StateFlow as a Tool of the Hybrid X-in-the-Loop Technique in the Model-Based Design Approach to the Control Systems Design in Industrial Automation

The rapid dynamics of changes in the definition of requirements when deploying new technologies means an increase in demands on the volume and scope of skills and knowledge of experts in the design of solutions and their implementation. PLC-based control systems designed for industrial automation can also be included in this problem area. The article deals with the possibility of rapid design and testing of PLC control algorithms using X-in-the-Loop techniques of Model-based Design approach. The control algorithm is implemented using visual programming techniques in the form of state diagrams utilizing the Matlab StateFlow tool. The given proposal is analyzed from the point of view of different approaches to the implementation of communication between the development PC and the real control PLC SIMATIC S7-300 connected to the real part of the model production line. Data exchange is carried out in two ways. The first way of communication is the exchange of uncompressed and compressed images of inputs and outputs via IP communication. The second way is to use the OPC UA architecture. The result of the article is a case study of the use of the XiL approach in the design phase of the control of the AFB Factory production line module with a summary of the possibilities, advantages and disadvantages of alternative partial solutions.