An-Najah National University 

Faculty of Engineering 

Department of Electrical and Computer Engineering 

 

Auto-Batch concrete control system 

 

 

 

Prepared by: 

Ameer Salam 

Mosab Bani jaber 

 

 

Supervisor: Dr. Samer Mayaleh 

 

"Submitted in partial fulfillment of the requirements for the bachelor’s degree in electrical 

engineering." 

 

Academic year 2023/2024 



1 

 

 

DEDICATION 

Our parents, everything we are because of you. Thank you for all that you have done for us. We 

will never be able to repay you for the time and love you showed us growing up, but know that we 

love and appreciate it all, every single day. Thank you for the countless memories. 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 



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ACKNOWLEDGEMENT 

 First and foremost, we would like to thank Allah for his blessings to complete our study journey 

and complete this project. 

 Our boundless gratitude to our wonderful supervisor Dr. Samer Mayaleh for his guidance, 

encouragement, and patience. Thank you so much for always being there when we needed you. 

Your shouting and toughness were the motivation key to our success here. You will make great 

engineers someday, as soon as you finish your coffee! 

 Many thanks for our lecturers for all efforts to make us open minded engineers. Our friends and 

colleges, thank you for all beautiful and vital moment that gathered us, you are the best. 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 



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Table of Contents 

 
DEDICATION .................................................................................................................................................. 1 

ACKNOWLEDGEMENT ................................................................................................................................... 2 

Table of Contents .......................................................................................................................................... 3 

List of Figures ................................................................................................................................................ 5 

List of Tables ................................................................................................................................................. 7 

NOMENCLATURE ........................................................................................................................................... 8 

Abstract ......................................................................................................................................................... 9 

CONSTRAINS ............................................................................................................................................... 10 

Chapter 1: Introduction .............................................................................................................................. 13 

1.1 Overview : ................................................................................................................................... 13 

1.2 Types concrete plants: ............................................................................................................... 15 

1.3 Concrete Recipes: ...................................................................................................................... 19 

1.4 Problem Statement: .................................................................................................................. 20 

1.5 Objectives and scope : ................................................................................................................ 21 

1.5.1 Objectives: ............................................................................................................................. 21 

1.5.2 Scope: .................................................................................................................................... 22 

1.6 Report Organization .................................................................................................................. 23 

Chapter 2: Literature Review ...................................................................................................................... 24 

Chapter 3: Methodology ............................................................................................................................. 27 

3.1 Requirements Analysis: ..................................................................................................................... 27 

3.2 System design: .................................................................................................................................. 28 

3.3 System Architecture and Hardware Components: ........................................................................... 31 

3.3.1 Level 0- Field Level/Production Process (devices, actuators and sensors): ............................... 31 

3.3.2 Level 1-Control Level/Sensing and Manipulation (PLC, DCS and PID): ...................................... 36 

3.4 Software Design and Implementation: ......................................................................................... 50 

3.4.1 Level 2- Supervisory Level/Monitoring and supervising (SCADA design): ................................. 50 

3.4.2 The UI for the program, completed in the of graduation project.............................................. 51 

3.4.3 Selecting a PLC and the selection process : ................................................................................ 60 

3.4.4 Serial communications .......................................................................................................... 70 

3.4.5 PLC programming using ISPsoft program: ................................................................................. 77 

Chapter 4: Results and Analysis .................................................................................................................. 86 



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Chapter 5: Discussion .................................................................................................................................. 87 

Chapter 6: Conclusions and Recommendation ........................................................................................... 89 

6.1 Conclusions ....................................................................................................................................... 89 

6.2 Recommendation .............................................................................................................................. 91 

6.3 future work ....................................................................................................................................... 92 

References .................................................................................................................................................. 93 

Appendices: ................................................................................................................................................. 95 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 



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List of Figures 

Figure 1: General appearance of the concrete plant ...................................................................... 13 
Figure 2: Basics of SCADA .......................................................................................................... 15 
Figure 3:Dry mix concrete plant ................................................................................................... 16 
Figure 4:Wet mix concrete plant ................................................................................................... 17 
Figure 5:Mobile concrete plant ..................................................................................................... 18 
Figure 6:Stationary concrete plant ................................................................................................ 19 
Figure 7:A diagram drawn up to illustrate the practical mechanism of a dry ready mix concrete 

plant............................................................................................................................................... 29 
Figure 8:A diagram drawn up to illustrate the practical mechanism of a wet ready mix concrete 

plant............................................................................................................................................... 30 
Figure 9:Automation pyramid....................................................................................................... 31 
Figure 10:S-type load cell ............................................................................................................. 32 
Figure 11:Moisture Sensor ............................................................................................................ 33 
Figure 12:Hydro-Probe installed above sand conveyor belt ......................................................... 33 
Figure 13:Moisture Sensor located under Aggregate Bin ............................................................. 33 
Figure 14 :Proximity Sensors........................................................................................................ 34 
Figure 15:RFID sensors ................................................................................................................ 36 
Figure 16: Distributed Control System ......................................................................................... 37 
Figure 17:PLC ............................................................................................................................... 38 
Figure 18 :PLC Schneider ............................................................................................................. 39 
Figure 19:PLC part ....................................................................................................................... 39 
Figure 20:CPU type ...................................................................................................................... 40 
Figure 21:Input module................................................................................................................. 41 
Figure 22:lithium batterie ............................................................................................................. 41 
Figure 23:RAM & EEPROM........................................................................................................ 42 
Figure 24:Flash memory ............................................................................................................... 42 
Figure 25:Compact or fixed PLC .................................................................................................. 43 
Figure 26:Modular PLS ................................................................................................................ 44 
Figure 27:Single ended or Stand-alone PLCs Application ........................................................... 44 
Figure 28:Multitask PLCs Application ......................................................................................... 45 
Figure 29:Control Management PLCs Application ...................................................................... 45 
Figure 30:companies that produce PLCs ...................................................................................... 46 
Figure 31:Siemens PLC and Program........................................................................................... 46 
Figure 32:DALTA PLC and Program ........................................................................................... 47 
Figure 33:Schneider PLC and Program ........................................................................................ 47 
Figure 34:Allen-Bradley PLC and Program ................................................................................. 47 
Figure 35:DIAVIEW software interface ....................................................................................... 50 
Figure 36:The main interface of the program ............................................................................... 51 
Figure 37:Orders page and control ............................................................................................... 52 
Figure 38:order information .......................................................................................................... 52 
Figure 39:Manual Page ................................................................................................................. 53 
Figure 40:Setting Page .................................................................................................................. 54 



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Figure 41:invoice page .................................................................................................................. 55 
Figure 42:Report Page .................................................................................................................. 56 
Figure 43:Recipes Page................................................................................................................. 57 
Figure 44:Timer Page .................................................................................................................... 58 
Figure 45:Alarm Page ................................................................................................................... 59 
Figure 46:configure the names of DVP Series Programmable ..................................................... 60 
Figure 47:DVP Series and ISP soft program ................................................................................ 61 
Figure 48:PLC DVP-14 SS2 ......................................................................................................... 61 
Figure 49:PLC Wiring................................................................................................................... 62 
Figure 50:number of basic inputs ................................................................................................. 62 
Figure 51:8 input MPU X0 …. X17 ............................................................................................. 63 
Figure 52:extensions in them 8 input and 16 input ....................................................................... 63 
Figure 53:extensions in 16 inputs ................................................................................................. 63 
Figure 54:number of basic outputs ............................................................................................... 64 
Figure 55:extensions 8 output and MPU Y0 …. Y17 ................................................................... 64 
Figure 56:extensions in them 8 output and 16 output ................................................................... 65 
Figure 57:extensions in 16 outputs ............................................................................................... 65 
Figure 58 :Connecting Extension Modules to Delta PLCs ........................................................... 67 
Figure 59:left-side High-speed Extension Modules ..................................................................... 68 
Figure 60: I/O Extension ............................................................................................................... 68 
Figure 61:I/O Analog Extension ................................................................................................... 69 
Figure 62: communication and Power Supply Modules ............................................................... 69 
Figure 63:maximum number of extension modules ..................................................................... 70 
Figure 64:connection  RS-232 ...................................................................................................... 71 
Figure 65:differential connection .................................................................................................. 72 
Figure 66::connection RS-485 ...................................................................................................... 73 
Figure 67:Modbus of Communication .......................................................................................... 75 
Figure 68: message sent via Modbus ............................................................................................ 76 
Figure 69: distribution board the PLC, Relays and C.B ............................................................... 82 
Figure 70:distribution board the mixer (contactor and over load) ................................................ 83 
Figure 71:distribution board the conveyor (contactor and overload) ........................................... 84 
Figure 72:distribution board the pump (contactor and over load) ................................................ 85 
 

 

 

 

 

 

 



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List of Tables 

Table 1: Number of ready-mix concrete manufacturing establishments in Palestine ................... 14 
Table 2:differences between wet and dry concrete plants ............................................................. 18 
Table 3:The difference between the American code and the European code in the ready-mix 

concrete industry ........................................................................................................................... 20 
Table 4:Addresses allowed for Auxiliary Relay ........................................................................... 65 
Table 5: Special Auxiliary Relay .................................................................................................. 66 
Table 6:Addresses allowed for Data Register ............................................................................... 66 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 



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NOMENCLATURE 

 

PLC Programmable Logic Controller 

SCADA Supervisory Control and Data Acquisition 

HMI Human Machine Interface 

RMC Ready-Mix Concrete 

RTU remote terminal unit 

ERP enterprise resource planning 

ANN Artificial Neural Network 

GA Genetic Algorithm 

ANN-GA Artificial neural networks for genetic algorithm 

WinCC Windows Control Center Open Architecture 

DIA VIEW Delta Industrial Analytics View 

PID Proportional-Integral-Derivative 

DCS Distributed Control System 

MTBF Mean Time Between Failures 

ABB Asea Brown Boveri 

(A Swiss-Swedish multinational company) 

 

 

 

 

 

 

 

 

 

 

 

 



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Abstract 

The automation of concrete factories plays a pivotal role in augmenting efficiency, 

productivity, and product quality. This graduation project is oriented towards the development and 

execution of an integrated automation system aimed at overseeing and managing the operations of 

a concrete factory. The proposed system will encompass a wide array of concrete production facets, 

including material handling, batching, mixing, pouring, and curing. It will leverage cutting-edge 

technologies such as programmable logic controllers (PLCs), industrial sensors, and supervisory 

control and data acquisition (SCADA) software to ensure real-time monitoring and control of the 

production process. The project will tackle the challenges associated with integrating diverse 

components, ensuring data integrity, and implementing robust control algorithms. The successful 

deployment of the automation system is anticipated to yield substantial enhancements in 

production efficiency, operational cost reduction, and product quality enhancement, thereby 

contributing to the overall success of the concrete factory. 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 



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CONSTRAINS 

Obstacles to the design of control and monitoring systems for ready-mix concrete factories: 

Specific project: 

1-Production capacity and productivity: 

• The design is based on the required hourly/daily productivity of concrete. 

• Consider variations in demand and peak production requirements. 

2-Types of concrete and mix designs: 

• The system must accommodate different types of concrete and their specific recipes. 

• Adapt to modifications in mix designs based on material properties or customer needs. 

3- Factory layout and equipment: 

• Seamlessly integrate with existing machines and workflows. 

• Consider physical limitations and potential expansion plans. 

 

4-Technical limitations: 

User interface and monitoring: 

• Design intuitive and easy-to-use interfaces for operators and supervisors. 

• Providing real-time data visualization and historical data analysis tools. 

 

When choosing a Programmable Logic Controller (PLC) for designing a control and 

automation system for a concrete factory, especially when integrating with a control interface 

designed using DIAView and programming using Delta PLCs, several technical constraints should 

be considered: 

 

1. Compatibility 

• DIAView Integration: Ensure that the chosen PLC is fully compatible with the DIA View 

HMI/SCADA software. Delta PLCs are designed to work seamlessly with DIA View, so 

opting for a Delta PLC model would ensure compatibility. 

• Communication Protocols: Verify the communication protocols supported by both the PLC 

and the DIAView program (e.g., Modbus, Ethernet/IP, CAN open, etc.). 

 

 



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2. Performance Requirements 

• Processing Speed: The PLC should have a sufficient processing speed to handle the control 

logic and data processing needs of a concrete factory. 

• I/O Response Time: The response time of the I/O modules should meet the real-time 

requirements of the automation system. 

3. I/O Requirements 

• Digital I/Os: Estimate the number of digital input and output points needed for sensors, 

actuators, and control devices. 

• Analog I/Os: Calculate the number of analog inputs and outputs for devices like 

temperature sensors, pressure transducers, and flow meters. 

• Expandable I/O Modules: Consider if the PLC supports expandable I/O modules for future 

scalability. 

4. Environmental Conditions 

• Temperature Range: The PLC should operate reliably within the temperature range typical 

of a concrete factory environment. 

• Dust and Moisture Protection: Look for PLCs with appropriate IP ratings to protect against 

dust and moisture. 

5. Power Supply 

• Voltage Requirements: Ensure the PLC supports the power supply voltage available at the 

concrete factory. 

• Power Consumption: Assess the power consumption to ensure it is within the limits of the 

power supply infrastructure. 

6. Reliability and Durability 

• MTBF (Mean Time Between Failures): Choose a PLC with a high MTBF for long-term 

reliability. 

• Shock and Vibration Resistance: Consider the mechanical robustness of the PLC in 

environments with significant shock and vibration. 

7. Networking and Communication 

• Network Connectivity: Ensure the PLC has adequate networking capabilities (Ethernet, 

serial, etc.) for integration with other systems and remote monitoring. 

• Communication Ports: Sufficient number and types of communication ports (e.g., RS-232, 

RS-485, USB, etc.). 

 

 

 

 



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8. Programming Capabilities 

• Software Tools: Compatibility with the Delta PLC programming software, like ISPSoft. 

• Programming Language Support: Ensure the PLC supports required programming 

languages (e.g., Ladder Logic, Structured Text). 

9. Data Logging and Storage 

• Memory Capacity: Adequate memory for data logging and program storage. 

• Data Retention: Non-volatile memory for data retention in case of power loss. 

10. Cost and Budget 

• Initial Cost: Consider the purchase cost of the PLC and any additional modules or 

accessories. 

• Maintenance Costs: Factor in potential maintenance costs over the PLC’s operational life. 

11. Vendor Support and Documentation 

• Technical Support: Availability of technical support and after-sales service from the vendor. 

• Documentation: Comprehensive documentation and user manuals for installation, 

programming, and troubleshooting. 

12. Redundancy and Safety 

• Redundancy Features: Availability of redundant power supplies, CPUs, and 

communication modules for high availability. 

• Safety Certifications: Compliance with safety standards and certifications relevant to the 

concrete industry. 

 

For a project involving the design of a control and automation system for a concrete factory using 

Delta PLCs and DIAView, it is crucial to select a PLC that aligns with the technical and 

environmental requirements of the application. Opting for Delta PLCs would ensure seamless 

integration and compatibility with DIAView and other Delta products, while also considering 

performance, I/O needs, environmental factors, and cost-effectiveness. 

 

 

 

 

 

 

 



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Chapter 1: Introduction 

1.1 Overview : 

The ready-mix concrete industry is one of the vital industries worldwide, given its essential 

role in construction and reconstruction projects. In Palestine, this industry is of great importance 

at present, as the country is witnessing a significant phase of activity in infrastructure and 

reconstruction, which enhances the demand for ready-mix concrete as a fundamental material in 

construction processes. This sector plays a significant role in supporting the local economy and 

providing direct and indirect job opportunities.[1] 

 

Ready-mix concrete plants offer many advantages, such as ensuring the quality of the mix 

and precise control over its composition and strength, as well as contributing to reducing waste in 

construction processes. These plants can produce a variety of concrete suitable to meet different 

needs in various application areas.[2]  

 

The concrete industry in Palestine has witnessed significant developments in recent years, 

leading to an increase in concrete production. This development is attributed to the growing 

demand for concrete, reflecting the country's economic growth and the rise in construction 

numbers.[2] 

 

 

Figure 1: General appearance of the concrete plant 



14 

 

 

The modernization of concrete plants is an important part of this progress, leading to 

increased production efficiency and improved product quality. This development includes the use 

of more advanced equipment, adopting modern production techniques, and compliance with 

international quality standards. The table below shows the number of concrete plants in Palestine 

according to the 2017 statistics from the Palestinian Central Bureau of Statistics. [3] 

Table 1: Number of ready-mix concrete manufacturing establishments in Palestine 

Concrete production in Palestine exceeded 2.5 million cubic meters in 2022, and continued 

growth is expected in the coming years. The future of the concrete industry in Palestine is expected 

to continue expanding, due to ongoing economic growth and increasing demand for housing and 

infrastructure development.[3]  

 

 Automation of production of concrete mix: Computer-aided design of concrete leads to a 

reduction in terms of production, the exclusion of product deficiencies, improve the quality of 

manufactured products. This approach allows to produce concrete to exact physical and 

mechanical characteristics, which makes the design more reliable and economical. The software 

package will allow: to reduce the settlement time in the design of concrete mixture, to improve the 

efficiency of the staff of the laboratory building, to improve the quality of the concrete mix due to 

higher accuracy of calculations, to apply a flexible approach to the design of concrete mixture in 

question of introducing new chemical additives and their characteristics. [4] 

Number of factories Governorate name Governorate symbol 

11 Jenin 1 

1 
Tubas and the northern Jordan 

Valley 
5 

6 Tulkarm 10 

8 Nablus 15 

5 Qalqilya 20 

3 Salfit 25 

8 Ramallah and Al-Bireh 30 

2 Jericho and the Jordan Valley 35 

6 Jerusalem 40 

12 Bethlehem 45 

16 Hebron 50 

5 North Gaza 55 

7 Gaza 60 

8 Dair Al Balah 65 

1 Khan Younes 70 

10 Rafah 75 

109 The total 



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Some companies design a visualization and control system for their concrete batching 

plants, which consists of a SCADA/HMI system and PLC.  the SCADA system allows, for 

example, the selection of plant types and models, the registration of vehicles and companies, and 

the generation of reports (inventory, production, distribution, sales), The Plant Configuration 

Wizard is available in SCADA for this purpose. SCADA is used to monitor control panel 

information, company, vehicle, driver, location, order entries, production plan creation, sales 

planning, dispatching, automated and manual production, among others, the data collected from 

the PLC (mixer motor, tool and coverage values) is transferred to the SCADA system using a 

server, and information from the plant configuration processor is sent to the PLC. The PLC 

automatically identifies and runs the work scenario based on this information. [5] 

 

Figure 2: Basics of SCADA 

 

1.2 Types concrete plants: 

There are numerous classification standards for concrete plants. These include dry mix plants 

and wet mixing plants, which depend on the use of a central mixer. Additionally, they can be 

categorized as stationary concrete plants and mobile concrete plants, based on their mobility. 

 

 

 

 



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• Dry mix concrete plant 

A dry mix concrete plant, also referred to as a transit mix plant, measures sand, gravel, and 

cement in weigh batchers using digital or manual scales. Subsequently, all the ingredients are 

discharged into a chute, which then feeds into a truck. Simultaneously, water is either weighed or 

metered volumetrically and discharged through the same charging chute into the mixer truck. 

These components are then mixed for a minimum of 70 to 100 revolutions during transportation 

to the jobsite.[6] 

 

 

Figure 3:Dry mix concrete plant 

 

 

 

 



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• Wet mix concrete plant 

In a wet mixed concrete plant, some or all the above ingredients (including water) are combined 

at a central location into a concrete mixer. The concrete is mixed at a single point and then agitated 

end route to the jobsite to prevent setting (using agitators or ready-mix trucks) or transported to 

the jobsite in an open-bodied dump truck. Dry mixed plants differ from wet mix plants in that wet 

mix plants contain a central mixer, which can provide a more consistent mixture in a shorter time 

(generally 5 minutes or less). Dry mix plants typically exhibit more break strength standard 

deviation and variation from load to load due to inconsistencies in mix times, truck blade and drum 

conditions, traffic conditions, etc. With a central mix plant, all loads undergo the same mixing 

action and there is an initial quality control point during discharge from the central mixer. Some 

plants combine both dry and wet characteristics for increased production or for seasonality. For 

instance, a mobile batch plant can be set up on a large job site. [6] 

 

Figure 4:Wet mix concrete plant 

The primary distinction between a wet and dry concrete plant lies in the mixing process. 

In a wet concrete plant, all the components are mixed in a large concrete mixer. In a dry concrete 

plant, the dry ingredients are first mixed, and then water is added on site. [6] 

Here is a table illustrating some of the key differences between wet and dry concrete plants: 

 

 

 



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Table 2:differences between wet and dry concrete plants 

The feature Wet concrete plant Dry concrete plant 

Mixing method Mix all ingredients together Mix the dry ingredients first, 

then add the water 

The quality Higher quality Lower quality 

The cost Higher cost lower price or cheaper 

Flexibility Less flexible More flexible 

Applications Applications that require high 

quality Such as bridges and 

tunnels 

Applications that do not 

require high quality such as 

sidewalks and roads 

 

The right choice of concrete plant depends on the project requirements. For high-quality 

projects like bridges and tunnels, a wet concrete plant is the best option. For projects that don't 

require high quality, like sidewalks and roads, a dry concrete plant is the most cost-effective choice. 

The type of mixing plant chosen depends on the specific project needs. [6] 

• Mobile concrete plant 

The mobile batch plant, also known as a portable concrete plant, is a highly productive, 

reliable, and cost-effective piece of equipment for producing concrete batches. It enables the user 

to batch concrete at any location, then relocate to another site and batch concrete. Portable plants 

are the ideal choice for temporary site projects or even stationary locations where equipment height 

is a factor, or the required production rate is lower. [6] 

 

Figure 5:Mobile concrete plant 

 

 



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• Stationary concrete plant 

The stationary concrete plant is engineered to produce high-quality concrete. It boasts large 

output, high efficiency, high stability, and high specification. Stationary concrete batching plants 

are dependable and flexible, easy to maintain, and have a low failure rate. They are widely utilized 

in various projects such as roads and bridges, ports, tunnels, dams, and buildings. [6] 

 

Figure 6:Stationary concrete plant 

 

 

1.3 Concrete Recipes: 

American and European Codes for Ready-Mix Concrete differ in design, manufacturing, 

and delivery. American Code emphasizes safety and quality, while European Code focuses on 

energy efficiency and sustainability. Specific differences include compressive strength, cement 

content, water-to-cement ratio, and concrete temperature. Overall, the American Code is more 

stringent, aiming for safety, while the European Code is more flexible, aiming for efficiency and 

environmental performance. In the table (3) that shows the difference between the American code 

and the European code in the ready-mix concrete industry.[7] 



20 

 

Table 3:The difference between the American code and the European code in the ready-mix concrete industry 

The American Code is generally more stringent than the European Code, prioritizing 

building and structure safety. In contrast, the European Code is typically more flexible, aiming to 

enhance efficiency and environmental performance. [7] 

In Palestine, the American code is adopted for concrete mix design, the American code for 

concrete mix design has been widely accepted and implemented in Palestine due to its proven 

effectiveness and reliability. This code provides comprehensive guidelines for determining the 

appropriate proportions of cement, water, aggregates, and admixtures to achieve the desired 

strength and durability of concrete. By adhering to this established standard, Palestinian 

construction projects can ensure the consistent and high-quality performance of their concrete 

structures. 

 

1.4 Problem Statement: 

Based on our research of the labor market, concrete factories in Palestine encounter 

significant challenges that mirror the actual working conditions and the prevailing environmental 

factors. 

1. Concrete factories in Palestine face a significant challenge due to the lack of programs 

specifically designed to address their unique needs. 

2. Discrepancies can arise between the measured materials and the values entered by the civil 

engineer in the concrete mix program, often attributed to inaccuracies in the cumulative scale. 

3. During winter, the increased water absorption of the aggregate directly impacts the amount of 

water added to the mixture, consequently affecting the quality of the concrete. 

Criteria American Code European Code 

Material selection Allows for a variety of materials 
Focuses on using more 
sustainable materials 

Mixing proportions Based on water-to-cement ratio Based on cement content 

Quality control 
Focuses on accuracy of mixing 
and quality control 

Focuses on improving 
manufacturing processes 

Compressive 
strength Minimum of 2,800 psi at 28 days Minimum of 3,000 psi at 28 days 

Cement content Up to 700 pounds per cubic yard Up to 600 pounds per cubic yard 

Water-to-cement 
ratio Up to 0.50 Up to 0.45 

Concrete 
temperature 

Between 40- and 90-degrees 
Fahrenheit Up to 100 degrees Fahrenheit 



21 

 

4. Human factors, such as communication challenges between the control room engineer and the 

mixer driver, as well as the complexity of managing multiple orders, can contribute to 

operational problems. 

5. The risk of the mixture spoiling during transport and the need to determine optimal delivery 

times remain key concerns. 

6. The number of orders executed daily is influenced by the entry and exit patterns of mixer 

drivers during their work shifts. 

1.5 Objectives and scope : 

The objectives and scope of industrial automation in concrete factories are aimed at 

enhancing efficiency, precision, and overall performance in the production process. Here are key 

objectives and the scope of industrial automation in concrete factories: 

 

1.5.1 Objectives: 

 

Enhanced Efficiency: Automation aims to streamline and optimize various processes within 

concrete factories, leading to increased production efficiency and reduced operational downtime. 

1. Improved Accuracy and Precision: Automation systems utilize sensors and control 

mechanisms to ensure precise measurements and accurate mixing of concrete components, 

contributing to the overall quality of the final product. 

 

2. Cost Reduction: By automating repetitive tasks and optimizing resource utilization, 

concrete factories can reduce labor costs and minimize waste, leading to overall cost 

savings. 

3. Consistent Quality: Automation helps maintain consistency in the quality of concrete by 

controlling variables such as mixing ratios, curing conditions, and other critical parameters. 

4. Increased Safety: Automation can handle hazardous tasks and reduce the need for manual 

intervention in risky environments, contributing to a safer working environment for factory 

personnel. 

5. Remote Monitoring and Control: Industrial automation enables remote monitoring and 

control of concrete production processes, allowing for real-time adjustments and 

troubleshooting without the need for on-site presence. 

 

 

 



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1.5.2 Scope: 

1. Batching and Mixing Automation: Automation systems can control the batching and 

mixing processes, ensuring accurate proportions of raw materials, water, and additives to 

achieve the desired concrete properties. 

2. Material Handling Automation: Automated systems can manage the movement of raw 

materials, finished products, and other supplies within the factory, optimizing logistics and 

minimizing manual handling. 

3. Quality Control Automation: Automation can integrate quality control mechanisms, such 

as sensors and testing equipment, to monitor and adjust the concrete's properties during 

production, ensuring compliance with industry standards. 

4. Equipment Maintenance Monitoring: Automation systems can track the condition of 

machinery and equipment, facilitating predictive maintenance to minimize unplanned 

downtime and enhance overall equipment reliability. 

5. Energy Management: Automation can contribute to more efficient energy usage by 

optimizing the operation of equipment and systems, leading to reduced energy 

consumption and environmental impact. 

6. Data Analytics and Reporting: Automation allows for the collection and analysis of data 

related to production processes, enabling informed decision-making and continuous 

improvement initiatives. 

 

7. Integration with Enterprise Systems: Automation systems can be integrated with broader 

enterprise resource planning (ERP) systems, connecting concrete factories with other 

business processes for seamless coordination and data sharing. 

 

By focusing on these objectives and the outlined scope, industrial automation in concrete 

factories can significantly enhance overall operational effectiveness, product quality, and 

competitiveness in the market. 

 

 

 

 

 

 

 



23 

 

1.6 Report Organization 

The works done in this thesis are summarized in five chapters as follows: 

 

Chapter 1: Introduction 

This chapter takes an overview about automation of ready-mix concrete plants, discusses the 

objectives of this study, and then explains the problem. 

 

Chapter 2: Literature Review 

This chapter examines various studies conducted to analyze different systems for controlling 

ready-mix concrete plants and enhancing their operation in various ways. 

 

Chapter 3: Methodology 

This chapter discusses the methodology for designing control systems in a ready-mixed concrete 

plant and finding the best solutions to related problems. 

 

Chapter 4: Results and Analysis 

This chapter details the outcomes of our project. 

 

Chapter 5: Discussion 

This chapter covers a discussion of system design, programming, and implementation. 

 

Chapter 6: Conclusions and Recommendation 

This chapter presents the conclusions and future recommendations of the project and what will be 

done in the future. 

 

 

 

 

 

 

 

 

 

 

 



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Chapter 2: Literature Review 

The history of concrete plant automation dates to the early 20th century, when the first 

automated control systems for concrete mixing were developed. Initially, these systems were 

relatively simple, but they helped reduce human error and improve the accuracy of concrete mix 

proportions.[8] 

In the 1950s and 1960s, concrete plant automation saw significant progress. More complex 

automatic control systems have been developed, which can control a variety of operations in a 

concrete plant, including concrete mixing, pouring, and curing. [8] 

In the 1970s and 1980s, concrete plant automation became more popular. Automated control 

systems have been installed in more and more concrete plants, increasing productivity and 

improving quality and safety. [8] 

In the 1990s and 2000s, concrete plant automation saw further development. Computer-based 

automated control systems have been developed that can collect and analyze data to improve 

concrete plant operations. [8] 

In the second decade of the 21st century, concrete plant automation continues to develop. 

Automated control systems are developed using new technologies, such as artificial intelligence 

and machine learning. In recent years, concrete plant automation has also focused on sustainability 

and environmental impact. New automated control systems are being designed to optimize energy 

usage and reduce waste, making concrete production more environmentally friendly. Additionally, 

remote monitoring and control systems are being developed to allow for greater flexibility and 

efficiency in concrete plant operations. As technology continues to advance, the future of concrete 

plant automation looks promising, with even more advanced and sustainable automated control 

systems on the horizon.[9] 

 

The chapter "Design, Simulation, and Development of Software Modules to Control 

Elements of a Concrete Production Plant" in the book "New Approaches in Automation and 

Robotics" explores the control and operation of a concrete production plant. The use of qualitative 

modeling is highlighted to improve production procedures and product quality. To ensure the 

reliability of the control system, a simulation tool was utilized that combines traditional numerical 

methods with advanced qualitative techniques to efficiently manage dynamic processes within the 

plant. Commercially available qualitative modeling tools and software have been effective in 

assisting with the operation and control of concrete production machinery. After obtaining the 

optimal control model through simulation using QMTOOL software, tests were performed on 

concrete element manufacturing machines. The effectiveness of this approach is determined by 

various attributes such as analyzing static and dynamic behaviors of machine operations, 

evaluating the operation of critical subsystems, redefining design specifications to improve 

machine control, producing reliable descriptions of collaborative factory machines based on 



25 

 

qualitative models, planning and testing route planning scenarios safely, and reducing the cost of 

manufacturing machines while minimizing the risk of breakdown.[10] 

  

Literature studies on production and delivery of RMC are currently limited. Several papers 

have addressed issues and solution methods related to this topic. For example, Wu and Low (2007) 

used JIT purchasing threshold value models. Feng, Cheng, and Wu (2004) employed a model based 

on genetic algorithms and simulation to optimize dispatch schedules, reducing truck waiting times 

at construction sites. Al-Araidah et al. (2012) developed a model considering costs related to 

distance, traffic, and late delivery to enhance financial performance. Mistassini’s (2004) designed 

a dynamic routing system for daily distribution of ready-mixed concrete in a multi-plant 

environment with time windows. Durbin and Hoffman (2008) created a tool for decision making 

related to scheduling and concrete delivery based on a time-space network with integer side 

constraints. Lu and Lam (2005, 2009) researched optimizing concrete delivery scheduling and 

resource provision for improved productivity. Naso et al. (2007) developed a model to coordinate 

production and JIT transport at partially independent plants. Yan, Lin, and Jiang (2012) studied the 

RMC production problem and developed a model for planning production and truck dispatch 

schedules with stochastic travel times. Schmid et al. (2009, 2010) proposed a solution for ready-

mixed concrete delivery with multiple plants, construction sites, and various vehicle types. Liu, 

Zhang, and Li (2014) focused on integrated scheduling of production and delivery of pumps and 

trucks, considering practical elements to improve efficiency and save costs. For a detailed review, 

see the work of Kinable, Wauters, and Vanden (2014). Most of these papers consider a one-plant-

multi-site approach and design travel times based on deterministic methods. This paper adopts a 

multi-plant-multi-site approach and models travel times based on stochastic methods with time 

windows. In this study, we aim to expand the existing literature on the production and delivery of 

ready-mixed concrete (RMC) by adopting a multi-plant-multi-site approach and modeling travel 

times based on stochastic methods with time windows. By doing so, we hope to address the 

limitations of previous research that primarily focused on a one-plant-multi-site approach and 

deterministic travel time methods. Our approach will provide a more comprehensive 

understanding of the challenges and opportunities in RMC production and delivery, particularly in 

scenarios involving multiple plants and sites. Through the utilization of stochastic methods, we 

seek to capture the inherent variability and uncertainty present in real-world transportation and 

logistics operations, ultimately contributing to the development of more robust and effective 

strategies for RMC production and delivery.[11] 

 

The study conducted by Jia Baiyu, Yang Yu, et al. (2014) explored an integrated knowledge 

management system tailored to meet the needs of ready-mixed concrete companies. It focused on 

knowledge content, related models, and methods of expressing knowledge based on its 

classification, with the aim of enhancing enterprise management, supporting production processes, 

managing production and operating costs, and improving relationships between marketing and 



26 

 

customers to achieve maximum benefits. The successful implementation of knowledge 

management in ready mix concrete companies was highlighted.[12] 

 

To address the issues of practicality and accuracy of the applied knowledge management 

system model, the paper used the knowledge mining-based quality cost model in the concrete 

industry as an example and investigated knowledge mining techniques based on the ANN-GA 

algorithm. The study chose 28-day compressive strength as the output, with five main indicators 

of water, cement, metakaolin, fine aggregate, and coarse aggregate as input layers affecting quality. 

These indicators integrated structural and non-structural factors affecting concrete quality, and GA 

was used to optimize the weights and thresholds of the artificial neural network to obtain the global 

optimal solution. This indicates that ANN-GA, as a knowledge extraction algorithm, can meet the 

requirements of convergence rate and prediction accuracy in knowledge management applications. 

[12] 

 

In this project, our focus was on creating an automated control system for a ready-mix 

concrete plant using the SCADA system, as well as developing new technologies and designs to 

enhance practicality and cost-effectiveness for widespread adoption. Furthermore, we explored 

methods to integrate these systems with other applications to achieve reliable, integrated solutions 

for improving production efficiency and reducing costs. These efforts are aimed at enhancing the 

quality of the final product and streamlining production processes to save time and effort. Our 

constant pursuit of innovation and development is geared towards meeting our customers' needs 

and ensuring their satisfaction. 

 

 

 

 

 

 

 

 



27 

 

Chapter 3: Methodology 

3.1 Requirements Analysis: 

Developing a concrete plant automation system necessitates the delineation of functional 

requirements to guarantee the system's efficient attainment of its intended objectives. The 

following are key functional requirements for a concrete plant automation system: 

1. Batching System: 

• Accurate Measurement: Ensuring precise measurement of raw materials (cement, 

aggregates, water, and admixtures) for each batch. 

• Flexibility: Allowing for the configuration of different concrete mix designs. 

• Automatic Batching: Enabling automatic batching based on predefined mix proportions. 

2. Material Handling: 

• Conveyor Control: Managing conveyor systems for the transportation of materials 

between different process stages. 

• Storage Management: Controlling material storage and retrieval systems for raw materials 

and finished products. 

3. Moisture Control : 

• Aggregate Moisture Control: Incorporating sensors to measure and adjust for aggregate 

moisture content. 

4. Quality Control: 

• Real-time Monitoring: Implementing a system for real-time monitoring of concrete quality 

parameters. 

• Testing Integration: Facilitating integration with quality testing equipment for on-site 

testing of concrete properties. 

5. Recipe Management: 

• Recipe Storage: Storing and managing a database of concrete mix recipes. 

• Version Control: Allowing for versioning of mix recipes to track changes and 

improvements. 

6. Process Automation: 

• Automated Start/Stop: Enabling automatic start and stop of the plant based on predefined 

schedules or demand. 

• Fault Detection: Implementing a system for detecting and responding to equipment 

malfunctions or deviations from set parameters. 

7. Reporting and Documentation: 

• Data Logging: Logging critical process data for future analysis and troubleshooting. 

• Reporting: Generating regular reports on production efficiency, material usage, and quality 

metrics. 

8. User Interface: 

• Intuitive Interface: Designing a user-friendly interface for operators to monitor and control 

the plant. 



28 

 

• Alarm System: Implementing an alarm system to notify operators of any issues or 

deviations. 

9. Security and Access Control: 

• User Authentication: Implementing secure user authentication to control access to system 

functions. 

These functional requirements serve as the foundation for the development of a comprehensive 

concrete plant automation system, enhancing efficiency, accuracy, and overall productivity. It is 

important to note that specific requirements may vary based on the scale and complexity of the 

concrete plant. 

 

3.2 System design: 

The control interface for ready-mixed concrete factories was designed based on our study of 

the labor market. It considered some of the problems faced by operators working in the factories 

and incorporated advice from them. After examining various control interfaces and programs, we 

developed our own, ensuring it was designed in a simple and user-friendly manner while 

encompassing all necessary functions required for efficient plant operation. 

 

The items within the interface are organized logically, facilitating quick search and access 

to information. Moreover, the interface was crafted with modern and advanced technologies to 

guarantee high performance and swift response times. We identified the factory’s working 

mechanism, including processes such as weighing, branching, loading, mixing, equipment 

protection, and minimizing error rates in the scales to produce concrete mixes with the required 

specifications. 

 

To enhance operational efficiency, a function was integrated to enable remote monitoring 

of the factory’s operations through the use of modern communication technologies. This empowers 

operators to monitor activities and make effective and timely decisions. Additionally, a 

multilingual user interface has been implemented, ensuring usability for all factory workers, 

irrespective of their mother tongue. 

 

The interface is designed to be customizable according to operators’ specific needs, thereby 

increasing work efficiency and facilitating adaptation to different requirements. 

 

 

 

 



29 

 

 Concrete production processes : 

The diagram in Figure 7 shows the operating mechanism of the dry ready mix concrete 

plant, which is widely used in Palestine. The process is done as follows: First, the type and quantity 

of the required mixture are selected from the program. After that, the factory is activated and all 

material gates (aggregate, sand, cement) as well as pumps (water and chemicals) are opened, and 

the weighing process begins until the required weight for each component is reached. Next, the 

aggregate and sand are unloaded onto the conveyor for transportation to the mixing truck. Then, 

cement and water are simultaneously released into the mixing truck. Finally, the chemicals are 

unloaded into the mixing truck. 

 

The flow chart in Figure 8 shows the operation of a wet ready mix concrete plant. The 

process includes selecting the type and quantity of mixture required, activating the plant, opening 

material gates and pumps, and beginning the weighing process until the desired weight is reached 

for each component. Then, the aggregate and sand are transported to the mixing host via conveyor, 

while the cement and water are released to the mixing host. In addition, the chemicals are unloaded 

into the mixing truck. The central mixer then combines the coarse stone, fine stone, sand, cement, 

water and additives to produce the final concrete at pre-determined composition ratios. 

 

 

Figure 7:A diagram drawn up to illustrate the practical mechanism of a dry ready mix concrete plant. 



30 

 

 

 

To control the operation of a concrete plant, it is essential to consider the hierarchy depicted 

in Figure 9. The automation pyramid visually illustrates the various levels of automation within 

the plant, providing a comprehensive understanding of the factory’s complexity. At the base of the 

pyramid is the field level, which consists of sensors and actuators that directly interact with the 

physical processes of the plant. The next level is the control level, where PLCs (Programmable 

Logic Controllers) and other control devices manage the operation of individual machines or 

processes. Above that is the supervisory level, which oversees the entire plant and may include 

SCADA (Supervisory Control and Data Acquisition) systems. Finally, at the top of the pyramid is 

the enterprise level, where higher-level decision-making and resource planning occur. 

Understanding and effectively managing the interactions between these levels is crucial for 

optimizing the performance and efficiency of a concrete plant.[13] 

 

Figure 8:A diagram drawn up to illustrate the practical mechanism of a wet ready mix concrete plant. 



31 

 

 

Figure 9:Automation pyramid 

 

3.3 System Architecture and Hardware Components: 

 

3.3.1 Level 0- Field Level/Production Process (devices, actuators and sensors): 

 

This layer contains devices, actuators, and sensors located in the field or on the production 

floor. The field level represents the production floor where physical work and monitoring take 

place. Examples of field level devices include electric motors, sensors, hydraulic and 

pneumatic actuators for moving machinery, as well as proximity switches to detect the 

movement of specific materials. Switches that detect similar movements are also commonly 

found at this level. Field-level devices are vital to the smooth running of production operations, 

providing real-time data and control of various machines and equipment used in manufacturing 

and industrial environments and providing data in fractions of a second. These devices play a 

critical role in ensuring efficiency, safety and optimal performance of the production floor. [13] 

 

 



32 

 

Below is a description of the sensors, actuators, and devices at this level for ready mix concrete 

plants: 

 

➢ Sensors: 

 

• Load Cell: 

A load cell transforms a force like tension, compression, pressure, or torque into a signal 

(electrical, pneumatic, or hydraulic pressure, or mechanical displacement indicator) that can 

be measured and standardized. It serves as a force transducer. As the force on the load cell 

increases, the signal changes proportionally. The most common load cell types for industrial 

applications are pneumatic, hydraulic, and strain gauge. A common example of a mechanical 

displacement indicator is non-electronic bathroom scales, where the applied weight (force) is 

indicated by measuring the deflection of springs supporting the load platform, technically a 

"load cell".[14] 

Commonly used in concrete plants to measure the weight of aggregate, cement, and 

additives. 

The S-type load cell:  is the most commonly used sensor for measuring tension and pressure 

between solids. It is also known as a tension pressure sensor due to its S-shaped design. These load 

cells are highly accurate, typically with ±0.025% non-linearity, and are suitable for measuring both 

tensile and compressive forces. The spring element is positioned in the center beam of the load 

cell. Interface S-Type Load Cells are cost-effective, accurate, easy to mount, and offer flexibility 

for tension and compression testing. They are available in capacities ranging from 25kg to around 

30 tonnes, primarily utilizing metal foil strain gauge technology. These load cells are a popular 

choice for applications due to their accuracy and compact design. [14] 

Figure 10:S-type load cell 



33 

 

• Moisture Sensor: 

Moisture Measurement in Aggregates and Sand 

Initially developed for the ready-mix and pre-cast concrete industries to improve batching 

accuracy and slump control, these systems have proven beneficial in other industries using sand 

or aggregates during processing. Advantages include a reduction in spoiled batches, the ability to 

batch the correct sand weight regardless of water content, and the capability to set high or low 

moisture level alarms. Modern plants can weigh aggregates with an accuracy of up to ± 0.5%. Any 

moisture variation in a batch of sand or aggregates between 2% to 10% affects the accuracy and 

proportions of the weighed materials, as water is effectively weighed instead of dry materials.[15] 

 

Moisture sensors can measure moisture levels in 

materials being discharged from bins, on conveyor belts, or 

within vibratory feeders. Placed directly in the material flow, 

the sensors take 25 measurements per second as the sand or 

aggregate flows over the ceramic measurement surface. 

These measurements are then transmitted to the plant control 

system in real time. This enables manufacturers to precisely 

control water addition during processing, ensuring consistent 

batch quality while reducing material wastage. The sensors 

offer various mounting options and can be installed in 

different locations based on plant-specific needs. Optimal 

results are achieved by mounting the sensor in the neck of a 

bin or underneath the gate. The popular sensor for this type of mounting is the Hydro-Probe, which 

takes readings as the sand or aggregate is released from the bin and flows over the sensor faceplate. 

If positioning the sensor in this location is challenging, good results have also been obtained by 

mounting the sensor inside the bin. [15] 

 

To measure moisture in sand and aggregates flowing on conveyors and belt feeds, a Hydro-

Probe or a Hydro-Probe Orbiter can be mounted above the belt. Readings can then be taken as the 

material passes along the belt, flowing around the sensor. [15] 

Figure 11:Moisture Sensor 

Figure 12:Hydro-Probe installed above sand 

conveyor belt 
Figure 13:Moisture Sensor located under 

Aggregate Bin 



34 

 

• Proximity Sensors: 

Proximity sensors are commonly used in concrete plants for various purposes, contributing to 

the automation and efficiency of the production process. Here are some ways proximity sensors 

may be employed in a concrete plant [16] :  

 

1) Aggregate Batching: Proximity sensors can be used to detect the presence or absence of 

aggregates in the storage bins. This information helps in automating the batching process, 

ensuring that the correct amount of each aggregate is dispensed into the mixer. [16] 

 

2) Cement Silo Level Monitoring: Proximity sensors can be installed at different levels within 

cement silos to monitor the level of cement. This data is crucial for inventory management and 

ensures that an adequate supply of cement is always available for the mixing process. [16] 

 

3) Admixture Dispensing: Proximity sensors may be used to monitor the dispensing of 

admixtures. By detecting the presence of containers or valves, the system can control the 

addition of admixtures to achieve the desired concrete properties. [16] 

 

4) Gate Positioning: In some plants, gates or valves control the flow of aggregates or cement. 

Proximity sensors can be employed to detect the position of these gates, ensuring they are open 

or closed as required during the batching process. [16] 

 

Figure 14 :Proximity Sensors 



35 

 

5) Monitoring mixer drum rotation in wet concrete plants: Proximity sensors can be used to 

monitor mixer drum rotation. This information is vital to ensure that the concrete mixture is 

well mixed and reaches the desired consistency before unloading. [16] 

 

6) Conveyor Belt Monitoring: Proximity sensors may be installed along conveyor belts to detect 

the presence of aggregates and other materials. This information is essential for maintaining a 

steady flow of materials during the production process. [16] 

 

7) Truck Loading: Proximity sensors can be used to automate the loading of ready-mixed concrete 

into delivery trucks. Sensors can detect the position of the truck, ensuring accurate loading and 

preventing overfilling. [16] 

 

8) Safety Applications: Proximity sensors can also play a role in safety by detecting the presence 

of personnel in specific areas. This information can trigger alarms or shut down certain 

equipment to prevent accidents. [16] 

 

The specific use of proximity sensors in a concrete plant depends on the plant's design, the 

level of automation, and the desired efficiency. These sensors help in monitoring and controlling 

various aspects of the production process, contributing to the overall quality and consistency of 

the ready-mixed concrete. [16] 

• RFID Sensors: 

RFID, or radio frequency identification, is a type of automatic identification technology that 

uses radio frequencies to capture and transmit data. It consists of tags and a reader. Each tag 

contains an integrated circuit chip and an antenna, enclosed in a protective shell. The reader 

includes an antenna and a scanner to communicate with the tags.[17] 

 

RFID tags can be active (battery-powered) or passive (powered by the reader through radio 

waves). They can also be categorized by working ranges: near-field RFID systems operate on 

lower band RF (e.g., 13.56 MHz) and use an inductive power mechanism, while far-field systems 

run on higher band RF (about 915 MHz) and use an electromagnetic powering mechanism to 

achieve interrogation distances greater than 10 feet. [17] 

 

 

 



36 

 

 RFID sensors improve automation, tracking, and monitoring in concrete plants. They are used 

for raw material tracking, inventory management, batching process automation, quality control, 

equipment and asset tracking, truck loading and dispatch, personnel tracking, and maintenance 

scheduling. This integration enhances efficiency, accuracy, and traceability in production and 

logistics. [17] 

 

 

3.3.2 Level 1-Control Level/Sensing and Manipulation (PLC, DCS and PID): 

 

At this level, you control and manipulate the devices in the field level that actually do the 

physical work. They take information from all of the sensors, switches, and other input devices to 

make decisions on what outputs to turn on to complete the programmed task. PLCs contain a 

processor, memory to hold their programming and other data and input and output modules. A PID 

is usually integrated into the PLC, DCS and stands for proportional–integral–derivative. That is 

what can keep a variable within a set of parameters. [18] 

DCS (Distributed Control System), PLC (Programmable Logic Controller), and PID 

(Proportional-Integral-Derivative) are terms associated with control systems, each serving 

distinct purposes and offering unique functionalities. 

 

Figure 15:RFID sensors 



37 

 

• DCS (Distributed Control System): 

 

Purpose: DCS is utilized to control and oversee intricate industrial processes. It is distributed 

as it involves multiple controllers spread across a system.  

Functionality: DCS is tailored for large-scale systems where multiple processes or units require 

control and monitoring. It utilizes a networked architecture, enabling centralized control and 

distributed processing units.  

Applications: Commonly found in industries such as power plants, chemical plants, and 

manufacturing facilities where numerous control loops and processes necessitate coordination. 

[18] 

 

 

→ Who are the largest manufacturers of Distributed Control System (DCS) Market 

worldwide? 

 

ABB, Yokogawa, Honewell, Emerson, SIEMENS, HITACH, Foxboro, HollySys, Supcon , 

Sciyon , Guodia , Xinhua, Shanghai Automation and Luneng 

Figure 16: Distributed Control System 



38 

 

• PLC (Programmable Logic Controller): 

 

Purpose: PLC is a ruggedized digital computer used for industrial automation, designed to 

execute real-time control functions. 

Functionality: PLCs are programmable and can be configured to control various industrial 

processes and machinery. They are frequently employed for discrete control applications, such as 

assembly lines or manufacturing processes. 

Applications: Widely used in manufacturing and process control, especially in scenarios 

requiring sequential or logic-based control. [18] 

→ Who are the largest manufacturers of Programmable Logic Controller (PLC) Market 

worldwide? 

 

Siemens, Rockwell Automation, Schneider Electric, Mitsubishi Electric, ABB, Omron, Delta 

Electronics, Yokogawa Electric, Honeywell, DALTA, Fatek and Panasonic. 

 

Figure 17:PLC 



39 

 

The PLC can be divided into several parts, as shown in the following figure: 

1. Power Supply: 

• It converts alternating current into direct current to feed the rest of the PLC parts. 

• Some PLC devices operate at VAC 220, so they are connected directly to the electricity 

source without a power unit.  

• In small PLC systems, the feeder is used to feed field devices 

(inputs and outputs). 

• In large systems, an external feeder is used to feed field 

devices.[19] 

 

 

 

 

 

 

 

Figure 18 :PLC Schneider 

Figure 19:PLC part 



40 

 

2. CPU: 

• The central processing unit is the brain of the PLC. 

• The CPU processes the signal data of the input devices and sends the results of the 

operations to the output devices according to the program stored in memory. 

• Each CPU has special specifications that affect its speed in performing operations. 

The central processing unit (CPU) is the PLC's brain. It processes input device signal data 

and sends operation results to output devices based on the stored program in memory. Each 

CPU has unique specifications influencing its operational speed. [19] 

 

 

Figure 20:CPU type 

 

3. Input Modules 

 

• The input modules receive signals from input devices and format them for processing by 

the central processing unit. 

• Input units can be digital, processing logical signals (0 or 1), or analog, with variable values 

like (10), (0), or (20-4). Analog-to-digital conversion circuits transform incoming analog 

signals from analog inputs into digital signals for CPU processing. [19] 



41 

 

 

4. Memory: 

Memory is the component that stores data, information, and programs. Writing is the 

process of storing data in memory, while reading is the process of retrieving data from memory. 

PLC memory is categorized into volatile and nonvolatile types: 

 

a) Volatile memory loses all stored data when power is lost and allows for data 

modification. It is user-friendly and suitable for many applications when a battery 

is used. 

b) Nonvolatile memory retains data even when power is disconnected. 

 

1. Read-Only Memory (ROM): is a type of nonvolatile memory that is programmed during 

manufacturing. It typically holds data essential for the operating system and PLC 

functionalities. [19] 

 

2. Random Access Memory (RAM): is a type of read and write memory 

that enables fast reading and writing processes due to its sequential 

access capability. RAM serves as temporary data storage and is 

volatile, requiring a battery to sustain its contents in PLC devices. 

CMOS-RAM technology is commonly used in PLCS, drawing a 

small current and preserving data for 2 to 5 years with lithium 

batteries. Some processors utilize a capacitor to help the RAM retain 

data for up to 30 minutes if power is disconnected. [19] 

 

Figure 21:Input module 

Figure 22:lithium batterie 



42 

 

3. Erasable Programmable Read Only Memory (EPROM): EPROM is a non-volatile memory 

that stands out from ROM as it can be erased and altered using ultraviolet rays. It is primarily 

utilized for storing and transferring PLC programs, providing a certain level of program 

security against unauthorized modifications. [19] 

 

4. Electrically Erasable Programmable Read Only Memory 

(EEPROM): EEPROM, another non-volatile memory 

type, offers the same programmability as RAM without the 

need for a battery or ultraviolet light for content 

modification. Its content is easily changed using a 

programming device, serving as a storage medium for 

PLC programs. [19] 

 

5. Flash EEPROM: Similar to EEPROM, Flash EEPROM can be used for program backup but 

excels in faster saving and retrieval processes. Content modifications do not require a special 

programming device, allowing for changes without 

disconnecting from the PLC. Some processors 

automatically reserve space for this memory, safeguarding 

critical data in case of power outages to ensure 

uninterrupted PLC functionality. [19] 

 

❖ Memory size depends on several factors: 

1. The amount of memory required depends on the 

complexity of the program. 

2. The PLC contains only one program in memory. It is not possible to store more than one 

program in the memory at the same time. If a new program is copied or loaded into the 

memory, this means erasing or losing the old program. 

3. Or Flash EEPROM, which some CPUs contain a Memory Cartridge and are of the 

EEPROM type, through which the program can be copied from one PLC to another of the 

same type. 

4. One of the most popular batteries used with a PLC device is the lithium battery. It is 

characterized by its constant voltage. One of its disadvantages is that its voltage reaches 

zero as soon as its life span ends without warning. It is preferable to change the battery 

every two years. 

 

5. There are some types of capacitors called Super Capacitors, which help the RAM to retain 

the program for up to 50 hours after the power is interrupted and the battery is lost. 

 

 

Figure 23:RAM & EEPROM 

Figure 24:Flash memory 



43 

 

❖ PLC Classification Based on Inputs and Outputs  

  The difference in industrial processes has led to the companies producing PLCS resorting 

to manufacturing different types of devices in order to cope with the size of the different industrial 

processes (one PLC production company has more than 

PLC type). 

   The classification of PLCS in markets depends on several factors, the most important of 

which are the function and number of inputs and outputs factors, price and volume. 

PLCS can be classified into four types in terms of the number of inputs and outputs as follows: 

1. Nano PLCs: It is the smallest size of PLCS and contains less than 15 input and output 

points. 

2. Micro PLCs: It contains a range from 15 to 128 input and output points. 

3. Medium PLCs: It contains a range from 128 to 512 input and output points 

4. Large PLCs: It contains more than 512 input and output points. 

 

❖ PLCs can be categorized into two types based on how the input and output modules are 

integrated: 

• Compact  or fixed PLC: This is a modern type where all components, including the feeder 

unit, input unit, output unit, and memory, are enclosed within a single box. It is expandable 

through a network port for adding more modules. 

 

Figure 25:Compact or fixed PLC 

 

• Modular PLS: This was the initial type introduced and is known for its capacity to handle 

numerous inputs, outputs, and memories. It can support large programs and advanced 

functions, with modules installed on a base independently. 



44 

 

 

Figure 26:Modular PLS 

 

❖ In general, PLCS applications can be classified into three types as follows: 

 

• Single ended or Stand-alone PLCs Application: 

In this application, a single PLC controls a single process, as it is an independent unit and is 

not connected to any other PLC or  computer. In these applications, the size and development 

factors of the process that is to be controlled are clear during the selection of the PLC. Most of 

these applications require PLCS of small types. 

 

 

 

 

 

 

 

 

 

Figure 27:Single ended or Stand-alone PLCs Application 



45 

 

• Multitask PLCs Application: 

In this application, a single PLC controls a group of processes. In these applications, the 

number of inputs and outputs to the PLC is the most important factor. Also, if the application is 

part of a large process, this requires the PLC to be connected to the central PLC or computer. 

 

 

• Control Management PLCs Application: 

In this application, the PLC controls a group of other PLCS. In these applications, a PLCS 

requires large processors and the ability to communicate with other PLCS and computers. 

 

 

Figure 28:Multitask PLCs Application 

Figure 29:Control Management PLCs Application 



46 

 

  There are many companies that produce PLCs, and each company has several different 

types of PLCs that it produces, and each series has a special program to program and connect them. 

As is the case in the following figures 30,31,32,33,34. 

 

 

 

 

 

Figure 30:companies that produce PLCs 

Figure 31:Siemens PLC and Program 



47 

 

 

 

 

Figure 33:Schneider PLC and Program 

Figure 32:DALTA PLC and Program 

Figure 34:Allen-Bradley PLC and Program 



48 

 

• PID (Proportional-Integral-Derivative): 

Purpose: PID is a type of control algorithm used in feedback control systems to regulate a 

process. 

Functionality: PID controllers utilize feedback from a process to continuously adjust the 

control output to maintain a desired setpoint. The three components (Proportional, Integral, and 

Derivative) contribute to the control action based on the error (difference between the setpoint and 

actual process variable). 

Applications: PID controllers are employed in various systems, including temperature control, 

pressure control, and flow control. They are versatile and widely used in both DCS and PLC 

systems. [18] 

 

In conclusion, DCS and PLC represent broader control system architectures, with DCS 

being more suitable for distributed and complex processes, while PLC is often utilized for discrete 

control applications. PID, on the other hand, is a specific control algorithm employed within both 

DCS and PLC systems to regulate processes and ensure they operate at desired setpoints. [18] 

 

3.3.3 Control Systems in Concrete Plants: A Comprehensive Guide to Choosing Between 

PLC, DCS, and PID 

When choosing between Programmable Logic Controller (PLC), Distributed Control System 

(DCS), and Proportional-Integral-Derivative (PID) control systems for a concrete plant project, 

several factors come into play. These include process complexity, control requirements, and project 

goals. Here are some considerations for selecting PLC over DCS and PID in a concrete plant 

project: 

 

• Process Complexity: 

If the concrete plant has a relatively simple process, a PLC may suffice, as it is well-suited for 

discrete and sequential control. 

 

• Flexibility and Scalability: 

PLCs offer flexibility and scalability, making them suitable for smaller to medium-sized 

concrete plants. They can easily adapt to changes in the production process and can be expanded 

or modified without significant challenges. 

 

 



49 

 

• Cost Considerations: 

PLCs are often more cost-effective than DCS for smaller and less complex applications. If 

budget constraints are a significant factor, opting for a PLC-based control system may be a 

practical choice. 

• Real-time Control: 

PLCs are designed for real-time control and can effectively manage time-critical processes. In 

a concrete plant, where precise control of mixing, batching, and other processes is essential, PLCs 

can provide the necessary responsiveness. 

• Specialized Functions: 

For specialized control functions, such as motion control, PLCs may be a better fit. They can 

be programmed to handle a wide range of control tasks, and their programming languages are well-

suited for discrete and sequential operations. 

• PID Control Integration: 

While PLCs can handle basic PID control, if advanced PID control strategies are a critical 

requirement, a dedicated PID controller or a DCS with advanced control capabilities may be more 

appropriate. 

• Integration with Other Systems: 

PLCs are often used for stand-alone applications, and they may be more suitable for integration 

with other control systems or enterprise-level software if needed. DCS, on the other hand, is 

designed for seamless integration across various processes in a plant. 

• Operator Interface: 

Consider the operator interface requirements. PLCs typically have simpler human-machine 

interfaces (HMIs) compared to DCS. If the plant operation doesn’t require a highly complex 

graphical interface, a PLC-based system may suffice. 

 

In summary, the choice between PLC, DCS, and PID control in a concrete plant project 

depends on the specific needs and characteristics of the plant. PLCs are often preferred for smaller 

and less complex applications, while DCS may be more suitable for larger and integrated systems. 

PID control can be integrated into either PLC or DCS based on the level of control sophistication 

required. 

 

 

 

 



50 

 

3.4 Software Design and Implementation: 

 

3.4.1 Level 2- Supervisory Level/Monitoring and supervising (SCADA design): 

 

This level is known as the supervisory level. Where the previous level utilizes PLCs, this level 

utilizes SCADA. SCADA is short for supervisory control and data acquisition. 

SCADA is essentially the combination of the previous levels used to access data and control 

systems from a single location. It usually adds a graphical user interface called an HMI, to control 

functions remotely. The important thing to remember about SCADA is that it can monitor and 

control multiple systems from a single location. It isn’t limited to a single machine. In addition, 

SCADA allows for real-time data collection, analysis, and reporting, enabling more efficient and 

effective decision-making processes. Furthermore, SCADA systems are designed to be highly 

secure, with advanced encryption and authentication measures in place to protect sensitive 

information and prevent unauthorized access. Overall, SCADA represents a significant 

advancement in the field of industrial automation and control, providing enhanced capabilities and 

functionality for supervisory and monitoring tasks. 

 

 

After researching various software options for creating a control interface for a concrete 

plant using SCADA software, we experimented with Siemens software including TIA Portal, 

WinCC, and others. Ultimately, we determined that DIA VIEW was the best fit for our needs 

due to its user-friendly interface and excellent features. Additionally, it is available for free 

download from the Chinese company Delta's website. We utilized this software to design a 

ready-mix concrete plant. 

 

 

 

Figure 35:DIAVIEW software interface 



51 

 

3.4.2 The UI for the program, completed in the of graduation project. 

 

➢ Main Screen: 

After implementing the main SCADA user interface on DIA View, it includes main icons for 

logging in, logging out, translating, and exiting the program. In addition, there is an order page bar 

that allows three orders to be prepared simultaneously for customers and there is also a laboratory 

samples page. This page includes the results of tests of materials and mixtures in the factory’s 

private laboratory. Furthermore, a toolbar is available, featuring sections for factory layout, guide, 

automatic, timer, username, recipes, settings, alarms, reports, printing, and history. These settings 

were incorporated following extensive research and visits to various ready-mix concrete factories, 

considering input from industry experts, and are illustrated in figure 36. 

 

➢ Orders page: 

In the user interface requests pages (Automated Concrete Control System), as depicted in 

Figure 37, control and monitoring of weights and quantities are carried out, along with the display 

of certain commands and information. 

In box (1): The required number of cups and the number of ready cups is shown. 

In box (2): Control operation buttons (automatic and manual) and order information, as depicted 

in Figure 38, are displayed. 

Figure 36:The main interface of the program 



52 

 

In Box (3): Three tables are provided for monitoring and controlling weights. 

In box (4): It includes buttons for controlling the operations occurring in the factory during the 

order. 

Figure 37:Orders page and control 

Figure 38:order information 



53 

 

 

➢ Manual Page: 

  Upon accessing the manual page, which displays control of all operations within the 

concrete plant the user will have full control over the concrete plant's operations and can easily 

navigate through the manual to find information on specific processes and procedures. This 

comprehensive guide ensures that all tasks can be carried out efficiently and safely, maximizing 

productivity and minimizing errors. The Python code was written to simulate manual operation 

and can be found on the Appendices page., as depicted in Figure 39. 

 

 

 

 

 

 

 

 

 

Figure 39:Manual Page 



54 

 

 

 

➢ Setting Page: 

When you enter the settings page, you can add a new username and create a password for 

it. You can also change the username and password of the current user. Additionally, you can 

create login permissions for all employees within the plant, including engineers, managers, 

and operators. For example, you can create login permissions for an engineer to access the 

recipes page, enter the required weights for each cup, and set up, adjust, and calibrate the 

scales through the page, as shown in Figure40. 

 

 

 

 

 

 

 

 

 

Figure 40:Setting Page 



55 

 

 

➢ invoice page : 

When you open the invoice page, this page appears at each end of an order, and contains the 

order information that was filled out form the orders page. Part of it is directed at the factory and 

the other part is directed to the customer. as depicted in Figure (41). 

 

Figure 41:invoice page 

 

 

 

 

 

 

 

 

 

 

 

 



56 

 

➢ Report Page: 

Concrete factory reports offer numerous benefits, aiding quality control, performance 

monitoring, resource management, compliance, cost analysis, and continuous improvement. They 

are vital for optimizing processes, reducing costs, and ensuring overall business success. 

 

As shown in the figure 42, When entering the report page, this is the factory’s page, which 

contains information about customers’ orders, time and date, quantity of water, super quantity, 

cement quantity. 

The amount of sand, quantity of aggregate 1, quantity of aggregate2, quantity of aggregate3, 

quantity of aggregate4, mixer loading time number one, mixer exit time number one where you 

can specify the start and end date and time to display the above quantities in the report additionally, 

the report page allows for the export of data in various file formats such as CSV or Excel, providing 

flexibility for further analysis or integration with other systems. The interface also supports 

filtering and sorting options to streamline data retrieval based on specific criteria, enhancing user 

experience and efficiency. This comprehensive functionality empowers users to gain insights into 

production metrics and make informed decisions to optimize operations. 

 

 

 

Figure 42:Report Page 



57 

 

➢ Recipes Page: 

The mixtures page in a concrete factory is crucial for recipe formulation, quality control, 

customization, resource optimization, consistency in production, documentation, adaptation to raw 

material variability, and research and development. It is central to the success and competitiveness 

of concrete manufacturing. The mixtures page serves as the foundation for creating concrete that 

meets specific requirements for strength, durability, and other performance characteristics. It 

allows for precise measurement and combination of raw materials, such as cement, aggregates, 

and water, to achieve the desired properties in the finished product. Additionally, it enables the 

monitoring of production parameters to ensure consistent quality and performance of the concrete. 

as depicted in Figure 43. 

 

 

 

 

 

 

 

 

 

Figure 43:Recipes Page 



58 

 

➢ Timer Page: 

On this page, you can adjust the unloading timing of aggregate, water, cement and 

superplasticizers. In addition, you can adjust the timing of mixing the materials inside the mixer 

and unloading them into the cement mixture truck, as shown in Figure 44. 

 

 

 

 

 

 

 

 

 

 

 

 

Figure 44:Timer Page 



59 

 

 

➢ Alarm Page: 

 

Through this page, you can easily identify issues with the conveyor, cement screw, cement 

pumps, and added chemicals, as well as check the status of water and cement tanks. Additionally, 

this page aids in streamlining maintenance procedures and promptly pinpointing any potential 

defects. This innovative solution integrates seamlessly with existing industrial systems, providing 

real-time monitoring and automatic alert generation for swift action. By centralizing data 

collection and analysis, it enhances operational efficiency and minimizes downtime, ultimately 

maximizing productivity and ensuring optimal performance across all components, as 

shown in Figure 45. 

 

Figure 45:Alarm Page 

 

 

 

 

 

 

 



60 

 

3.4.3 Selecting a PLC and the selection process : 

Based on the prior labor market study and availability of parts and taking into account costs 

and consultation with Supervisor, a PLC controller from Delta Company was selected from 

a series suitable for the needs of the project. The virtual system model is built using specific 

PLC programming, and basic tests are performed to verify its compliance with the project 

requirements. Successful results were achieved, confirming the accuracy and effectiveness of 

the controller in managing production processes, making it the ideal choice for project 

implementation. 

The following figure (46) shows how to configure the names of DVP Series Programmable 

Logic Controllers (MPU), Digital Input/Output (DI/DO) and Analog I/O (AI/AO) and helps 

in making the correct decisions for the project. 

 

 

Figure 46:configure the names of DVP Series Programmable 



61 

 

The PLC DVP 14 SS2   was chosen for the project and was programmed using Delta's ISPsoft 

software. Since the DVP 14 SS2 series PLC offers a versatile range of functions and reliable 

performance, it was the ideal choice for this project. With Delta's ISPsoft software, the 

programming process was streamlined and efficient, allowing for seamless integration of various 

control functions. The user-friendly interface of the software made it easy to program complex 

logic and ensure smooth operation of the system. as depicted in Figure (). 

 

DVP-14 SS2 

Economic and Compact PLC. Max. 480 I/O points: 

➢ Adopts 32-bit CPU 

➢ Program capacity: 8k steps/Data register: 5k words 

➢ Higher execution speed compared to the \ 

competition: LD: 0.35μς, ΜΟΥ: 3.4με 

➢ Built-in RS-232 and RS-485 ports (Master/Slave) 

➢ Supports standard MODBUS ASCII/RTU protocol  

and PLC Link function 

Motion Control Functions 

➢ 4 points of 10kHz pulse output 

➢ 8 points of high-speed counters: 

➢ 20kHz/4 points, 10kHz/4 points 

 

 

➢ PLC Wiring: 

• The PLC feed is divided into three parts [CPU feed - input units feed - output units feed]. 

Figure 48:PLC DVP-14 SS2 

Figure 47:DVP Series and ISP soft program 



62 

 

 

• Powering the CPU requires connecting electricity according to its type, for example, whether 

it is an alternating or direct voltage, considering the voltage value. 

➢ Addressing: 

Addressing system for PLC inputs and outputs is fundamental to their operation, enabling 

precise identification and control of various signals. Inputs, typically denoted by X, and outputs, 

denoted by Y, follow a structured format, facilitating seamless integration and expansion. With 

digital and analog, I/O options, Delta PLCs cater to diverse automation needs. Understanding the 

addressing conventions, especially for specialized modules and extensions, is crucial for effective 

programming and maintenance. This systematic approach ensures efficient data handling, 

minimizes errors, and enhances overall system performance, making Delta PLCs an indispensable 

tool in modern industrial settings. 

• Inputs: 

The following figure(50) shows the number of basic inputs reserved in memory in all PLC 

Delta companies. 

• Digital inputs X0 to X7 ……. X10 to X17(Octal number system) 

 

Figure 50:number of basic inputs 

Figure 49:PLC Wiring 



63 

 

• If number of inputs in MPU: 

 

➢ Less than or equal 16 

If all extensions: 

If extensions in them 8 input and 16 input: 

 

➢ Greater than 16 

 

Figure 51:8 input MPU X0 …. X17 

Figure 52:extensions in them 8 input and 16 input 

Figure 53:extensions in 16 inputs 



64 

 

 

• Output: 

The following figure (54) shows the number of basic outputs reserved in memory in all PLC Delta 

companies. 

• Digital output Y0 to Y7 ……. Y10 to Y17(Octal number system) 

 

• If number of Outputs in MPU: 

 

➢ Less than or equal 16 

 

If all extensions 8 output and MPU Y0 …. Y17: 

 

 

 

 

 

 

Figure 54:number of basic outputs 

Figure 55:extensions 8 output and MPU Y0 …. Y17 



65 

 

If extensions in them 8 output and 16 output: 

 

Figure 56:extensions in them 8 output and 16 output 

 

➢ Greater than 16 

 

➢ Auxiliary Relay: 

• Used only in program starting M0 to Mxxx (Decimal system)  

Figure 57:extensions in 16 outputs 

Table 4:Addresses allowed for Auxiliary Relay 



66 

 

 

1. General: It does not maintain its state when the power supply. 

2. Latched: It retains its state during power outages and returns to its initial state when reset. 

3. Special: It has a specific function that can be used within the program. As shown in the table 5 

that. 

Table 5: Special Auxiliary Relay 

 

 

➢ Data Register: 

• Used to store data starting from D0 to Dxxx (Decimal system) 

Table 6:Addresses allowed for Data Register 

 

The size of data registers in a PLC can vary depending on the specific model and manufacturer. In 

general, data registers in PLCs, including those from Delta Electronics, typically have the 

following characteristics: 

 

 

 

 



67 

 

• Common Sizes of Data Registers 

1. 16-bit Registers (Word): 

Most data registers in PLCs are 16-bit, meaning they can store an integer value ranging from 0 to 

65535 (unsigned) or -32768 to 32767 (signed). 

These are sufficient for many typical control and automation tasks. 

2. 32-bit Registers (DWord): 

 

Some PLCs also support 32-bit registers for applications requiring larger numerical values or more 

precision. These registers can store values from 0 to 4,294,967,295 (unsigned) or -2,147,483,648 

to 2,147,483,647 (signed). 

They are used for more complex calculations or where larger ranges are needed, such as in 

advanced data logging or higher precision control. 

 

Connecting Extension Modules to Delta PLCs: 

extension modules are used with PLCs to extend input and output capabilities beyond what is 

available in the main unit. These units can include additional digital inputs and outputs, analog 

inputs and outputs, and specialized functions such as communication ports. Extension units can be 

networked on the right or on the left, Specialized I/O Modules, Function Modules, Safety Modules, 

Analog Signal Processing Modules, if ends with "SL" it connects in the PLC from the left; if it 

ends with "S" it connects in the PLC from the right. As in the following figures 58, 59, 60, 61 and 

62 . 

Figure 58 :Connecting Extension Modules to Delta PLCs 



68 

 

 

Figure 59:left-side High-speed Extension Modules 

 

 

Figure 60: I/O Extension 

 



69 

 

 

Figure 61:I/O Analog Extension 

 

Figure 62: communication and Power Supply Modules 

 

 

 



70 

 

the maximum number of extension modules that can be connected to a Delta PLC varies by model. 

For the DVP series, the number can range from 8 to 16 modules, depending on the specific PLC 

model. Always refer to the technical specifications and manuals for your specific PLC model to 

determine the exact limitations and ensure proper configuration and power supply arrangements. 

 

 

3.4.4 Serial communications 

 There are many types and protocols for serial communications, such as: 

• RS -232: It is the oldest type of serial communication, but it has existed until now and we use 

it, and it can continue for a long time. 

• RS-422/RS-485: It is considered newer than the 232-RS and is built in with most types of PLC 

or other peripheral devices without adding any module. They are considered faster than the 

232-RS and we will talk about their advantages and disadvantages in detail. 

• CAN. 

• Ethernet. 

• USB. 

• HDMI. 

RS-232 

• The RS-232 serial communication is considered one of the oldest serial communications, as it 

was introduced in late 1962. This type allows communication between two points only, point 

to point, the first being a sender and the other being a receiver. 

• This connection can be simplex or full duplex 

• Reception sensitivity is ∓3 Volts 

• . Logical levels are 15 to 5 

• . One of the disadvantages of this communication style is that the maximum length of the 

communication cable is 20 meters. 

• The maximum connection speed or data transmission speed is 20 Kbits/s 

Figure 63:maximum number of extension modules 



71 

 

• The connection method is single ended 

That is, we have two parties, the first to which we send data, while the second party is the 

receiver from which we will take data for the landline, meaning the GND line must be 

connected to the connection. 

 

Figure 64:connection  RS-232 

RS-485: 

• This connection works with the Master Slave system, meaning that it will not be Point to Point 

as we saw in the RS-232, meaning this connection will allow us to form a network. The 

maximum number of Master will be 32 devices and the maximum number of Slave or Receiver 

will be 32, but on the condition that there is one device on bus communication at the same 

time, one driver on the bus, that is, if there is more than one sender, for example, and the first 

sender has finished sending his message to the future, he must exit the bus for the second sender 

to enter, and so on. Of course, programmatically, there must be a time limit to address the 

peripheral devices connected to the communication bus, and not It is permissible to address all 

devices at the same time. 

 



72 

 

• This type of connection allows us to increase the number of Slaves to 254 receivers, but we 

must add an RS-485 repeater such as the Delta IFD8510, as each repeater supports a specific 

group of Slaves. 

 

• The RS-485 is considered a HALFDUPLEX connection, meaning it is not permissible to send 

and receive at the same time. That is, first we send the data and then we receive it. 

• The connection for the 485-RS is considered a differential connection, meaning: 

 

Figure 65:differential connection 

 

• The comparator compares the two input signals on the positive pole and the negative pole. In 

the normal state, there is always a signal equal to and opposite to the signal on the positive 

pole in the negative pole. Therefore, the output of the analogue comparator is a logical 1. 

However, when a noise signal arrives, it will affect both the reflective and non-reflective inputs 

with the same value. Then the comparator outputs a logical 0 and deletes the incoming noise 

signal. In this process, we have eliminated Noise cancellation. 

 

• The reception sensitivity is 200, that is, from zero until this value, the receiver will delete it, 

considering it a interference signal. 

• Logic levels are (∓1.5 to ∓6)V. 

• The maximum length of the communication cable is 120