IEEE TRANSACTIONS ON ENERGY CONVERSION, VOL. 19, NO.

3, SEPTEMBER 2004 469

Design and Implementation of PLC-Based

Monitoring Control System for Induction Motor
Maria G. Ioannides, Senior Member, IEEE

Abstract—The implementation of a monitoring and control in a five-axis rotor position, direction and speed, reducing
system for the induction motor based on programmable logic con- the number of circuit components, lowering the cost, and
troller (PLC) technology is described. Also, the implementation of enhancing reliability [18]. For switched reluctance motors as
the hardware and software for speed control and protection with
the results obtained from tests on induction motor performance a possible alternative to adjustable speed ac and dc drives, a
is provided. The PLC correlates the operational parameters to single chip logic controller for controlling torque and speed
the speed requested by the user and monitors the system during uses a PLC to implement the digital logic coupled with a power
normal operation and under trip conditions. Tests of the induction controller [19]. Other reported application concerns a linear
motor system driven by inverter and controlled by PLC prove a induction motor for passenger elevators with a PLC achieving
higher accuracy in speed regulation as compared to a conventional
Vf control system. The efficiency of PLC control is increased the control of the drive system and the data acquisition [20].
To monitor power quality and identify the disturbances that
at high speeds up to 95% of the synchronous speed. Thus, PLC
proves themselves as a very versatile and effective tool in industrial disrupt production of an electric plant, two PLCs were used to
control of electric drives. determine the sensitivity of the equipment [21].
Index Terms—Computer-controlled systems, computerized Only few papers were published in the field of induction
monitoring, electric drives, induction motors, motion control, motors with PLCs. A power factor controller for a three-phase
programmable logic controllers (PLCs), variable-frequency induction motor utilizes PLC to improve the power factor and
drives, voltage control.
to keep its voltage to frequency ratio constant under the whole
control conditions [3]. The vector control integrated circuit
I. INTRODUCTION uses a complex programmable logic device (CPLD) and integer
arithmetic for the voltage or current regulation of three-phase
S INCE technology for motion control of electric drives be-
came available, the use of programmable logic controllers
(PLCs) with power electronics in electric machines applications
pulse-width modulation (PWM) inverters [22].
Many applications of induction motors require besides the
has been introduced in the manufacturing automation [1], [2]. motor control functionality, the handling of several specific
This use offers advantages such as lower voltage drop when analog and digital I/O signals, home signals, trip signals,
turned on and the ability to control motors and other equip- on/off/reverse commands. In such cases, a control unit in-
ment with a virtually unity power factor [3]. Many factories volving a PLC must be added to the system structure. This
use PLCs in automation processes to diminish production cost paper presents a PLC-based monitoring and control system
and to increase quality and reliability [4]–[9]. Other applica- for a three-phase induction motor. It describes the design and
tions include machine tools with improved precision comput- implementation of the configured hardware and software. The
erized numerical control (CNC) due to the use of PLCs [10]. test results obtained on induction motor performance show
To obtain accurate industrial electric drive systems, it is nec- improved efficiency and increased accuracy in variable-load
essary to use PLCs interfaced with power converters, personal constant-speed-controlled operation. Thus, the PLC correlates
computers, and other electric equipment [11]–[13]. Neverthe- and controls the operational parameters to the speed set point
less, this makes the equipment more sophisticated, complex, and requested by the user and monitors the induction motor system
expensive [14], [15]. during normal operation and under trip conditions.
Few papers were published concerning dc machines con-
trolled by PLCs. They report both the implementation of the II. PLC AS SYSTEM CONTROLLER
fuzzy method for speed control of a dc motor/generator set
using a PLC to change the armature voltage [16], and the A PLC is a microprocessor-based control system, designed
incorporation of an adaptive controller based on the self-tuning for automation processes in industrial environments. It uses a
regulator technology into an existing industrial PLC [17]. Also, programmable memory for the internal storage of user-orien-
other types of machines were interfaced with PLCs. Thereby, tated instructions for implementing specific functions such as
an industrial PLC was used for controlling stepper motors arithmetic, counting, logic, sequencing, and timing [23], [24].
A PLC can be programmed to sense, activate, and control in-
Manuscript received December 2, 2002. Paper no. TEC-00004-2002. This dustrial equipment and, therefore, incorporates a number of I/O
work was supported by the National Technical University of Athens. points, which allow electrical signals to be interfaced. Input de-
The author is with the Faculty of Electrical and Computer Engineering of vices and output devices of the process are connected to the
the National Technical University of Athens, Athens 15773, Greece (e-mail:
[email protected]). PLC and the control program is entered into the PLC memory
Digital Object Identifier 10.1109/TEC.2003.822303 (Fig. 1).
0885-8969/04$20.00 © 2004 IEEE
470 IEEE TRANSACTIONS ON ENERGY CONVERSION, VOL. 19, NO. 3, SEPTEMBER 2004

Fig. 1. Control action of a PLC.

In our application, it controls through analog and digital in-

puts and outputs the varying load-constant speed operation of
an induction motor. Also, the PLC continuously monitors the
inputs and activates the outputs according to the control pro-
gram. This PLC system is of modular type composed of spe-
cific hardware building blocks (modules), which plug directly
into a proprietary bus: a central processor unit (CPU), a power
supply unit, input-output modules I/O, and a program terminal.
Such a modular approach has the advantage that the initial con-
figuration can be expanded for other future applications such as
multimachine systems or computer linking.

III. CONTROL SYSTEM OF INDUCTION MOTOR

In Fig. 2, the block diagram of the experimental system is
illustrated. The following configurations can be obtained from
this setup.
a) A closed-loop control system for constant speed opera-
tion, configured with speed feedback and load current
feedback. The induction motor drives a variable load, is
fed by an inverter, and the PLC controls the inverter
output.
b) An open-loop control system for variable speed operation.
The induction motor drives a variable load and is fed by
an inverter in constant control mode. The PLC is
inactivated.
c) The standard variable speed operation. The induction
motor drives a variable load and is fed by a constant
voltage-constant frequency standard three-phase supply.
The open-loop configuration b) can be obtained from the
closed-loop configuration a) by removing the speed and load
feedback. On the other hand, operation c) results if the entire
control system is bypassed.

IV. HARDWARE DESCRIPTION Fig. 2. Electrical diagram of experimental system.

The control system is implemented and tested for a wound
rotor induction motor, having the technical specifications given
TABLE I
in Table I. The induction motor drives a dc generator, which sup- INDUCTION MOTOR TECHNICAL SPECIFICATIONS
plies a variable load. The three-phase power supply is con-
nected to a three-phase main switch and then to a three-phase
thermal overload relay, which provides protection against cur-
rent overloads. The relay output is connected to the rectifier,
which rectifies the three-phase voltage and gives a dc input to
the insulated gate bipolar transistor (IGBT) inverter. Its tech-
nical specifications [25] are summarized in Table II. The IGBT
IOANNIDES: DESIGN AND IMPLEMENTATION OF PLC-BASED MONITORING CONTROL SYSTEM FOR INDUCTION MOTOR 471

TABLE II
INVERTER TECHNICAL SPECIFICATIONS

inverter converts the dc voltage input to three-phase voltage

output, which is supplied to the stator of the induction motor.
On the other hand, the inverter is interfaced to the PLC-based
controller.
This controller is implemented on a PLC modular system
[5], [26]–[28]. The PLC architecture refers to its internal hard-
ware and software. As a microprocessor-based system, the PLC
system hardware is designed and built up with the following
modules [29]–[37]:
• central processor unit (CPU);
• discrete output module (DOM);
• discrete input module (DIM);
• analog outputs module (AOM) Fig. 3. Flowchart of the main program.
• analog inputs module (AIM)
• power supply. TABLE III
PLC CONFIGURATION
Other details of the PLC configuration are shown in Tables III
and IV.
A speed sensor is used for the speed feedback, a current
sensor is used for the load current feedback, and a second
current sensor is connected to the stator circuits [32]. Thus,
the two feedback loops of the closed-loop system are setup by
using the load current sensor, the speed sensor, and the AIM.
A tachogenerator (permanent magnet dc motor) is used for
speed sensing. The induction machine drives its shaft mechani-
cally and an output voltage is produced, the magnitude of which ical rather than numerical computational algorithms. Most of
is proportional to the speed of rotation. Polarity depends on the the programmed operations work on a straightforward two-state
direction of rotation. The voltage signal from the tachogener- “on or off” basis and these alternate possibilities correspond to
ator must match the specified voltage range of the AIM (0–5 V “true or false” (logical form) and “1 or 0” (binary form), respec-
dc and 200-k internal resistance). Other PLC external control tively. Thus, PLCs offer a flexible programmable alternative to
circuits are designed using a low-voltage supply of 24 V dc. electrical circuit relay-based control systems built using analog
For the manual control, the scheme is equipped with start, devices.
stop, and trip push buttons, as well as with a forward and back- The programming method used is the ladder diagram
ward direction selector switch. As shown in Fig. 2, all of the method. The PLC system provides a design environment in the
described components: a main switch, an automatic three-phase form of software tools running on a host computer terminal
switch, an automatic single phase switch, a three-phase thermal which allows ladder diagrams to be developed, verified, tested,
overload relay, a load automatic switch, signal lamps (forward, and diagnosed. First, the high-level program is written in ladder
backward, start, stop, trip), push buttons (start, stop, trip), a se- diagrams, [33], [34]. Then, the ladder diagram is converted
lector switch (for the forward/backward direction of rotation), a into binary instruction codes so that they can be stored in
speed selector, a gain selector, as well as the PLC modules and random-access memory (RAM) or erasable programmable
read-only memory (EPROM). Each successive instruction is
the rectifier-inverter are installed in a control panel. The pro-
decoded and executed by the CPU. The function of the CPU
gram is downloaded into the PLC from a personal computer PC
is to control the operation of memory and I/O devices and to
and an RS232 serial interface.
process data according to the program. Each input and output
connection point on a PLC has an address used to identify
V. SOFTWARE DESCRIPTION the I/O bit. The method for the direct representation of data
PLC’s programming is based on the logic demands of input associated with the inputs, outputs, and memory is based on the
devices and the programs implemented are predominantly log- fact that the PLC memory is organized into three regions: input
472 IEEE TRANSACTIONS ON ENERGY CONVERSION, VOL. 19, NO. 3, SEPTEMBER 2004

TABLE IV
PLC MODULES AND I/O DESIGNATION

image memory (I), output image memory (Q), and internal

memory (M). Any memory location is referenced directly using
%I, %Q, and %M (Table III).
The PLC program uses a cyclic scan in the main program loop
such that periodic checks are made to the input variables (Fig. 3).
The program loop starts by scanning the inputs to the system
and storing their states in fixed memory locations (input image
memory I). The ladder program is then executed rung-by-rung.
Scanning the program and solving the logic of the various ladder
rungs determine the output states. The updated output states are
stored in fixed memory locations (output image memory Q).
The output values held in memory are then used to set and reset
the physical outputs of the PLC simultaneously at the end of the
program scan. For the given PLC, the time taken to complete
one cycle or the scan time is 0, 18 ms/K (for 1000 steps) and
with a maximum program capacity of 1000 steps.
The development system comprises a host computer (PC)
connected via an RS232 port to the target PLC. The host
computer provides the software environment to perform file
editing, storage, printing, and program operation monitoring.
The process of developing the program to run on the PLC
consists of: using an editor to draw the source ladder program,
converting the source program to binary object code which
Fig. 4. Flowchart of speed control software.
will run on the PLC’s microprocessor and downloading the
object code from the PC to the PLC system via the serial
communication port. The PLC system is online when it is in pushing the manual start pushbutton, the motor begins the ro-
active control of the machine and monitors any data to check tation. If the stop button is pushed, then the rotation stops. The
for correct operation. corresponding input signals are interfaced to the DIM and the
output signals to the DOM as shown in Table IV.
A. PLC Speed Control Software The AIM receives the trip signal from the stator current
In Fig. 4, the flowchart of the speed control software is illus- sensor, the speed feedback signal from the tachogenerator, and
trated. The software regulates the speed and monitors the con- the signal from the control panel. In this way, the PLC reads
stant speed control regardless of torque variation. The inverter the requested speed and the actual speed of the motor. The dif-
being the power supply for the motor executes this while, at the ference between the requested speed by the operator and the ac-
same time, it is controlled by PLC’s software. The inverter alone tual speed of the motor gives the error signal. If the error signal
cannot keep the speed constant without the control loop with is not zero, but positive or negative, then the PLC according to
feedback and PLC. the computations carried out by the CPU decreases or increases
From the control panel, the operator selects the speed setpoint the of the inverter and, as a result, the speed of the motor
and the forward/backward direction of rotation. Then, by is corrected.
IOANNIDES: DESIGN AND IMPLEMENTATION OF PLC-BASED MONITORING CONTROL SYSTEM FOR INDUCTION MOTOR 473

During motor operation, it is not possible to reverse its direc-

tion of rotation by changing the switch position. Before direc-
tion reversal, the stop button must be pushed.
For motor protection against overloading currents during
starting and loading, the following commands were pro-
grammed into the software.
i) Forward/backward signal is input to DIM.
ii) Speed setpoint signal , the load current , the stator
current , and the speed feedback signal are input to
AIM.
iii) At no load , if the speed set point is lower
than 20% or r/min, the motor will not start.
iv) At an increased load over 0, 4 N m (40% of rated
torque), , and a speed setpoint lower than 40%
or r/min, the motor will not start.
v) If the load is increased more than 1, 0 N m (rated torque)
and if the speed set point exceeds 100% or
r/min, the motor enters the cutoff procedure.
vi) In all other situations, the motor enters in the speed con-
trol mode and the speed control software is executed as
described in Subsection A.

C. Cutoff and Restart Motor Software

In Fig. 6, the flowchart of this software is shown.
• In overloading situations, the motor is cut off and the trip
lamp (yellow) is lit. The operator must release the thermal
relays and then must turn off the trip lamp by pushing trip
or stop button. The thermal relays are set to the motor rated
current 1, 5 A. Following this, the motor can be started
again.
• The motor can be cut off by the operator pushing the stop
button: the display of the actual speed is set to zero, the
start lamp (green) turns off, and the stop lamp (red) turns
on and remains lit for 3 s.
• The load must be disconnected immediately after the
motor cuts off and before the drive system is restarted.
The motor will not start before 3 s after cutoff even if the
Fig. 5. Flowchart of monitor and protection software.
start button is pushed.

The implemented control is of proportional and integral (PI)

type (i.e., the error signal is multiplied by gain , integrated,
VI. RESULTS
and added to the requested speed). As a result, the control signal
is sent to the DOM and connected to the digital input of the The system was tested during operation with varying loads
inverter to control variations. At the beginning, the operator including tests on induction motor speed control performance
selects the gain by using a rotary resistor mounted on the and tests for trip situations. The PLC monitors the motor oper-
control panel (gain adjust) and the AIM receives its voltage drop ation and correlates the parameters according to the software.
as controller gain signal (0–10 V). At the beginning, for reference purposes, the performance of
The requested speed is selected using a rotary resistor induction motor supplied from a standard 380 V, 50-Hz network
and the AIM reads this signal. Its value is sent to the AOM and was measured. Then, the experimental control system was op-
displayed at the control panel (speed set point display). Another erated between no load and full load (1, 0 N m) in the two
display of the control panel shows the actual speed computed different modes described in Section III:
from the speed feedback signal. A third display shows the load a) induction motor fed by the inverter and with PLC control;
torque computed from the load current signal in Newton-meters b) induction motor fed by the inverter.
(N m). Their corresponding signals are output to the AOM The range of load torque and of speed corresponds to the de-
(Table IV). sign of the PLC hardware and software as described in the pre-
vious sections.
B. Monitor and Protection Software The speed versus torque characteristics were studied in the
In Fig. 5, the flowchart of this software is shown. range 500–1500 r/min and is illustrated in Fig. 7. The results
474 IEEE TRANSACTIONS ON ENERGY CONVERSION, VOL. 19, NO. 3, SEPTEMBER 2004

Fig. 7. Experimental speed–torque characteristics with PLC and inverter.

tion. From a theoretical point of view, if we neglect magnetizing

current, an approximate value for the efficiency is
Fig. 6. Flowchart of cutoff/restart motor software.

show that configuration b) operates with varying speed-varying

load torque characteristics for different speed setpoints . where is the slip and are the stator and rotor winding
Configuration a) operates with constant-speed-varying load resistances, respectively. As can be seen from Fig. 7, the PLC-
torque characteristics in the speed range 0–1400 r/min and controlled system a) works with very low slip values, almost
0–100% loads. However, in the range of speeds higher than zero. In all speed and load torque conditions, the configuration
1400 r/min and loads higher than 70%, the system operates a) has a smaller slip than configuration b), thus the higher values
with varying-speed-varying-load and the constant speed was of efficiency can be justified and especially at high speeds and
not possible to be kept. Thus, for r/min both con- frequencies. At lower frequencies, the magnetic flux increases
figurations a) and b) have a similar torque-speed response. This and, thus, there is an increase in magnetizing current resulting
fact shows that PI control for constant speed as implemented in increased losses.
by the software with PLC is effective at speeds lower than 93% Fig. 9 shows the stator voltage versus stator frequency
of the synchronous. characteristics of the inverter with PLC control for the same
The efficiency for different values of was also studied. In range of speeds and torques as in Fig. 7. For each one of
Fig. 8, the efficiency is shown normalized, using as base value the speed–torque characteristics from Fig. 7, the relationship
or 1 p.u. the efficiency of the induction motor supplied from the between stator voltage and stator frequency is constant. How-
standard network. As depicted in Fig. 8, the results show that ever, this relationship, which corresponds to the motor flux,
configuration a) in all cases has a higher efficiency than con- increases with the decrease of frequency from 8, 3 at 50 Hz up
figuration b). Also, at operation with loads higher than 70%, to 11, 25 at 12 Hz, as shown in Fig. 10. Thus, as can be seen
the normalized efficiency is , meaning that the ob- from Fig. 7, where the available torque decreases from 100%
tained efficiency with PLC control is higher than the efficiency at 50 Hz up to 60% at 20 Hz, when both voltage and frequency
of induction motor operated from the standard 380-V, 50-Hz decrease, there is an increase in magnetic flux with a decrease
network without the control of PLC and without the inverter. Ac- of maximum available torque.
cording to this figure, the efficiency of PLC-controlled system is The regulator gain is plotted in Fig. 11 for all speed and
increased up to 10–12% compared to the standard motor opera- torque ranges. The results show that it presents an almost linear
IOANNIDES: DESIGN AND IMPLEMENTATION OF PLC-BASED MONITORING CONTROL SYSTEM FOR INDUCTION MOTOR 475

Fig. 10. Rate for stator voltage/stator frequency.

Fig. 8. Efficiency of controlled system with and without PLC per unit of
efficiency of standard supplied motor.

Fig. 11. Control characteristics of PLC.

VII. CONCLUSION
Successful experimental results were obtained from the pre-
viously described scheme indicating that the PLC can be used
Fig. 9. Stator voltage versus frequency characteristics of an inverter with PLC in automated systems with an induction motor. The monitoring
control.
control system of the induction motor driven by inverter and
controlled by PLC proves its high accuracy in speed regulation
variation with for varying loads, with small displacements at constant-speed-variable-load operation.
between characteristics. The effectiveness of the PLC-based control software is satis-
This system presents a similar dynamic response as the factory up to 96% of the synchronous speed. The obtained ef-
closed-loop system with speed control. Its transient per- ficiency by using PLC control is increased as compared to the
formance is limited due to oscillations on torque [32] and this open-loop configuration of the induction motor fed by an in-
behavior restricts the application of this system to processes verter. Specifically, at high speeds and loads, the efficiency of
that only require slow speed variation. PLC-controlled system is increased up to 10–12% as compared
476 IEEE TRANSACTIONS ON ENERGY CONVERSION, VOL. 19, NO. 3, SEPTEMBER 2004

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