Application of PLC with Multi-Core Processors and Codesys Environment for Virtual Adjustment of Technical Systems

A current trend in the development of digital twins and technological automation systems is using programmable logic controllers (PLC) based on multi-core processors. This makes it possible to locate the object simulator on a separate PLC core and conduct operations in a cycle of up to 1 ms. For such PLCs, the use of modern Controller Development System (Codesys) software is considered promising. This software is efficiently applied in almost all industries, including automation systems for rolling mills and casting & rolling units. The mentioned combination of hardware and software facilitates task distribution across the cores with the allocation of a core for an object simulator; this helps to improve speed and performance and reduce the cost of the digital twin (DT) hardware and software. The report provides configuration options for dual-core PLCs, and describes the cases of Codesys being used in automation systems. With such a controller and software Codesys 3.5, the author tested a program to study the transients of interconnected electric drives in a rolling mill stand using a simulator of the control object. In addition, several industrial electric drives have been investigated, as a result of which a multiple performance margin has been confirmed. The research contribution: based upon the analysis of actual processes, the possibility and prospects of using the considered hardware and software complex for the virtual adjustment of automation systems at a metallurgical production facility have been theoretically and experimentally confirmed.