Industrial Control System Simulation using Modbus TCP/IP

This repository contains scripts simulating an industrial control system for managing 10 air conditioning units using Modbus TCP/IP communication protocol. The system includes a server-side PLC simulation, a client-side HTTP server, and two web-based interfaces for monitoring and controlling the units.

Overview

Key Components:

1. Two PLCs (simulated locally) with IDs 1 and 2.
2. Modbus TCP/IP protocol for client-server communication.
3. Web-based HMIs:
   • Control Dashboard: Allows monitoring and controlling air conditioning units.
   • Temperature Graph Interface: Displays temperature trends over time.

Components and Functionality

1. PLC Server (2PLCs_server_modbus.py)

• Simulates two PLCs (IDs 1 and 2) locally, managing 10 air conditioning units.
• Manages three types of Modbus registers:
  • Holding Registers: Store real-time temperature data.
  • Discrete Inputs: Represent the ON/OFF status of the air conditioning units.
  • Coils: Allow user control to turn units ON or OFF via the HMI.
• Behavior:
  • Units decrease the temperature by 1°C every 10 seconds when ON.
  • Units increase the temperature by 1°C every 10 seconds when OFF.
  • Target operating temperature is 7°C; maximum temperature is 30°C.

2. Client (2PLCs_client_web_hmi_modbus_graph.py)

• Implements an HTTP server providing web-based HMIs.
• Communicates with the PLCs via Modbus protocol.
• Includes two interfaces:
  • Dashboard HMI (dashboard.html):
    • Displays real-time data for temperature, status, and controls.
    • Allows users to turn units ON/OFF.
    • Highlights high temperatures (≥12°C) with 🚨 alerts.
  • Graph Interface (graph.html):
    • Displays real-time temperature graphs for all 10 units.
    • Uses Chart.js for dynamic graph updates.
    • Highlights critical conditions with visual cues.

3. AC System Operation

Once the server-side and client-side scripts are launched, the system operates as follows:

• The server script reads the value of the discrete inputs to verify if each air conditioning unit is ON or OFF.
• If an air conditioning unit is ON, the system decreases the corresponding holding register value (temperature) by 1 degree every 10 seconds to simulate cooling.
• If the unit is OFF, the holding register value (temperature) increases by 1 degree every 10 seconds to simulate a lack of cooling.
• The temperature changes are visible in the HMI, allowing users to monitor the real-time status of each unit.
• Through the HMI, users can manually turn ON or OFF the air conditioning units by interacting with the coils to maintain an operating temperature of 7 degrees.
• The maximum temperature that can be reached with all air conditioning units OFF is 30 degrees.

Web Interfaces

Dashboard HMI

• Features:
  • Real-time temperature, status, and control actions.
  • Alerts for high temperatures (≥12°C) with 🚨.
  • Buttons for ON/OFF control of each unit.
• Background: Air-conditioning-themed design.

Graph Interface

• Features:
  • Line graphs showing temperature trends.
  • Updates every 5 seconds.
  • Color-coded temperature thresholds for clear visualization.
• Design: Minimalist, responsive layout with color-coded graphs.

Installation and Usage

Prerequisites

• Python 3.7 or higher.
• Install dependencies using:

  pip install -r requirements.txt

Running the Simulation

1. Start the PLC Server:

   python3 2PLCs_server_modbus.py

   • Simulates the PLCs and initializes Modbus registers.

2. Start the Client:

   python3 2PLCs_client_web_hmi_modbus_graph.py

   • Starts the HTTP server providing access to the HMIs.

3. Access the HMIs:

   • Control Dashboard: http://localhost:8000/dashboard
   • Graph Interface: http://localhost:8000/graph

Folder Structure

• 2PLCs_server_modbus.py: PLC simulation script.
• 2PLCs_client_web_hmi_modbus_graph.py: HTTP server for HMIs.
• templatess/dashboard.html: Control and status interface.
• templates/graph.html: Temperature graph visualization interface.
• requirements.txt: List of Python dependencies.

Technologies Used

• Python: Core simulation and server.
• Modbus TCP/IP: Industrial communication protocol.
• Flask: HTTP server for web-based interfaces.
• Chart.js: Interactive temperature graphs.
• HTML/CSS/JavaScript: Web HMI development.

Features

• Real-time temperature control and monitoring.
• Dynamic graph visualization.
• Scalable design for additional features.

Contact

For questions or suggestions, contact [codewars87@gmail.com].