Automationscenter & Bråvalla Elteknik AB is a company that offers the market completed total solutions where the customer can operate and monitor their production from the terminal. In these total solutions they lack standard circuit which are developed by the company and which could manoeuvre/control/monitor controlled process objects. This report defines the work of developing the most common standard circuits.The report is initiated by a short theoretical part about PLC and the PLC system, with a connected terminal, which has been used. Thereafter, the turnout of the demands of specification is reported, after discussing with the supervisor in the course of the project. The report concludes with a disclosure of how the programming, the documentation and the testing have proceeded and a final discussion concerning the project and proposals on continuation.The result is a CD with the documentation of standard circuits and how they are implemented in a new project. One library file with the program code to all standard circuit. Program code and documentation for both demonstration and testing are also on the CD. This project represents a start of POS (Process Objektsstyrnings Standard) as the collection is called at Automationscenter. / Automationscenter & Bråvalla Elteknik AB är ett företag som erbjuder marknaden färdiga totallösningar där kunden kan manövrera och övervaka sin produktion från operatörspaneler. I denna totallösning saknar företaget egna framtagna ”typkretsar” som manövrerar/kontrollerar/övervakar styrda processobjekt. En typkrets skall ha en del som implementeras i PLC och en del som implementeras i operatörspanelen.Denna rapport redogör för hur några av de vanligaste ”typkretsarna” tas fram.Rapporten inleds med en kort teoridel om PLC och det PLC‐system med tillhörande operatörspanel som använts. Därefter redogörs hur typkretsarnas kravspecifikation blev efter att ha diskuterat med handledaren under arbetets gång. Rapporten avslutas med en redovisning för hur programmeringen, dokumentationen och testningen gått till och en avslutande diskussion om arbetet och förslag på fortsättning.Resultatet blev en CD‐skiva med dokumentation om typkretsarna och hur de implementeras i ett nytt projekt: en biblioteksfil med programkoden till alla typkretsar. Programkod och dokumentation för både visning och testning finns också med på skivan. Ex‐jobbet utgör en början på POS Process Objektsstyrnings Standard som samlingen heter på Automationscenter & Bråvalla Elteknik AB.

The goal of the project is to evaluate a new setup for the company Iberobot Svenska AB, using HMI and PLC, for resistance spot welding equipment controller. The purpose of the controller is to control the weld process; weld power and time. One of the question raised is if this setup could be used as an RWE controller and thereby be able to re-place an old proprietary controller called TEC6000. A prototype is built compatible with current single phase RWE and literature study is conducted to answer this question.  The new setup is based on Beijer iX T7B Softmotion which includes an HMI and a PLC with EtherCAT support. EtherCAT input and output modules from Beckhoff are chosen because they can handle the speed required by the weld process. The controller is implemented using theory for RMS value, timing diagram and state diagram based on weld process. The prototype is revised three times. A zero crossing detector is implemented. A control element driver using opto-triac is implemented. Measurements using oscillo-scope are conducted which shows that the controller is able to start a weld, but zero crossing detection is unstable and further research into this and current regulation is needed before an end user product can be made.

The project was commissioned by Tobias Hedin, who is a lecturer at the Kalmar Maritime Academy. The mission was to install a physical compressor facility that would replace an existing graphic simulator. The goal of the assembly was also, to the extent where it was possible, to emulate the compressor plants onboard ships. With the help of literary studies, but also through own experience, the necessary data were developed around compressors and facilities on board. The final choice of compressor was also done with regard to the budget, noise and capacity. Apart from the compressors, the budget also included the purchase of some peripherals that were necessary to adapt the compressor to the task. The Maritime Academy provided drawing program for schedules, and also electrical supplies. The work resulted in a fully functional compressor system with a control cabinet and control system. The client also received documentation of the facility. / Projektet utfördes på uppdrag av Tobias Hedin som är universitetsadjunkt vid Sjöfartshögskolan i Kalmar. Utbildningen, för Sjöingenjörerna vid Sjöfartshögskolan, innehåller en praktisk kurs kallad Tillämpad Elteknik. Ett av delmomenten i kursen är en programmeringsuppgift, vilken bestod av att med hjälp av en grafisk simulator programmera två kompressorer att gå enligt vissa villkor. Uppdraget var att installera en fysisk kompressoranläggning som skulle ersätta den befintliga grafiska simulatorn. Målet med anordningen var även att i den mån det var möjligt efterlikna de kompressoranläggningar som finns ombord på fartyg, då kursen Tillämpad Elteknik riktar sig till sjöingenjörsstudenter. Med hjälp av litteraturstudier, men också genom egen erfarenhet, togs fakta fram kring kompressorer och anläggningar ombord. Genom fakta från litteraturstudierna gjordes först val av kompressor. Detta gjordes med hänsyn till budget, bullernivå och kapacitet. I budgeten ingick även inköp av en del kringutrustning som var nödvändig för att anpassa kompressorerna till uppgiften. Sjöfartshögskolan tillhandahöll ritprogram för scheman, och även materiel som redan fanns tillgängligt i Trångsundet. Arbetet resulterade i en fullt fungerande kompressoranläggning med manöverskåp och styrsystem. Beställaren fick också dokumentation över anläggningen.

With the help of the internet, teaching is not constrained in the traditional classroom pedagogy; the instructors can put the course material on the website and allow the students go on to the course webpage as an alternative way to learn the domain knowledge. The problem here is how to design a web-based system that is intelligent and adaptive enough to teach the students domain knowledge in Programmable Logic Controller (PLC). In my research, I proposed a system architecture which combines the pre-test, cased-based reasoning (i.e., heuristic functions), tutorials and tests of the domain concepts, and post-test (i.e., including pre-exam and post-exam) to customize students’ needs according to their knowledge levels and help them learn the PLC concepts effectively. I have developed an intelligent tutoring system which is mainly based on the feedback and learning preference of the users’ questionnaires. It includes many pictures, colorful diagrams, and interesting animations (i.e., switch control of the user’s rung configuration) to attract the users’ attention. From the model simulation results, a knowledge proficiency effect occurs on problem-solving time. If the students are more knowledgeable about PLC concepts, they will take less time to complete problems than those who are not as proficient. Additionally, from the system experiments, the results indicate that the learning algorithm in this system is robust enough to pinpoint the most accurate error pattern (i.e., almost 90 percent accuracy of mapping to the most similar error pattern), and the adaptive system will have a higher accuracy of discerning the error patterns which are close to the answers of the PLC problems when the databases have more built-in error patterns. The participant evaluation indicates that after using this system, the users will learn how to solve the problems and have a much better performance than before. After evaluating the tutoring system, we also ask the participants to submit the survey (feedback), which will be taken into serious consideration in our future work.

With the help of the internet, teaching is not constrained in the traditional classroom pedagogy; the instructors can put the course material on the website and allow the students go on to the course webpage as an alternative way to learn the domain knowledge. The problem here is how to design a web-based system that is intelligent and adaptive enough to teach the students domain knowledge in Programmable Logic Controller (PLC). In my research, I proposed a system architecture which combines the pre-test, cased-based reasoning (i.e., heuristic functions), tutorials and tests of the domain concepts, and post-test (i.e., including pre-exam and post-exam) to customize students’ needs according to their knowledge levels and help them learn the PLC concepts effectively. I have developed an intelligent tutoring system which is mainly based on the feedback and learning preference of the users’ questionnaires. It includes many pictures, colorful diagrams, and interesting animations (i.e., switch control of the user’s rung configuration) to attract the users’ attention. From the model simulation results, a knowledge proficiency effect occurs on problem-solving time. If the students are more knowledgeable about PLC concepts, they will take less time to complete problems than those who are not as proficient. Additionally, from the system experiments, the results indicate that the learning algorithm in this system is robust enough to pinpoint the most accurate error pattern (i.e., almost 90 percent accuracy of mapping to the most similar error pattern), and the adaptive system will have a higher accuracy of discerning the error patterns which are close to the answers of the PLC problems when the databases have more built-in error patterns. The participant evaluation indicates that after using this system, the users will learn how to solve the problems and have a much better performance than before. After evaluating the tutoring system, we also ask the participants to submit the survey (feedback), which will be taken into serious consideration in our future work.

Detta examensarbete på 22,5 hp är en del av mekatronikingenjörsutbildningen vid Karlstads universitet. Uppdragsgivaren är Valmet AB (tidigare Metso AB) i Hagfors som tillverkar och säljer malsegmentslitdelar för pappersindustri och massaindustri.Projektet behandlar en av de tre formmaskiner som finns på företaget, kallad M01. Formningsmomentet är grunden till gjutresultatet av produkterna och i dagsläget är det för stora variationer på kvalitetsutfall, delvis orsakat av för många frihetsgrader i hur maskinen opereras. Målet är att komma fram till en automatiserad lösning av utstötning av skalhalvor, hålla en jämnare nivå i sandkassen genom nivåmätning samt minska spill vid påfyllningen av sand.En tryckvakt och en ultraljudsgivare användes för att kunna mäta maskinens tillstånd och som styrning användes en extern PLC, Siemens LOGO! utöver den ordinarie PLC:n som används.Resultatet blev en prototyp som tillsammans med ett antal nya sensorer kan göra testmätningar och tillfälligt styra maskinen för att få en anvisning om det kan vara en bra lösning i framtiden. Lösningen ska senare kunna utvecklas fullt ut med bättre sensorer och dess funktioner ska kunna implementeras i den ordinarie PLC:n för att användas i samtliga formmaskiner.Alla lösningar fick inte fullt önskvärt resultat men de är ändå ett steg i rätt riktning. Skalen släpper inte lättare men en automatiserad utstötningsfunktion har tagits fram och kan användas som ett komplement för att underlätta för operatören. Lösningen har även lett till att det har blivit minskat spill samt att tiden för sandpåfyllning numera kan styras genom nivåmätning. Dock måste den startas manuellt i varje tillverkningscykel. / This degree project of 22.5 hp is part of the Mechatronics Engineering education at Karlstad University. The client is Valmet AB (formerly Metso AB) in Hagfors, which manufactures and sells grinding segments for the paper and pulp industry.The project highlights one of the three formwork machines at the company, called M01. The formwork is the basis to the molding results of the products and in the current situation it is of great variability in quality outcomes, partly caused by too many degrees of freedom in how the machine operated. The goal is to come up with an automated solution for ejection of shell halves, maintain a more stable level of sand in the sandbag through level measurements and reduce spillage during filling of sand.A pressure sensor and an ultrasonic sensor have been used to measure the state of the machine and to control an external PLC, Siemens LOGO addition to the ordinary PLC has used.The result was a prototype that together with a number of new sensors can make test measurements and temporarily control the machine to get a hint about if it could be a good solution in the future. The solution could later be fully developed with better sensors and its features implemented into the regular PLC to be used in any formmachine.All the solutions were not fully desirable but they are still a step in the right direction. The shells doesn’t let go easier but an automated ejection program has been developed and that be used as a supplement and assist the operator. The new solution has also led to reduced waste, and that the time for sand filling is now controlled through level measurements. However, it must be started manually in each production cycle.

Automatic control of processes is a field that has evolved extensively over theyears to reduce downtime, improve quality and increase the productivity ofprocesses in manufacturing industries. ÅF Consult is a consult organization thatprovides industrial solutions worldwide. In order to test equipment andintroduce employees and students to control systems, a PLC based lab station isnecessary. The methodology used in the project is based on a literature study,followed by the solution approach and finally an evaluation. A DistributedControl System setup using a Siemens S7-300 and a Siemens S7-400 PLC hasbeen developed. The PLCs communicate using PROFIBUS DP. The station isdivided into two major parts: a conveyor belt with transportation functionalityand a robotic arm with pick-and-place functionality. The station is providedwith equipment similar to systems currently used in paper and pulp industries.Existing solutions for unloading of paper reels in the paper and pulp industriesare non-universal due to extra equipment like pre-installed rails in trailers. Anautomated solution for unloading using a robotic arm is therefore presented,designed to reduce paper reel handling and to have the possibility to unload toany trailer. The lab station is implemented according to ÅF Consults demandsof a portable, field related station. The low budget resulted in cheap equipmentthat lack accuracy, mainly resulting in issues relating to the ability to control therobotic arm properly. The unloading solution is emulated as a lab task on thestation, showing that a control setup similar to the lab station would be a goodapproach for a real implementation solution.

För att korta ner den totala driftsättningstiden i projekt beslutade Volvo Cars Skövde om att undersöka möjligheterna för verifiering av PLC-logik mot simuleringsprogram. Det övergripande målet med examensarbetet var att undersöka möjligheterna för att upprätta kommunikation mellan flödesimuleringsprogrammet Siemens Plant Simulation och en PLC-enhet. En ingripande förståelse av området virtuell driftsättning skapades vid skrivandet av referensramen och en litteraturstudie vilket legat till grund för det fortsatta praktiska arbetet. Genom en datainsamling med intervjuer, diskussioner och en omfattande litteraturstudie kunde en bättre förståelse bildas kring hur kommunikation mellan de olika programmen fungerar, samt viktiga punkter som bör has i åtanke vid virtuell driftsättning överlag. Ett hypotetiskt system utvecklades i Plant Simulation av Volvo Cars Skövde för att användas som testsystem. I emuleringsmjukvaran Simumatik3D skapades en modell för att efterlikna Plant Simulation modellen samtidigt som PLC-logiken utvecklades i Siemens Step 7. Under utvecklingens gång verifierades delsystem i Simumatik3D mot den skapade PLC-logiken tills det att modellen var färdigutvecklad. För att säkerhetsställa att både Simumatik3D modellen och Plant Simulation modellen var valid undersöktes ett antal valideringspunkter. Experimentfasen tog vid efter valideringstestet där olika scenarier undersöktes och testades för att föra upp eventuella problem i modellerna till ytan. En omfattande utvärdering presenteras där hela uppbyggnadsfasen av modeller utvärderas med avseende på tidsåtgång, för- och nackdelar och kommunikation med PLC. De två programmen Simumatik3D och Plant Simulation utvärderades mot varandra för att få ut vilket program som mest lämpar sig för virtuell verifiering av PLC-logik. Ett översiktligt arbetssätt togs fram utifrån den utvärdering som gjorts samt erfarenheter från genomförandet av arbetet. Resultatet av det framtagna arbetssättet presenteras vilket beskriver uppdelningen mellan beställare och leverantör, kommunikationen mellan parterna samt en överskådlig visualisering av arbetssättets process. Resultatet från utvärderingen visade att Simumatik3D lämpar sig åt att verifiera PLC logik på detaljnivå. Utvärderingen visade även att PLC-logik kan verifieras med hjälp av Plant Simulation, dock inte på samma detaljnivå. Plant Simulation lämpar sig istället till att göra simuleringsmodeller mer verklighetstrogna. Virtuell driftsättning av PLC-logik är ett nytt koncept på Volvo Cars Skövde och därför kan resultatet från detta arbete ligga till grund för fortsatt arbete inom detta område. Virtuell verifiering av PLC-logik diskuteras där flera aspekter som är viktiga att tänka på presenteras. Projektens huvudmål att virtuellt verifiera PLC-logik mot simuleringsprogram uppnåddes och gav goda resultat, de uppsatta delmålen resulterade i en omfattande utvärdering och framtida rekommendationer. / To shorten project lead times Volvo Cars Skövde decided to explore the possibilities regarding verifi-cation of PLC-logic in simulation programs. The overall objective of the thesis was to analyze the pos-sibilities for establishing communication between the flow simulation program Plant Simulation and a PLC-device. A thorough understanding of the area virtual commissioning was obtained by writing the frame of reference and a literature review which served as basis for the continued practical work. Through a collection of interviews, discussions and an extensive literature review a better under-standing regarding how the communication between the different programs works, along with im-portant points that should be considered under a virtual commissioning project was obtained. A hy-pothetical system was developed in Plant Simulation by Volvo Cars Skövde to be used as a test sys-tem. The Simumatik3D model was created by emulating the Plant Simulation model and at the same time developing the PLC-logic in Siemens Step 7. During the development progress subsystems were verified in Simumatik3D against the created PLC-logic until the model was fully developed. To make sure that both the Simumatik3D model and the Plant Simulation model was valid a number of valida-tion points were tested. After the validation test the experimental phase started were different sce-narios were analyzed and tested to bring up any problems in the models to the surface. A thorough evaluation is presented in which the entire construction phase of the models is evaluated in terms of time required, advantages and disadvantages and communication with the PLC-device. The two pro-grams Simumatik3D and Plant Simulation was evaluated against one another in order to find out which program that is the most suited for virtual verification of PLC-logic. An overall methodology was developed based on the evaluation carried out and the experience gained from the implementa-tion of the work. The result from the developed methodology is presented which describes the parti-tion between the client and supplier, the communication between them and a visualization of the methodology-process. The result from the evaluation showed that Simumatik3D was more suitable for verification of PLC logic on a detailed level. The evaluation also showed that the PLC logic could be verified with Plant Simulation, but not on the same detailed level. Plant Simulation was more suit-able for making simulation models more realistic. Virtual commissioning of PLC-logic is a new con-cept on Volvo Cars Skövde and therefore can the result from this thesis form a basis for future work in this area. Virtual verification of PLC-logic is discussed in which several important aspects to think about is presented. The projects main goal to virtually verify PLC-logic in simulation programs was achieved and yielded good results, the partial objectives resulted in a thorough evaluation and future recommendations.

This qualitative study offers an in-depth description of a high school professional learning community (PLC) as it focuses on enhancing the teaching and learning of the Grade 9 Applied Mathematics curriculum. The teachers’ goal in this PLC is to implement strategies they believe best meet the needs of their students. Over the course of one school year data was collected during PLC meetings and through individual participant interviews. Data was analyzed and used to answer the following research questions: How is a PLC formed and sustained, and how does it evolve throughout the process of teachers examining their practice? What happens when a professional community of learners comes together to discuss, dissect and reflect on their own practice with the intention of broadening their understanding of teaching mathematics? Analysis of the data revealed that teachers came together through their shared work of teaching in ways that address the needs of students in applied level mathematics. Through external funding and strong leadership and support from the school Principal, this PLC created opportunities to meet and collaborate. During meetings the PLC members discussed their pedagogical challenges, focused on the needs of students and student learning, designed lessons that would specifically target the needs of their students, observed each other teach these co-designed lessons, and finally discussed and reflected on the taught lesson. This process was repeated throughout the year, each time building on lessons learned from previous experiences. Although the PLC members described how being out of their class to collaborate did pose some challenges, overall they described their experience in the PLC as the most powerful professional development of their careers.

abstract: Utilities infrastructure like the electric grid have been the target of more sophisticated cyberattacks designed to disrupt their operation and create social unrest and economical losses. Just in 2016, a cyberattack targeted the Ukrainian power grid and successfully caused a blackout that affected 225,000 customers. Industrial Control Systems (ICS) are a critical part of this infrastructure. Honeypots are one of the tools that help us capture attack data to better understand new and existing attack methods and strategies. Honeypots are computer systems purposefully left exposed to be broken into. They do not have any inherent value, instead, their value comes when attackers interact with them. However, state-of-the-art honeypots lack sophisticated service simulations required to obtain valuable data. Worst, they cannot adapt while ICS malware keeps evolving and attacks patterns are increasingly more sophisticated. This work presents HoneyPLC: A Next-Generation Honeypot for ICS. HoneyPLC is, the very first medium-interaction ICS honeypot, and includes advanced service simulation modeled after S7-300 and S7-1200 Siemens PLCs, which are widely used in real-life ICS infrastructures. Additionally, HoneyPLC provides much needed extensibility features to prepare for new attack tactics, e.g., exploiting a new vulnerability found in a new PLC model. HoneyPLC was deployed both in local and public environments, and tested against well-known reconnaissance tools used by attackers such as Nmap and Shodan's Honeyscore. Results show that HoneyPLC is in fact able to fool both tools with a high level of confidence. Also, HoneyPLC recorded high amounts of interesting ICS interactions from all around the globe, proving not only that attackers are in fact targeting ICS systems, but that HoneyPLC provides a higher level of interaction that effectively deceives them. / Dissertation/Thesis / Masters Thesis Computer Science 2020