Commands
To Drive
Analog
Feedback
From Drive
Control Unit
ZCU-11

ACS880 control and communication
Standard Fieldbus connections and options
© ABB Group
August 24, 2025 | Slide 122
 Wide range of I/O connections as
standard
 Communication with all major
fieldbus protocols
 Supports Ethernet drive monitoring,
diagnostics, and parameter handling
 Drive-to-drive (D2D) enables fast
peer-to-peer communications

Single Data Cable
• Only single multi-drop
communication cable is required –
greatly reducing cabling cost
• Cable break is detected by
Protocol Specific Keep-Alives OR
Pre-set Cyclic Read/Write Cmd
intervals – if R/W Cmd is not
received every say 1s then
communication break is assumed
and Drive goes to configured safe
state
• Large number of Cmd/Status
Signals can be R/W
• Drive can be remote configured
using the communication cable

Refer slide
“Speed
Reference
Source
Selection 1“
Modbus
Read
Modbus
Write
PLC DRIVE
ACS880 Fieldbus Interface

• State Diagram IGBT Supply Unit (ISU)
ISU interlock
Main contactor open
DC link charged. Not modulating
Charged and modulating
Check the Status Word and accordingly write
to the Control Word to remotely operate the
drive over Modbus
Ready Run
Ready Ref

Modbus Interface may have different Addresses for different Vendors, requiring rework with
a different Drive Vendor
Ideally All Drive Vendors need to agree on standard Modbus Addresses for Control and
Status Registers
Alternatively, PLC programs can be parameterized so that the Modbus Addresses and
Control Register Bit Positions can be easily changed with Drive Model/Manufacturer

• Profinet ( at Physical & Network Layer) ensures that Devices are Interconnectable
& Interoperable
• ProfiDrive is an Application Layer Specification and ensures that devices are
Interchangable
• PROFIdrive is a vendor-neutral application profile from PROFIBUS and PROFINET
International (PI) which is focused on drives, encoders, motors, and their
applications, which range from simple to very demanding motion control tasks.
PROFINET allows scalable update times starting from 31.25μs and a jitter of less
than 1μs for the most demanding motion applications while supporting open TCP
communications. PROFIdrive provides interoperability through standardized drive
IO data sets, messages, and parameter sets as well as manufacturer-specific
options to allow vendors to implement additional features to foster competition and
innovation.

Profisafe & ProfiDrive
ProfiDrive

Set-up Profinet Communication between
Drive(Device) and PLC(Controller)
• Profinet Devices Manufacturers provide associated GSDML (General
Station Description - XML) files
• Import the GSDML file into a Standard Profinet Configuration Tool (typically
your Controller Programming Environment), the Device Type now shows in
the catalog
• For Manual Configuration
– Drag and Drop the Device from Catalog into the Configuration View to create a
Device Instance.
• For Auto Configuration
– Scan the network to automatically add Device Instances for all connected
devices
• Configure the Device Instance with Parameters like – Names, Network IP
Address, Add Device Options like for Drive Devices - Power Card, Control
Card, Encoders, Default Fail-safe IO State in case of loss of Communication
• Configure the Profinet Telegrams, map to PLC Registers. Write the PLC
program to Read Status/Write Setpoints to the mapped PLC Registers
• Download the configuration to the Field Devices(Drive) & Controller(PLC)

WebServer
Remotely browse status of connected drives
Remotely view and set
selected drive’s parameters

Servo Drives
Servo Systems : A closed–loop system to control position and/or derivatives like
velocity and acceleration.

Servo-Amplifier Control Loops –
Position, Speed, Torque

PTI Control
Pulse Train Input Position Control
Control Signals between
PLC and Servo Drive
Displacement = Number of Pulses
Speed = Frequency of Pulses
Control/
Set-point Cable

PTI Control – Electronic Gear Ratio
Displacement = Number of Pulses
Speed = Frequency of Pulses
16-bit Encoder = 65K pulses per rev
2000 rpm = 33rps =>2MHz pulses per rev
Set Electronic Gear = 1000
2000 rpm => 2MHz/1000 = 2KHz pulses per rev
• Electronic Gear used to keep
the Number and Frequency of
Pulses within System limits
• Generate pulse counts that
intuitively correspond to final
displacement
eg. 1mm = 10 counts

Relative Position Control with Pulse Train
– Delta PLC Program for basic 1-axis motion
Displacement 
Speed

Displacement
Pulse Count
Speed
Pulse Freq (Hz)
PLC
O/p
A
PLC
O/p
B
• PLC programmer has to correctly
set-up the pulse counts
• Siemens PLCs have Motion
Technology Objects with configurable
gear ratios, screw pitch,.. that
internally take care of the pulse count
generation and allows the user to
configure in terms of final load
parameters like linear speed (m/s) and
displacement (m) – this is not covered
in this presentation, refer the Siemens
Manuals for details

NO Pulse Train Inputs
ONLY Fieldbus Communication

Planning, design, engineering, operation, maintenance,
upgrades, modernization & migration of existing user code
Metering, Transformers, Chokes, Switch-Gear, Filters, Drives, Motors,
Couplings, GearBoxes, Encoders..
PLC, IPC, HMI, SCADA, MES, Cloud

Digitalization Software Portfolio

Using the Siemens TIA Software
Totally Integrated Automation
Single Integrated Development Environment (IDE) for :
• Drive Sizing and Selection
• Bill of Material Generation and Ordering
• Drive Configuration
• Motion Programming
• PLC, HMI, SCADA Programming
• System Commissioning, Testing and Validation
• Firmware Updates, Replacement Parts, Program Migration

Drive Dimensioning
Add – New Device

Select – Drive Technology
Drive Dimensioning

Select >60V power supply
Drive Dimensioning

Select >Add Load
Drive Dimensioning

Configure > Load Properties Select > Add Motor
Drive Dimensioning

Configure > Motor and Gear Box
Drive Dimensioning

Select Motor from Options Select > Add Frequency Converter
Drive Dimensioning

Select Drive from Options
Drive Dimensioning

Select > Add Cable
Drive Dimensioning

Select Cable from Options
Drive Dimensioning

System is now fully configured
Drive Dimensioning

Select >Belt conveyor
Drive Dimensioning
Second Axis Configuration using the standard load types

Mechanics
Configure >Properties of Load Mechanics
Drive Dimensioning

Configure >Motion Profile of Load
Drive Dimensioning

Layout Control Panel
• Drag and drop items from list
• Dimensioned items help in layout and size estimation of Panel

Generate Bill Of Material
Check Inventory and Place Order

Drive Configuration
and Commissioning

Select Drive Command Interface

Enable Motor Parameter Measurement
Motor parameters are measured when Drive is turned ON the 1st
time

Testing the Drive from StartDrive

Testing the Drive from StartDrive
1. 2.

Motor Parameter Measurement
Drive automatically turns OFF when parameter measurement is complete

Rotating the Motor
1. Enter Speed (SP)
2. Click Forward/Backward buttons to rotate the Motor
3. Actual (PV)
Speed, Current
Is displayed. Motor
ramps up to the
Speed SP
4. Stop the Drive
5. Reset the Drive
6. Give Up Master Control

Drive Parameters – Functional View

Drive Parameters – Parameter List View
ALL Parameters can be listed OR Parameters can be grouped as per function

Online Monitoring of Drive Parameters

Online Monitoring – Diagnostics with Trace

Motion Control using
Siemens TIA software

Fixed
Speed
Ratio
between
shafts
Slave
Axis
Profile
is function
of Master
Outputs
are ON/OFF
based On
position
Movements that previously used mechanical coupling for coordinated motions can now be controlled by separate
(smaller) motors that are electronically coordinated with no mechanical linkage.
Gear ratios and Cam profiles are software configured

Hardware Platforms
SIMOTIOND
=SIMOTION+S120 Drive
SIMOTIONP
=SIMOTION+Industrial PC
SIMOTIONC
=SIMOTION+S7-300PLC
ET200SP
Remote I/O
SIMATIC HMI
Or
Industrial Monitor
S120
Drive
PLC S7-15xxT

Hardware Platforms
Drive Control
Hydraulic System Control
via interface to Servo-Hydraulics
S120
Drive

Kinematic Package – Path Objects

Create a project in Siemens TIA
_1

Create & Configure the System Axes

Configure System Axes – Assign to Drive
X

Select PATH Technology Package

For PATH Object define the Kinematics
- 2D Gantry

Map the Path Object Axes to System Axes
A1 A2

Create a MCC Unit
Define Global Variables

Insert a MCC Object
Define Local
MCC Variables

Configure the linear PATH : AB
As configured
earlier

Calc derivatives for Curve PATH : BC

Check the Motion using Trace
Variables added to Trace
A BC DE
Z X
FB
F A
The MCC in the Motion
Controller is triggered from the
PLC logic when the given
movement profile is required.
The Motion Controller
executes the MCC and
updates the PLC on current
position (during and) on
completion of the movement

Motion
Controller
CNC Controller Hardware
Add-on
Machine Control Panel
with Hand-Wheel
Remote I/O
Numerical
Control Extension
Module
NCU – Numerical Control Unit consists of
1. PLC ( Machine Logic, Sequencing, Interlocks, Robot Interface..)
2. NCK (Numerical Control Kernel)
3. CP (Communications Processor)
4. Operator Panel / HMI (TCU+MCP OR PC for integrated CAM support)
5. Drive Communications and Control
6. NX (Numerical Control Extension Module – for additional Axis)
7. Remote IO
Thin Client Unit
NCU1760 is a specialized PLC
S7-1500F with NCK (Nunerical
Control Kernel) that has direct
communication bus access

A Typical Robot
Robot Arm – Manipulator
•Contains the Mechanical parts like
Linkages and Motors - the
Kinematics that perform the
ordered Commands
Robot Controller
•Co-ordinates movement of the
robot
•Calculates the co-ordinate
transformations
•Controls the Axis Motors
•May also contain the Power
units for the Axis Motors
Robot Operator Unit
(Teach Pendant)
•User Interface that
enables input of the
program and settings
•Displays status, alarms.
Enables start, stop, jog,
manual movements and
training
Commercially available Robots have an optimized set of Kinematic Equations based
on the manufacturer’s knowledge of their mechanical construction.

CNC/PLC  Robot Interface
Machining/Handling
Robot
Robot
Controller
Robot
Operator
Unit
CNC Controller
Machine Tool
1. PLC Handshake
IO Signals Kinematics
Robot UI
Machining/Handling
Robot
CNC Controller
Machine Tool
3. Robot Direct Control
CNC
Servo
Drive
Kinematics
Robot UI
Machining/Handling
Robot
CNC Controller
Machine Tool
2. Robot Command Interface
Robot
Controller
Kinematics
Robot UI
Robot Controller represented as a
Profinet IO Device, by a GSDML file
(General Station Description -
Markup Language, XML based)

SINUMERIK Operator Interface - Combines
CNC and Robotic Programming Environments

• Uniform UI to program and control
Robots from different vendors and
different coordinate systems
• Combined Status and Logs
• System can be taught in jog
Mode – using cartesian or axial
co-ordinates
• Both individual Positions and trajectory
curves Paths can be saved

CNC/PLC  Robot
using Command Interface
The KUKA.PLC mxAutomation block library
commands from the SIMATIC controller are
received by the Interpreter on the Robot Controller
which computes kinematic transformations and
executes them on the Robot’s mechanical system.
/SINUMERIK

1. Import Workbench CAD
2. Import WorkPiece CAD
3. Select Robotic Arm
4. Select Tool
5. Set the Axes
6. Program the Tool
Movements
7. Run the System in Off-line
Simulation Mode and
Optimize
8. Download Program to
Shop-Floor Robot for use
in On-line Production

Plant Simulation – Discrete Manufacturing
• Process definition
• Layout definition and integration
• Robotic programming
• Mechanical sequencing
• Material flow
• Automation control
• Virtual commissioning
• Man-machine interaction
• Safety Systems
• Virtual reality for presentation and
collaboration
• Validating PLC code offsite with virtual
commissioning
Virtual commissioning is the simulation and
debug of PLC code using a ‘digital twin’
this is an exact functional replica of the production line
in the virtual world, where unlimited testing can take
place in an environment with no risk. The virtual
commissioning approach facilitates interdisciplinary
collaboration between mechanical and electrical teams
much earlier on in a project, allowing more of the
programming to be completed and tested before
physical installation. This leads to less time spent on
the factory floor

For a Machine Design
• Integration of 3-Domains
• Changes made in one
domain are reflected in the
other domains
• Eg. – increase in mechanical
load will result in electrical
overload and necessitate
increasing the ratings of the
Electrical(Motor, switch-gear)
and Automation(Drive)
components. Changes in loop
gains, etc..
CAM/CAD/CAE
Create a complete digital twin of your product and use simulation tools to test its
validity, saving on costly prototypes and reducing time-to-market.

Design & Test
Virtual Prototype

SIMIT Simulation Platform
Similar to Matlab

1. TIA Portal used for editing PLC Program and Drive Configuration.
2. PLCSim used to run downloaded PLC Program.
3. SIMANTICS DriveSIM loads Drive FMU (Functional Mock-up Unit/Model) into Process Simulator SIMIT
4. SIMIT runs the Drive FMU and exchanges signals with PLCSim and NX Mechatronic Concept Designer
5. NX Mechatronic Designer uses the Torque/Speed inputs to visualize how the mechanics would move.
6. SIZER / TIA Selection Tool uses the simulation results - load profiles - Torque or Speed curves over time to
select Drive & Motor best fitted to the demand
PLC Program Validation + Drive Sizing & Selection + Mechanical Validation
1
2
3
4
5
6

Software to help with Certifications

Circuit Diagrams Panel Layouts
ePlan Macros provided by Drive/Component Manufacturers
Standard Enclosures, Bus-bar Systems, Cooling, etc..

CAD for Circuit Diagrams
and Panel Layouts

Online Resources –
Product Replacement Selector

Help Forums : Browse Issues

Help Forums : Post Queries

CodeSys Software Platform
for PLC/Drive
Configuration and Runtime
Used by 250+ Device Manufacturers, including
several leading names in the Automation Industry
Proven platform enables rapid full-featured product
development – enabling the Device Manufacturer
R&D Team to focus only on the unique
differentiating features of their product

ACS880 drive programming
Common engineering tool for Drives and PLC`s
 Built-in PLC functionality in the drive
 The common engineering tool Control
Builder Plus is used for drive and PLC
programming and configuration
 ContolBuilder plus is based on the
CoDeSys IEC programming
environment.
• Easy integration of ABB´s drive and
PLC systems
• Creation of user parameters and
events
• 5 different IEC 61131-3 programming
languages
• Debugging and on-line features

CODESYS Dev & Run-time
Codesys provides Industry Standard Editors
Codesys generates a runtime binary for PC based system or embedded controller.

• Safety controllers are designed as
add-ons to standard controllers. The
system is dual channel (1oo2).
• Runtime system toolkit for Dual-
Channel Hardware, pre-certified in
accordance with IEC 61508 SIL3
• PLCOpen Safety Function Modules

Project structure for SIL3 in CodeSys Editor

IT Communication Functions
/Drive
Embedded Web Server

IT Communication Functions
- Your Drive can now tweet it’s status

Role of Open Source in the PLC /
Industrial Automation Domain
• Limited by
– Stringent Safety, Performance and Liability Requirements, High
Cost, limited access for trails at large installations, proprietary
nature of existing hardware
– Customer Risk Aversion and tendency to order what is proven
from large reputable vendors
– Customer lack of IT Expertise and focus on Production core-
competency
– Educational Institutes treat PLCs, Drives, CNCs, Robots as
Black-Boxes and do not focus on how the Industry Standards
should be used to design the underlying hardware and software
• Almost all Open Source hardware offerings are related to
the Arduino(roughly ARM Cortex-M4) and
RasberryPi(ARM Cortex-A) platforms

https://www.openplcproject.com/
http://scada-lts.org/
The PLC Runtime is targeted at RasberryPI devices
with Arduino devices treated as Remote-IO Modbus
Slaves
PLC & SCADA
PLC https://cq.cx/ladder.pl
Ladder Editor with compiler for ATMega and PIC targets.
Alternatively ANSI C code can be generated and used with the C-
Compiler for another hardware target
Alternatively Byte-Code can be generated and used with target
specific interpreters
Editor is old with 1990s look and feel and may not be IEC61131-3
compliant. Not Industry-grade, but should be a good starting point
for students

Cross Platform Graphic Frameworks to build
your own HMI and SCADA System
http://www.wxwidgets.org/
https://www.gtk.org/
https://www.qt.io/
https://www.cranksoftware.com/

IEC 61131-3 & PLCOpen
• PLCOpen had come up with standards that enables
export/import of IEC 61131-3 compliant PLC programs
and Function Blocks in XML format
• The PLCOpen XML Exchange Standard has enabled
development of 3rd
party Function Blocks containing
Logic for specific functions (eg. Motion/Robot Interface)
that can be imported into the Editors of multiple PLC
vendors (Siemens, Allen Bradley, Mitsubishi, Beckhoff..)
and then configured to connect with the PLC specific IO
and Communication registers. This enables code reuse
across PLC systems from different manufacturers

CNC Freeware
• http://linuxcnc.org/ LinuxCNC (formerly Enhanced Machine Controller or EMC2) implements numerical
control capability using general purpose computers to control CNC machines

Robot Freeware
• https://www.ros.org/ The Robot Operating System (ROS) is a
flexible framework for writing robot software. It is a collection of
tools, libraries, and conventions that aim to simplify the task of
creating complex and robust robot behavior across a wide variety of
robotic platforms.
• https://rosindustrial.org/ to solve the issue that despite billions of
dollars of research by governments and academia, new robotic
applications were not being introduced in the industry due to
incompatibility between the research and the industrial robotic
platforms

Industrial Cyber Security
• Open communication and the increased networking of production
systems involve not only huge opportunities, but also high risks
• Effects of a Cyber attack on Industrial system
– Safety
– Quality
– Uptime
– Espionage
– Ultimately resulting in revenue loss
• IEC 62443 International Industrial Security Standard
Cisco Industrial Security Appliance ISA 3000
-Firewall & N/w Security Policies

Core Functional Components of the Siemens SIMATIC PCS 7 Control System
A cyber-physical attack involves three layers and
their domain-specific vulnerabilities:
1. IT layer which is used to spread the
malware – exploiting
2. Control system layer which is used to
manipulate (but not disrupt) process
control
3. Physical layer where the actual damage
is created

Stuxnet… Worm, Trojan, Virus
• State sponsored Cyber Weapon specifically targeted Iranian Uranium refining
centrifuges
– Delivery Introduced into the computer networks of several Iranian Industrial Automation
companies by USB pen-drives “found” near the organizations
• Spread through the company networks using multiple “zero-day exploits” on vulnerabilities in RPC,
Printer sharing on Windows PCs and replicated itself on all USB pen-drives used on the networks
• Jumped the “air-gap” to the isolated Industrial Control System network (ICS n/w) at the Iranian Natanz
Nuclear Facility on a USB pen-drive and replicated across the Natanz ICS n/w
• On PCs with Siemens PCS7 (DCS) & Step7 Programming Software used an unchanged “Default
Password” that gave Admin access to install/replace a .dll file using a genuine (but stolen)
authentication key
– Payload Scanned the PLC program for certain key parameters example “164” => typical
centrifuges in a cascade and configured Profibus network for Control Valves & Motor Control
Drives
• Updated the Controller Program when Step7 connected to S7-400/S7-300 Controller Hardware
• At pre-programmed intervals every around 2 weeks
– Varied gas pressure to over-pressurize a centrifuge stage
– varied the set-speed of the drives drastically with rapid acceleration and deceleration cycles
taking them near their critical resonance speeds The Controller could continue to report correct
Gas Pressure & Drive Speed values to the SCADA so there would be no automatic shutdown by
safety routines or chance for manual intervention from the Control Room or post-mortem
troubleshooting when analyzing logged process data. The durations of the injected malfunctions
were short so as to increase wear and tear on the motor and mechanical systems but not cause
immediate catastrophic destruction
• The slow delayed action – an event every 2 weeks
– made problem isolation difficult
– could destroy even replacement hardware
– caused frustration and loss of morale among the project team
– Effect
• 2000 centrifuges around 1/5th
of the total installation were destroyed and had to be completely replaced
• Stuxnet presents a text-book methodology of “Attack Engineering”

Layered Security
• Plant security
– Protection against access by unauthorized persons – fenced zones based on roles
– Physical access protection for critical components – locked cabinets
• Network security
– Controlled interfaces between the office and plant networks, e.g., using firewalls, DMZ
– Segmentation of the plant network ( could be using vLANs )
• Group on need-to-communicate basis
• Group Legacy systems / out-dated OS
• Groups behind VPN, Firewalls
– Network Monitoring – traffic density, intrusion, blocking of devices attempting to flood the
network at port / segment level
– Secure IT Functions
• Enable Encrypted Communications where possible
• Web-Access using encrypted protocols, VPN, IPSec, HTTPS, MQTT over TLS, FTPS, NTP(secured),
Secure SNMP
• System integrity
– Use of antivirus software with regular updates of virus signatures
– Only “Whitelisted” programs are allowed to execute on PCs
– Maintenance and update processes
– User authentication for machine or plant operators – use Windows Users, Policies –
password life
– Device authentication by passwords and certificates
– Integrated access protection mechanisms in automation components
– Disable unused ports Ethernet/USB/Fieldbus/ WLAN/Bluetooth..
– Accept messages only from known sources
– Disable unused functions Webserver, FTP..
– PLC program locking, function block locking, upload prevention, Audit Trails

Siemens Industrial Security
• Industrial Grade Networking
Security Modules – Firewall,
VPN
• PLC Communication
Processors can also act as
Firewalls

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