Modeling and simulation of control system for electron beam machine (EBM) using programmable automation controller (PAC)

An EBM electronic model is designed to simulate the control system of the Nissin EBM, which is located at Block 43, MINT complex of Jalan Dengkil with maximum output of 3 MeV, 30 mA using a Programmable Automation Controllers (PAC). This model operates likes a real EBM system where all the start-up, interlocking and stopping procedures are fully followed. It also involves formulating the mathematical models to relate certain output with the input parameters using data from actual operation on EB machine. The simulation involves a set of PAC system consisting of the digital and analogue input/output modules. The program code is written using Labview software (real-time version) on a PC and then downloaded into the PAC stand-alone memory. All the 23 interlocking signals required by the EB machine are manually controlled by mechanical switches and represented by LEDs. The EB parameters are manually controlled by potentiometers and displayed on analogue and digital meters. All these signals are then interfaced to the PC via a wifi wireless communication built-in at the PAC controller. The program is developed in accordance to the specifications and requirement of the original real EB system and displays them on the panel of the model and also on the PC monitor. All possible chances from human errors, hardware and software malfunctions, including the worst-case conditions will be tested, evaluated and modified. We hope that the performance of our model complies the requirements of operating the EB machine. It also hopes that this electronic model can replace the original PC interfacing being utilized in the Nissin EBM in the near future. The system can also be used to study the fault tolerance analysis and automatic re-configuration for advanced control of the EB system. (Author)