Industrial Shields®’s Post

Can a Variable Frequency Drive (VFD) be simulated on a PC? 1. What is a VFD? A Variable Frequency Drive (VFD) is fundamentally: A power stage (rectifier + DC link + inverter) that converts AC line power into a controlled-frequency, controlled-voltage AC output for a motor. A control stage (DSP/PLC logic, feedback loops, PWM generation) that manages torque, speed, ramping, etc. So it’s both software/firmware (control algorithms) and hardware (high-power semiconductors, filtering, protection). 2. Can it be simulated on a PC? Yes (partially): The control algorithms of a VFD can be simulated virtually on a PC — using tools like MATLAB/Simulink, PSIM, or even custom C/C++/Python code. You can model PWM signals, feedback loops, motor dynamics, etc. No (fully): The actual power electronics stage can’t be “virtualized” because it’s tied to switching high voltages and currents. A PC doesn’t have power electronics hardware, so you can’t directly feed a real motor virtually from a PC. In practice, this means you can digitally twin the control side and simulate the electrical side, but you cannot replace the physical drive. 3. What would prevent full virtualization in an industrial automation setting? Several factors: Power interface: A VFD must deliver kilowatts of actual power to motors. A PC can’t source or sink that. You’d need real IGBTs/MOSFETs and a DC bus. Real-time constraints: VFD controllers run on DSPs with microsecond-level PWM precision. A standard PC OS (Windows/Linux) can’t guarantee this level of deterministic timing without specialized real-time kernels. Isolation & safety: Industrial VFDs have safety layers (fault protection, overcurrent trips, ground fault, safe torque off). Virtualizing would remove the physical safety layers needed for real-world use. Industrial certification: Drives must comply with standards (IEC, UL, CE, etc.). A “virtual drive” can’t directly meet compliance for machine safety and EMC. I/O & fieldbus: While communication protocols (Modbus, EtherCAT, Profinet) can be emulated, the physical power wiring to the motor cannot. 4. Where virtualization is used today Digital twins: Virtual VFDs are used in simulation to test control logic and system behavior before deploying. Soft starters & motor models: Engineers simulate motor acceleration/deceleration with virtual drive software. PLC/HMI training simulators: Operators can “run” a line virtually with a simulated VFD that mimics feedback values and faults. Hardware-in-the-loop (HIL): Real drive controllers are tested against PC-based motor and plant models before connecting to actual motors. Summary: On a PC, you can simulate the brains of a VFD (control logic, communication, feedback loops), but not the muscle (power electronics). In industry, this means VFDs can be virtualized for training, development, and testing, but in real operations they can’t be replaced — because you need the hardware to physically deliver controlled power to motors.

"Unlocking Precision and Efficiency with PLC Automation!"- 1️⃣ Power Supply: The PLC system relies on a power supply to provide the necessary electrical energy to all components, ensuring continuous operation. #PLCAutomation #PowerSupply 2️⃣ Central Processing Unit (CPU): The CPU acts as the brain, executing control commands by processing input data and generating output signals. It interprets the program stored in memory. #PLCProgramming #CPU 3️⃣ Memory: Divided into program memory (stores the control logic) and data memory (holds runtime variables), memory is crucial for the PLC's operation and data management. #PLCMemory #AutomationTech 4️⃣ Input Sensing Devices: These devices, like sensors and switches, detect physical conditions (e.g., temperature, pressure) and send signals to the PLC via optical isolation for processing. #InputDevices #SensorTechnology 5️⃣ Output Load Devices: Controlled by the PLC, these include actuators, relays, and motors that execute actions based on CPU-processed data, also protected by optical isolation. #OutputDevices #IndustrialAutomation 6️⃣ Optical Isolation: This safeguards the PLC from electrical noise and voltage spikes by isolating input/output modules from the CPU, enhancing system reliability. #OpticalIsolation #SystemSafety 7️⃣ Programming Device: A computer or HMI is used to write, edit, and download the control program to the PLC’s memory, enabling system configuration. #ProgrammingDevice #HMIAutomation ⭐⭐⭐Working Operation: The PLC system operates in a cyclic process. Input sensing devices collect data, which is transmitted through optical isolation to the CPU. The CPU processes this data using the program stored in memory and sends commands to output load devices via optical isolation. This cycle repeats, ensuring real-time control and automation of industrial processes. # 👉👉👉The diagram illustrates a robust PLC setup, ideal for efficient automation. #Engineering #TechInnovation #AutomationSolutions #IndustrialControl #PLCOperation

TDK Intros HWS3000G Programmable Batteries: NATIONAL CITY, CA — TDK Corporation (TSE 6762) announces the introduction of the 3000 watt TDK-Lambda brand HWS3000G programmable AC-DC power supplies. The nominal output voltages and output currents are fully programmable (CV/CC) from zero up to their maximum rating. These new models have an /HD option for board coating and the ability to meet MIL-STD-810G Shock and Vibration in harsh environments. The /RF option provides the ability to have the airflow direction reversed for compatibility with the user’s end system. The HWS3000G can deliver 1500W with a low-line single-phase input voltage (85 to 132Vac) and 3000W at high-line (170 to 265Vac). Four nominal output voltages, 24V, 48V, 60V and 130V, can be programmed to provide 0 - 28.8V, 0 - 52.8V, 0 - 66V, and 0 - 156V. Up to three units can be connected in series, or ten units in parallel. The output voltage slew rate can be digitally programmed and monitored, along with information regarding cumulative operating time, fault log, and product identification information. Digital programming can be performed without turning the power supply on. Output programming can be achieved using a serial RS485 interface (MODBus protocol) or analog 1 - 5V or 4 - 20mA signals. These very compact products also feature a variable speed fan with typically 45dB audible noise at http://dlvr.it/TMJ3j1

Memory Areas in Siemens S7-1200 PLCs Every memory location in a PLC has a unique address. Your user program accesses these addresses to read or write data. In Siemens S7-1200, memory areas are categorized based on: 🔹 Function 🔹 Accessibility 🔹 Retention behavior Process Image vs Physical Access Process Image: Inputs (I) and Outputs (Q) are copied once per scan cycle into internal memory. Example: I0.3, Q1.7 refer to the process image. Physical Access: To read/write the actual hardware state immediately, append ":P". Example: I0.3:P, Q1.7:P, or symbolic tag like "Stop:P" Key Notes for Programming ✅ Use :P suffix for real-time access to hardware I/O ✅ Forcing is allowed only on physical I/O (I_:P, Q_:P) ✅ Retentive memory retains values after power loss—ideal for flags, counters, set points ✅ Temporary memory is cleared after each block execution—use for local calculations This concept is essential for mastering scan cycles, optimising logic, and troubleshooting I/O behaviour in real-world automation systems. Let’s make learning easier—share your thoughts to simplify this concept for students. #PLCProgramming #SiemensS7 #IndustrialAutomation #SCADA #Mechatronics #AutomationTraining #EngineeringEducation #SkillDevelopment #NovatechSolution #DigitalLearning #Industry4.0 #LinkedInLearning #PLCLogic #AutomationIndia

What Makes a PLC Advanced in Today’s Industrial Environment? A modern advanced PLC goes far beyond simple relay logic or on/off control. It plays a critical role in smart factories, enabled systems, and real time industrial data processing. As industrial systems evolve with the integration of IIoT, edge computing, and smart manufacturing, the role of PLC programming languages has become more critical than ever. Under the IEC 61131-3 standard, there are five primary programming languages used to develop scalable and robust control logic for PLCs: 1_ Structured Text (ST) – Preferred for advanced control strategies, mathematical computations, and integration with high-level systems. 2_ Function Block Diagram (FBD) – Ideal for continuous process control, PID tuning, and modular design. 3_ Ladder Diagram (LD) – Still widely used in discrete manufacturing for its readability and maintenance simplicity. 4_ Sequential Function Chart (SFC) – Optimal for batch processing, step-sequencing, and complex workflows. 6_ Instruction List (IL) – Now largely deprecated but relevant in legacy systems. Example: Advanced PLC Use Case In an automated bottling plant:- A_ The PLC synchronizes 50+ servos. B_ Sends real-time data to the cloud via MQTT. C_ Runs local fault detection algorithms. D_ Ensures functional safety (SIL3 logic). E_ Provides predictive maintenance insights to operators. #IndustrialPLC #AdvancedAutomation #SmartFactory #IIoT #ControlSystems #EdgeComputing #TIA #Rockwell #Siemens #SCADA #Industry40 #PLCProgramming #OpenToWork

🔄 Power System Oscillations: Visualizing the Grid as a Mechanical Playground ⚙️⚡ When a power system experiences a disturbance — like a generator tripping or a sudden change in load — it doesn’t just calmly settle into a new operating point. Instead, something fascinating happens... It oscillates. Power swings back and forth. Voltages ripple. Machines start to behave like they’re "shaking hands across long distances." But why? Let’s dive into a simple yet powerful mechanical analogy that brings this behavior to life. 💡 🏗️ A Mechanical Model of the Grid: Imagine each generator in your power system is represented by a weight suspended by rubber bands. 🏋️ Heavier weights represent larger generators — they have more inertia, and resist changes in speed. 🧵 The rubber bands are the transmission lines — specifically, their inductive reactance. 🏔️ An infinite bus (a very strong, stable grid) is like a solid ceiling to which all rubber bands are tied. It doesn’t move, no matter what we do in our local system. Now, give one of the weights a tug — maybe you pull it to the side and release. What happens? Just like in the power grid, that weight starts oscillating. The motion spreads through the rubber bands, making other weights start swinging too. This is exactly how power oscillations behave across geographically distributed generators! 🧠 What This Analogy Teaches Us About Power Systems: 1️⃣ Inertia Defines the Oscillatory Character Large generators (heavier weights) are harder to start moving — they have high inertia. But once they start, their oscillations persist longer. Small generators (light weights) start oscillating easily, but their motion damps out quickly. 🔁 This is why inertia plays a stabilizing role in power systems — it slows down frequency deviations and helps absorb shocks. 2️⃣ System Strength = Rubber Band Thickness Thicker bands = stronger electrical connections → lower reactance, better damping. Thinner bands = weak grid → higher oscillation amplitude. If a large enough oscillation occurs in a weak connection, the “rubber band” may snap — just like a generator going out-of-step. 💥 Tripping a transmission line is like cutting a rubber band. The more critical the line, the greater the disturbance that follows. 3️⃣ Location & Propagation of Oscillations If you tug a weight near the infinite bus (a strong grid), the system absorbs the oscillation well. But disturb a remote generator tied with thin bands? The motion spreads far and wide, amplifying the impact. This mimics how inter-area oscillations arise — where clusters of machines across regions swing against each other at frequencies between 0.2 to 0.7 Hz. 4️⃣ Oscillation Frequencies Vary by Scope Local oscillations (within one plant or nearby machines): ~1–2 Hz. Inter-area oscillations (wide-area swings): ~0.2–0.7 Hz. Sub-synchronous resonance (e.g., generator-turbine systems) — dangerous and fast.

We at #CMSys provide an industrial control systems that utilize sophisticated hardware and software to manage and automate complex industrial processes. 💡Key Features of #CMSys Advanced PLC Systems: ✨ High-Speed Processing ✨ Multi-Core Architecture ✨ Large Memory Capacity ✨ Advanced Communication Protocols ✨ Sophisticated Programming ✨ Motion Control and Robotics Integration ✨ Scalability ✨ Enhanced Security (NIS2) 🎯Benefits of #CMSys Advanced PLC Systems: ✨ Increased Efficiency: Advanced PLCs can optimize processes, leading to increased productivity and reduced downtime.  ✨ Improved Precision and Accuracy: Faster processing and advanced control algorithms lead to more precise and accurate control of industrial processes.  ✨ Reduced Costs: Increased efficiency and reduced downtime can lead to significant cost savings.  ✨ Enhanced Flexibility and Adaptability: Advanced PLCs can be easily reprogrammed and adapted to changing needs and requirements.  ✨ Improved Safety: Advanced safety features and integration with safety systems can improve the overall safety of industrial operations. 💣Reach out to us to schedule a meeting to explore the possibilities of digitalization and automatization for your production processes. (E: cmsys@cmsys.cz). #CMSys ✨FUTURE-DRIVEN DIGITALIZATION✨ #picktolight #manufacturingsystems #digitalization #digital #control #system #effectivity #CMSys #Automation #IndustrialAutomation #ConveyorSystems #systemintegrators #SoftwareDevelopment #Teamwork #OEE #automotive #aerospace #FMCG #logistics #railindustry #railway #plasticproduction #defenceindustry #glassmaking #agriculture #precisionmachining #CNC #finance #administration #foodandbeverages #heavyindustry #warehousingsolutions #logistics #PLCsystems #qualitycontrol #robotics  #roboticsengineering #andonsystems #vision #CMSteam

Learn Together 😇 (Part 11) ⭕ Role of the Electronic Control Module in engines: The ECM ensures the smooth operation of the engine by monitoring and collecting data from sensors positioned throughout the engine and vehicle. This data flow allows the ECM to not only optimize engine performance but also adjust critical parameters like fuel consumption and ignition timing, thereby playing a pivotal role in enhancing engine efficiency while reducing fuel usage. The ECM also conducts diagnostics, a vital tool for mechanics and technicians to conduct preventative maintenance or troubleshoot if issues arise. In the event of an engine malfunction, the ECM records a series of unique fault codes that are specific to the problem. ⭕ What are the components of the Electronic Control Module (ECM)?  ✔️ Microcontroller: It controls and coordinates the actions of all other components in the system. It receives raw data from various sensors located throughout the engine. The microcontroller processes this data and converts it into actionable insights. This allows the engine to respond to different operating conditions and demands. ✔️ Memory: The ECM’s memory includes read-only memory (ROM) and random-access memory (RAM). ROM is the permanent storage for crucial software like the ECM’s operating system and firmware, which controls the ECM's basic operations. RAM temporarily stores data about the engine's current state, enabling the ECM to adjust engine performance in real time. Input/Output (I/O) ports: The I/O ports are the ECM's communication channels. They connect with the vehicle's sensors and other components and help enable data flows. ✔️ Analog-to-Digital Converter (ADC): Microcontrollers need information in digital format for processing information. The ADC converts analog signals from the vehicle's sensors into digital signals for the ECM. Voltage Regulator: The voltage regulator maintains the steady voltage supply from the vehicle's battery to the ECM. A constant voltage supply is essential for the ECM to perform tasks accurately and reliably like maintaining optimal engine speed under various load conditions. ✔️ Clock: The clock synchronizes the microcontroller within the ECM. By keeping the ECM's operations timed correctly, it ensures smooth engine operation. It helps determine the precise firing of spark plugs, a vital action for proper engine combustion. If the spark plugs do not fire at the right time it can result in incomplete combustions which can lead to increased emissions.  ✔️ Power Capacitor: The power capacitor stabilizes the ECM's voltage supply during sudden changes or voltage spikes. This stability is critical for maintaining the ECM's accuracy and reliability. ⭕ Source: https://lnkd.in/dQQK78td

For electronics engineers working in the environmental field, here is a precise sensor for measuring environmental parameters: The BME688 is a 4-in-1 environmental sensor developed by Bosch Sensortec, capable of detecting gases, temperature, humidity, and barometric pressure. Main features: Integrated environmental sensor: Combines gas detection, temperature, humidity, and barometric pressure measurement capabilities in a single module. AI function: The BME688 is the first gas sensor compatible with artificial intelligence (AI) algorithms to detect various gas compositions by measuring their unique electronic fingerprint. Compact design: With a size of n3.0 × 3.0 × 0.93 mm³, it is ideal for mobile and connected applications where size and low power consumption are crucial. Wide range of applications: Perfect for measuring indoor and outdoor air quality, smart home applications, and devices requiring precise environmental monitoring. Interface: Compatible with I²C and SPI interfaces for data communication with microcontrollers. Development: Configurable and optimized through Bosch’s BME AI-Studio software, designed for general users with an intuitive interface.

I want to remind you of this incredible device! 😲😃 The BME688 is a 4-in-1 environmental sensor from Bosch Sensortec. It's a small, integrated device that measures: - Temperature - Barometric Pressure - Humidity - Air Quality (Gas) What makes the BME688 unique is its built-in Artificial Intelligence (AI) capabilities. This feature allows the sensor to "scan" and "learn" specific gas and odor signatures, making it highly customizable for a wide range of applications. 🔝🤓📈 Paradox Engineering MinebeaMitsumi Europe Bosch