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Research Article
A Real-Time Temperature Data Transmission Approach for
Intelligent Cooling Control of Mass Concrete
Copyright 2014 Peng Lin et al. This is an open access article distributed under the Creative Commons Attribution License, which
permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.
The primary aim of the study presented in this paper is to propose a real-time temperature data transmission approach for intelligent
cooling control of mass concrete. A mathematical description of a digital temperature control model is introduced in detail. Based
on pipe mounted and electrically linked temperature sensors, together with postdata handling hardware and software, a stable,
real-time, highly effective temperature data transmission solution technique is developed and utilized within the intelligent mass
concrete cooling control system. Once the user has issued the relevant command, the proposed programmable logic controllers
(PLC) code performs all necessary steps without further interaction. The code can control the hardware, obtain, read, and perform
calculations, and display the data accurately. Hardening concrete is an aggregate of complex physicochemical processes including
the liberation of heat. The proposed control system prevented unwanted structural change within the massive concrete blocks
caused by these exothermic processes based on an application case study analysis. In conclusion, the proposed temperature data
transmission approach has proved very useful for the temperature monitoring of a high arch dam and is able to control thermal
stresses in mass concrete for similar projects involving mass concrete.
the process directly. In DDC systems, analog controllers were to be transmitted in relation to temperature control during
no longer used. In 1970s, microcomputers have already made concrete block pouring.
a great impact on the process control field. They are replacing This paper, relating to a real-time temperature data trans-
analog hardware even as single loop controllers [15]. Multiple mission approach at a super high arch dam site, presents a
loop single computer systems have variability interface and detailed description of certain aspects of a control system
software design. The distributed computer control system that is intended to ensure the structural integrity of massive
(DCCS) was developed, which is facilitated by adopting a concrete structures during the construction process. The
multilevel or hierarchical viewpoint of control strategy. On cooling control system prevents unwanted structural changes
the lowest level of control, main tasks handled acquisition within massive concrete blocks by carrying away the heat
of process data and collection of data. For complex process generated by the exothermic processes of cement hydration.
plant monitoring, supervisory control and data acquisition The proposed temperature transmission approach collects
(SCADA) systems are available. The basic functions of temperature data from many sensors and prevents the hard-
SCADA system include data acquisition and communication, ening concrete from overheating by controlling the water
events and alarms reporting, data processing, and partial flow inside the cooling pipes constructed within the concrete
process control. The other main and early application area structure. The temperature transmission system includes
of digital methods was machine tool numerical control, the acquisition of temperature data, management of vari-
which developed at about the same time as computer control ous intelligent modules, temperature data handling, sorting
in process industries, for example, numerically controlled and filtering, and temperature data transfer to the module
(NC), computerized numerical control (CNC), and direct control server. The detailed PLC software configuration and
numerical control (DNC). One of the most ingenious devices programming are also illustrated. An application case of
ever devised to advance the field of industrial automation is temperature monitoring of the Xiluodu arch dam during the
the PLC. The PLC, a microprocessor-based general-purpose construction period is discussed in detail. The paper aims
device, provides a menu of basic operations that can be to provide a convenient solution to the process of cooling
configured by programming to create logic control system for control via the pipes in a situation where the laying of cables
any application [16]. Thus, the recent appearance of powerful is not possible.
and inexpensive microcomputers has made digital control
practical for a wide variety of applications. In fact, now every
process is a candidate for digital control [17]. 2. Temperature Digital Data
Digital data transmission technologies have attracted the Transmission Approach
attention of many researchers and engineers in recent years
[1827]. For example, Italiano et al. [19] developed the SMM, 2.1. Mathematical Description of Digital Temperature Control
sea-floor monitoring module, for real-time data transmission Model. In this study, each basic poured block temperature
from the sea bottom, equipped with multidisciplinary sen- control unit has a fixed structure (see Figure 1): one electric
sors. Bayindir and Cetinceviz [20] describe a water pumping solenoid proportional valve, one outlet water flow transmitter
control system designed for production plant and imple- and two or more temperature sensors installed at the water
mented experimentally in a laboratory. An intelligent system pipe inlet and outlet, adjacent concrete temperature, and so
for distributed control of an anaerobic wastewater treatment forth. The mass concrete temperature control kernel collected
process was developed by Flores et al. [21]. Language of all the data and commanded the execution of individual
temporal ordering specification (LOTOS) was used in the control actions indirectly via the PLC system, which was
specification of industrial bus communication protocols [22]. easily set up to handle the field bus.
Communication structures have been used for sensory data In this study, a prerequisite signal processing technique
in mobile robots [23], and the network is used as a bus system was used [10, 11] as the proposed closed-loop digital control
for long discharge data acquisition and data processing [24]. system for mass concrete cooling on a construction site.
The timing behaviour of real-time stations in legacy bus based The digital control system with analog sensors (flow sensor,
industrial Ethernet networks has been enforced [25]. A study thermometer) included an analog prefilter placed between
on real-time sensor signal transmission based on polynomial the sensor and the sampler (A/D converter) as antialiasing
predictive filtering technology has also been carried out device, shown in Figure 2. The prefilters are low-pass, and the
by Dong et al. [27]. Connecting PLC to control and data simplest transfer function is used:
acquisition enabled a comparison of the Joint European
Torus (JET) and Wendelstein 7-X approaches to be made pf () = , (1)
+
[26]. These studies have demonstrated convenient solutions,
reliable operation, and robust and flexible construction suit- so that the noise above the prefilter breakpoint was attenu-
able for industrial applications. However, few studies were ated. The design goal is to provide enough attenuation at half
concerned with the cooling control of mass concrete in a the sample rate ( /2) so that the noise above /2, when
dam under complex electromagnetic environment, especially aliased into lower frequencies by the sampler, will not be
the problem of the large quantity of temperature digital data detrimental to the control-system performance.
Mathematical Problems in Engineering 3
Multichannel
temperature logger
Control server
Cooling pipe
Analog Sensors
prefilter H(s)
For this cooling control system, the basic configuration output modules which are cyclically converting the A/D
and block diagram are shown in Figure 2, where or D/A signals. Mathematical models generally are used to
represent the digital control devices and the system. The
() = transfer function of the controlled system A/D converter model [14] used in this system is shown
(continuous-time system); in Figure 3(a). For the field temperature control process, a
() = transfer function of the analogue sensor; continuous-time function(), 0, is the input and the
() = transfer function of the digital control algo- sequence of real numbers (), = 0, 1, 2, . . ., is the output.
rithm. The following relationship holds between input and output:
The analogue and digital parts of the system are con- () = ( = ) , (2)
nected through D/A and A/D converters. The server with
its internal clock drives the D/A and A/D converters. It where is the sampler time interval between enquiring flow
compares the command signal () with the feedback signal or temperature and acquiring the result. The sequence ()
() and generates the control signal () to be sent to the can be treated as a train of impulses represented by the
final control elements of the cooling control system. These continuous-time function ():
signals are computed fusing the digital control algorithm
(), stored in the memory of the compute server. () = (0) () + (1) ( )
To suit the complications of a real construction site,
(3)
the field bus is designed to link the sensors and actuators: + (2) ( 2) + = () ( ) .
the Profibus network links all the analogue signal input and =0
4 Mathematical Problems in Engineering
(1) AAN (CR). The command name: to read all the sensors
0 k 0 t ID linked to the channel of the specified intelligent
f (t) f (t) module (ranging from 00 h to FF h); here CR is the
f(k) sT
gh0 (s) = 1 e /s
T carriage return character (ASCII code 0Dh).
Each ID is preset by a handy tool or PC software to escape
(b)
the same numbering on the same channel.
Figure 3: A model of an A/D or D/A converter.
(2) #AAN (CR). The command name: similar to the above
; this command tries to read all the sensors data
The model of D/A converter is shown in Figure 3(b). A linked to the channel of the specified intelligent module
sequence of numbers (), = 0, 1, 2, . . ., is the input, and .
the continuous-time function (), 0, is the output. The The above two frequently used commands enable PLC to
following relationship holds between input and output: get exactly the total numbers and numbering of linked sen-
sors, as well as their current temperature values.
() = () ; < ( + 1) . (4)
2.2.2. Data Handling, Sorting, and Filtering. As long as there
Each sample of the sequence () may be treated as an is a valid response from the intelligent module, the temper-
impulse function of the form()( ). The zero-order ature digital data will be first transferred into a data buffer,
hold (ZOH) of Figure 3(b) can thus be viewed as a linear which is previously defined in the PLC, and then analyzed
time-invariant system that converts the impulse ()() according to the predefined data format. The standard func-
into a pulse of height () and width . The D/A converter tion block for the PLC will copy the data from the RS485
may, therefore, be modelled by Figure 3(b), where the ZOH network to that buffer and generate a pulse indicating that
is a system whose response to a unit impulse () is a unit new data is coming; the user program will fetch the channels
pulse 0 () of width . The Laplace transform of 0 () is the related data and copy them to corresponding data block
transfer function of the hold operation; namely, according to the current counter.
Since channel data sets are separated, the PLC decides
1
0 () = . (5) whether they are valid or not on the basis of the received
telegram header (here > means data are valid). The program
will then transfer the raw temperature data into standardized
2.2. Temperature Digital Data Transmission. For dam tem- format (floating type). For the specific LTM8663 module used
perature control system, shown in Figure 1, the temperature in this system, the original temperature data format is 16# A
sensors sampling time could be as long as one minute. A (byte 1) B (byte 2), and the conversion formula is
Profibus network and corresponding modules would domi-
nate the control cost unnecessarily and therefore a lower cost [256 (&16#7) + ]
field bus called ITU was engaged. An intelligent module can = . (6)
16
transfer the ITU signals into RS485 protocol, which most
kinds of PLC support. The intelligent temperature module, According to the LTM8663 specification, the RS485 com-
which has 8 channels, can link a maximum of 256 different munication protocol is ASCII, and the parameters should be
ITU sensors usually via three core cables. After initialization, configured in the hardware interface as; the speed transmis-
the module can exchange the digital data with PLC basis of sion rate is 9,600 bps, data bits are 8, stop bits is 1, and the
RS485 protocol. One RS485 master can communicate with operating mode is half duplex (RS485) two-wire mode.
127 slaves and this means one PLC CPU can acquire up to After the PLC program has distinguished the total num-
32,512 ITU temperature sensors. In this control system, the ber of sensors of the module, each ID, and actual data, it is
Siemens Simatic S7-300 PLC was used as the data bridge not difficult to sort and copy them to the right offset location
between the control model computer and the field sensors in the summary data block. Obviously, each sensor ID in
and actuators. The specified PLC programming language one module must be unique. The summary data block is the
FBD (function block diagram) and standard function library transmission information to the module control server.
Mathematical Problems in Engineering 5
Network 14: Sending to the intelligent module Network 16: Receiving from the intelligent module
Comment: Comment:
DB8
FB8 DB7
... EN FB7
... L TYP . . .
SF ... EN
M200.2 REQ The logic address of L NO . . .
... CP341 module M201.0 EN R
R
L OFFSET . . .
512 LADDR ... R
DB NO L CF BYT . . .
20 512 LADDR
The telegram from PLC to
0 DBB NO L CF BIT . . .
the intelligent module 30 DB NO
5 LEN
NDR M202.0
... R CPU NO 0 DBB NO
... R TYP ERROR M202.1
... R NO DONE M201.0 LEN . . .
The telegram from the
... R OFFSET ERROR M201.1 intelligent module to PLC
STATUS MW206
... R CF BYT STATUS MW204
... R CF BIT ENO ENO
Figure 4: Function blocks for communication between CP341 and LTM8663 modules.
2.3. Management of Various Intelligent Modules. On the dam (RS485), temperature digital data treatment, filtering and
construction site, thousands of sensors were installed on the sorting, communication with the module server (TCP/IP),
cooling pipes or cast inside the concrete, enabling various and the cooling water PID control.
identified intelligent modules to be linked to PLC via RS485
network; PLC software autodecided the polling strategy for 3.1. Communication with the Intelligent Module LTM8663.
the whole network to avoid data acquisition conflicts. To poll The standard function block FB7 and FB8 (P SND RK)
each module and channel cyclically, a counter is utilized to are designed for RS485 communication structure, shown in
differentiate the time frames for each task. In addition, the Figure 4.
PLC sends two different commands for each channel since the The CP341 module is an extended communication pro-
time interval must be considered. The brief polling sequence cessor which supports RS422 and RS485 protocol. The data
is illustrated in [10]. block DB20 stores the inquiring command (5 bytes) to the
To achieve communication between CP343-1 and the intelligent module, and DB30 is the receiving data buffer from
module server, the server must be configured in the Simatic the module. The execution of FB7 and FB8 is separated by
manager. The module server is taken as another station logic.
here, and in the net two connections should be established
for sending and receiving. For the Transmission Control 3.2. Temperature Digital Data Analysis. When the specific
Protocol (TCP) connection; the port addresses of both parties channel temperature digital data is recognized, it is trans-
should be fixed. ferred from DB30 to another data block for handling. For
The real-time data transmission from concrete construc- example, DB31 handles raw data coming from channel 1,
tion site to the remote module control server was achieved module 0. As the total number of sensors and each ID is
using an industrial Ethernet communication board, with known by the program, each temperature value can be con-
TCP/IP protocol. Depending on the distance, a fibre optic verted into target floating format. The source code below con-
converter or a wireless AP can be used for the data bridge. verts the data according to (6).
The standard PLC Ethernet communication function block After the treatment, the sensor actual values are copied to
can easily transfer the data block contents to the target server. a summary data block (e.g., DB10 for module 0). The offset
The network structure is independent of the sensors. If one in the data block will follow the ID. For example, the offset
or several sensors fail, the master can still read data from address for the sensor ID 3 is 12 as in Table 1.
other sensors. After replacement, the sensors can be accessed
again as the master collects the data on the whole network 3.3. Communication with the Module Server. Two other
repeatedly. standard functions (FC50 and FC60) are used for the TCP/IP
communication with the module server, as shown in Figure 5.
3. PLC Code Configuration The Ethernet port is integrated in the CPU module. The DB1
is the sending buffer which collects all the sensor information
In this study, the structured control language (SCL) was used and telegram time stamp, shown in Table 2.
as the PLC code. The FBD and the Standard Template Library The telegram length is 2022 bytes, including the title, tele-
(STL) included communication with the intelligent module gram label, length, telegram type, sending time, total circuit
6 Mathematical Problems in Engineering
Table 1: The PLC data structure of DB10 for communication with intelligent module.
Number Address offset Name Data type Comments
1 0 Module SN Integer Module serial number
2 2 Total sensors Real Total sensors number
3 4 Value ID1 Real SensorValue ID1
4 8 Value ID2 Real SensorValue ID2
5 12 Value ID3 Real SensorValue ID3
6 16 Value ID4 Real SensorValue ID4
.. .. .. .. ..
. . . . .
256 1016 Value ID254 Real SensorValue ID254
257 1020 Value ID255 Real SensorValue ID255
258 1024 Value ID256 Real SensorValue ID256
Table 2: The PLC data structure of DB1 for sending telegram to module server.
Number Address offset Name Data type Comments
1 0 Label String(4) Fixed as EDAM
2 4 Length Integer Telegram length
3 6 Tel type INT Telegram type
4 8 SendTime String(12) Format: YYYYMMDDHHMM
5 20 TotalNumber INT Total circuits
6 22 Telegram1 UDT1 User defined data type
.. .. .. .. ..
. . . . .
+5 ( 1) 10 + 22 Telegram() UDT1 User defined data type
.. .. .. .. ..
. . . . .
Table 3: The user defined type (UDT) for each circuit value as a template.
Number Address offset Name Data type Comments
1 0 Number Integer The circuit number
2 2 Mode Byte Mode, 1 = auto, 2 = manual
3 3 AlarmWarnning Byte 0 = OK, 1 = warning, 2 = alarm
4 4 InletTemp Integer Water inlet tmperature
5 6 OutletTemp Integer Water outlet temperature
6 8 ActFlow Integer Actual water flow
numbers, and every item of circuit data. Here a special UDT during construction [28, 29]. The project is located on the Jin-
(user data type, 10 bytes) is defined for each water cooling shajiang River, in the Leibo County of Sichuan province. The
circuit, including the serial number, auto- or manual mode, principal structures consist of a double-curvature arch dam
status, inlet and outlet temperature, and actual water flow, 285.5 meters high, crest length about 700 meters, spillway,
shown in Table 3. Correspondingly, the DB2 is the receiving underground powerhouse, and logway. A total of 6,000,000
buffer containing the commands for each circuit from the cubic meters of concrete were poured. Because of the high
module servers control strategy system. stresses in an arch dam structure and the construction
Similarly, the receiving telegram contains the label, process control difficulties, the basic temperature control
length, type, and command for each circuit and the personal- principle was to maintain ultimately small temperature differ-
ized control solution is then realized in this way. Every circuit ences between neighbouring areas of concrete by slow cooling
can have its own cooling water flow target set point or fixed and early cooling. The cooling process should be based on
water valve opening output. the concrete temperature measurement results taking into
consideration the partitioning of the concrete, pouring
temperature, water pipes, density of concrete, and ambient
4. Application Case Study temperature. The cooling water flow is adjusted in a timely
manner to meet the targeted temperature requirements.
4.1. Brief Introduction to Dam Site. The proposed method was A flexible network structure for field temperature mon-
applied to the temperature control of the Xiluodu arch dam itoring of the super high arch dam during construction was
Mathematical Problems in Engineering 7
Network 7: Sending telegram to module server Network 8: Receiving telegram from module server
Comment: Comment:
FC50 FC60
... EN The logic address of ... EN NDR M104.0
CPU Ethernet port
T32 ACT 2 ID ERROR M104.1
1 ID W#16#3FFC LADDR STATUS MW106
W#16#3FFC LADDR DONE M100.0 P#DB2. LEN MW108
DBX0.0
P#DB1. ERROR M100.1 BYTE 2048 RECV ENO
DBX0.0
BYTE 2048 SEND STATUS MW102
2048 LEN ENO
Figure 5: The PLC functions for TCP/IP communication with the module server.
-RS422 COM/+UR0/5.6
-RS422 COM+/+UR0/5.6
Figure 7: The circuit diagram for connecting the temperature sensors to the module.
-A3
Rack0
Slot3
8
SIEMENS
SM 331
AI 8 13 BIT
-W401 -W501 -W505 -W402
/4.1 1 CH0 U+ 21 /4.7
/4.1 CH4 U+ /4.8
3 0.75 +CBL1-X1 1 9 +CBL1-X1
3 0.75 2 CH0 I+ 22 3 0.75 3 0.75
1 1 V V CH4 I+ 1 1
+CBL1-XP2 1/+CBL1/3.4 S+ S S S+ +CBL1-XP2 2/+CBL1/3.4
3 CH0 S CH4 S 23
A A
1 -FT501 2 4 CH4 M+ 24 2 -FT505 1
CH0 M+
420 mA 5 25 420 mA
CH0 M CH4 M
-W502 6 26 -W506
/4.1 CH1 U+ CH5 U+ /4.7
3 0.75 +CBL1-X1 3 7 CH5 I+ 27 11 +CBL1-X1 3 0.75
1 CH1 I+ V V 1
CH5 S 28 S S+
S+ S 8 CH1 S A A
water flow transducers
29 2 1
1 -FT502 2 9 CH1 M+ CH5 M+ -FT506
420 mA
The inlet or outlet
30 420 mA
10 CH1 M CH5 M
-W503 -W507
/4.1 +CBL1-X1 11 CH6 U+ 31
CH2 U+ /4.7
3 0.75 5 12 32 13 +CBL1-X1 3 0.75
1 CH2 I+ V V CH6 I+ 1
S+ S 13 33 S S+
CH2 S CH6 S
A A
1 -FT503 2 14 CH2 M+ CH6 M+ 34 2 1
-FT507
420 mA 15 35 420 mA
CH2 M CH6 M
-W504 16 36 -W508
/4.1 CH3 U+ CH7 U+ /4.7
+CBL1-X1 7 15 +CBL1-X1
3 0.75 17 CH3 I+ CH7 I+ 37 3 0.75
1 V V 1
S+ S 18 CH3 S 38 S S+
CH7 S
A A
1 -FT504 2 19 39 2 1
CH3 M+ CH7 M+ -FT508
420 mA 20 CH3 M 40 420 mA
CH7 M
6ES7 331-1KF02-0AB0
+CBL1-XM1 1/+CBL1/2.4
Figure 8: The circuit diagram for connecting the temperature sensors to the module.
gradient. A web graphical user interface (GUI) was provided function, and (3) enabling a 3D real-time temperature field
for integrated query, analysis, and prewarning [1]. analysis be carried out, as illustrated in Figure 10. Based on
Based on the proposed temperature data transmission the real-time temperature field analysis, further stress fields
system, the intelligent cooling system overcomes the short- can be analyzed to study alternative temperature control
comings in traditional manually collected data systems, plans, not only limited to water flow, but the whole pipework
providing an effective dam concrete temperature control and scheme can be adjusted to more optimal configurations.
cracking prevention technology both advanced and more
intelligent. In particular the advances consist of (1) changing
5. Conclusions
simple manual data collection to real-time data acquisition
and feedback, (2) automatically obtaining large quantities This paper presents a real-time temperature data transmis-
of thermodynamic parameters with respect to every block sion approach for intelligent cooling control of early age mass
of poured concrete enabling a more customized control concrete based on A/D converter model and PLC technology.
Mathematical Problems in Engineering 9
-A4
Rack0
Slot4
8
SM 332 SIEMENS
AO 8 12 BIT
+CBL1-XP1 1/+CBL1/2.4 1/L+ 1
1/L+ 21
-W401
/3.1 -W501 2 22 -W402
-W505
3 0.75 /3.2 2 +CBL1-X1 +CBL1-X1 10 /3.7 /3.8
2 2 3 CH0 QV+ 23 2 2
CH4 QV+
M 24 V Y1 U U Y1 24 V M
+CBL1-XM2 1/+CBL1/3.5 4 CH0 S+ CH4 S+ 24 +CBL1-XM2 2/+CBL1/3.5
1 2 3 4 4 3 2 1
-YVP501 5 CH0 S 25 -YVP505
6/Mana0 CH4 S
420 mA 26/Mana4 420 mA
6 CH0 Mana CH4 Mana 26
-W502 -W506
2 /3.2 4 +CBL1-X1 7 27
+CBL1-X1 12 /3.7
CH1 QV+ CH5 QV+ 2
proportional valves
M Y1 U
8 CH1 S+ CH5 S+ 28
1 2 3 4 4 3 2 1
-YVP502 9 CH1 S- CH5 S 29 -YVP506
420 mA 10/Mana1 30/Mana5 420 mA
10 CH1 Mana CH5 Mana 30
-W503 -W507
2 /3.2 6 +CBL1-X1 11 31
+CBL1-X1 14 /3.7
CH2 QV+ CH6 QV+ 2
M 24 V Y1 U U Y1 24 V M
12 CH2 S+ CH6 S+ 32
1 2 3 4 4 3 2 1
-YVP503 13 CH2 S CH6 S 33 -YVP507
420 mA 14/Mana2 420 mA
14 CH2 Mana CH6 Mana 34 34/Mana6
-W504 -W508
2 /3.2 8 +CBL1-X1 15 35
+CBL1-X1 16 /3.7
CH3 QV+ CH7 QV+ 2
M 24 V Y1 U U Y1 24 V M
16 CH3 S+ 36
CH7 S+
1 2 3 4 4 3 2 1
-YVP504 17 CH7 S 37 -YVP508
18/Mana3 CH3 S
420 mA 38/Mana7 420 mA
18 CH3 Mana 38
CH7 Mana
19 39
20/M
20 20/M 40
6ES7 332-5HF00-0AB0
+CBL1-XM1 2/+CBL1/2.5
Figure 9: The circuit diagram for connecting the electric valves to the analog output module.
16
20 15 numerical simulation on thermal stress for control cracking
14
10 13 of mass concrete in construction period.
50 12
0 11
0 20 40 60 80 100 120 140 160 180 200 100
X
Conflict of Interests
Figure 10: Real-time three-dimensional temperature field.
The authors declare that there is no conflict of interests
regarding the publication of this paper.
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