Research ArticleA Real-Time Temperature Data Transmission Approach forIntelligent Cooling Control of Mass Concrete

Peng Lin Qingbin Li and Pinyu Jia

State Key Laboratory of Hydroscience and Engineering Tsinghua University Beijing 100084 China

Correspondence should be addressed to Peng Lin celinpetsinghuaeducn

Received 28 December 2013 Accepted 7 February 2014 Published 12 March 2014

Academic Editor Ting-Hua Yi

Copyright copy 2014 Peng Lin et alThis is an open access article distributed under the Creative Commons Attribution License whichpermits unrestricted use distribution and reproduction in any medium provided the original work is properly cited

Theprimary aimof the study presented in this paper is to propose a real-time temperature data transmission approach for intelligentcooling control of mass concrete A mathematical description of a digital temperature control model is introduced in detail Basedon pipe mounted and electrically linked temperature sensors together with postdata handling hardware and software a stablereal-time highly effective temperature data transmission solution technique is developed and utilized within the intelligent massconcrete cooling control system Once the user has issued the relevant command the proposed programmable logic controllers(PLC) code performs all necessary steps without further interactionThe code can control the hardware obtain read and performcalculations and display the data accurately Hardening concrete is an aggregate of complex physicochemical processes includingthe liberation of heat The proposed control system prevented unwanted structural change within the massive concrete blockscaused by these exothermic processes based on an application case study analysis In conclusion the proposed temperature datatransmission approach has proved very useful for the temperature monitoring of a high arch dam and is able to control thermalstresses in mass concrete for similar projects involving mass concrete

1 Introduction

In hydraulic engineering due to the poor conductivity ofconcrete high temperature gradients may occur between theinterior and the surface of the structural elements or betweenparts of an element due to processes of sequential concretingin phases [1 2] The temperature gradients may easily causetensile stresses which exceed the tensile strength and resultin the cracking of early age mass concrete [3 4] Much engi-neering practice has showed that it is difficult to control itshighest temperature within an allowable range when pouringconcrete in the hot season This is because pouring concreteis affected by the pouring temperature solar radiation andcooling pipes As the thermal control of mass concrete is acommon problem in civil engineering sensor technologieshave developed quickly and are much utilized in structuralhealth monitoring in civil and hydraulic engineering [5ndash9]Accurate real-time field control must be achieved

Data communication plays an important role in the rapiddevelopment of intelligent cooling control systems Intelli-gent cooling control systems [1 10ndash12] enable units of con-crete poured during dam construction to cool appropriately

Making data communication possible between all coolingcontrol information from all field control systems is alsoprovided to top-level management The current temperaturedigital data collectionmethods and the control exercisedwiththe use of manual records are very rudimentary due to pooraccuracy and lack of data reliability [10 13] The main factorssupporting accurate temperature control are real-time mea-surements accurate collection in real time of dam internaltemperature data cooling pipe inlet and outlet water temper-atures and weather temperature dataThus the developmentof a real-time temperature data transmission approach forintelligent cooling control of mass concrete is of importantacademic and engineering significance

Digital computers were first applied to industrial processcontrol in the late 1950s [14] The individual temperaturepressure flow and the like and feedback loops were locallycontrolled by electronic or pneumatic analog controllersEach individual loop operated can optimize the overall oper-ation In 1962 imperial chemical industries made a drasticdeparture from this approach and a direct digital control(DDC)was coined to emphasize that the computer controlled

Hindawi Publishing CorporationMathematical Problems in EngineeringVolume 2014 Article ID 514606 10 pageshttpdxdoiorg1011552014514606

2 Mathematical Problems in Engineering

the process directly In DDC systems analog controllers wereno longer used In 1970s microcomputers have already madea great impact on the process control fieldThey are replacinganalog hardware even as single loop controllers [15] Multipleloop single computer systems have variability interface andsoftware design The distributed computer control system(DCCS) was developed which is facilitated by adopting amultilevel or hierarchical viewpoint of control strategy Onthe lowest level of control main tasks handled acquisitionof process data and collection of data For complex processplant monitoring supervisory control and data acquisition(SCADA) systems are available The basic functions ofSCADA system include data acquisition and communicationevents and alarms reporting data processing and partialprocess control The other main and early application areaof digital methods was machine tool numerical controlwhich developed at about the same time as computer controlin process industries for example numerically controlled(NC) computerized numerical control (CNC) and directnumerical control (DNC) One of the most ingenious devicesever devised to advance the field of industrial automation isthe PLC The PLC a microprocessor-based general-purposedevice provides a ldquomenurdquo of basic operations that can beconfigured by programming to create logic control system forany application [16] Thus the recent appearance of powerfuland inexpensive microcomputers has made digital controlpractical for a wide variety of applications In fact now everyprocess is a candidate for digital control [17]

Digital data transmission technologies have attracted theattention of many researchers and engineers in recent years[18ndash27] For example Italiano et al [19] developed the SMMsea-floormonitoringmodule for real-time data transmissionfrom the sea bottom equipped with multidisciplinary sen-sors Bayindir and Cetinceviz [20] describe a water pumpingcontrol system designed for production plant and imple-mented experimentally in a laboratory An intelligent systemfor distributed control of an anaerobic wastewater treatmentprocess was developed by Flores et al [21] Language oftemporal ordering specification (LOTOS) was used in thespecification of industrial bus communication protocols [22]Communication structures have been used for sensory datainmobile robots [23] and the network is used as a bus systemfor long discharge data acquisition and data processing [24]The timing behaviour of real-time stations in legacy bus basedindustrial Ethernet networks has been enforced [25] A studyon real-time sensor signal transmission based on polynomialpredictive filtering technology has also been carried outby Dong et al [27] Connecting PLC to control and dataacquisition enabled a comparison of the Joint EuropeanTorus (JET) and Wendelstein 7-X approaches to be made[26] These studies have demonstrated convenient solutionsreliable operation and robust and flexible construction suit-able for industrial applications However few studies wereconcerned with the cooling control of mass concrete in adam under complex electromagnetic environment especiallythe problem of the large quantity of temperature digital data

to be transmitted in relation to temperature control duringconcrete block pouring

This paper relating to a real-time temperature data trans-mission approach at a super high arch dam site presents adetailed description of certain aspects of a control systemthat is intended to ensure the structural integrity of massiveconcrete structures during the construction process Thecooling control system prevents unwanted structural changeswithin massive concrete blocks by carrying away the heatgenerated by the exothermic processes of cement hydrationThe proposed temperature transmission approach collectstemperature data from many sensors and prevents the hard-ening concrete from overheating by controlling the waterflow inside the cooling pipes constructed within the concretestructure The temperature transmission system includesthe acquisition of temperature data management of vari-ous intelligent modules temperature data handling sortingand filtering and temperature data transfer to the modulecontrol server The detailed PLC software configuration andprogramming are also illustrated An application case oftemperature monitoring of the Xiluodu arch dam during theconstruction period is discussed in detail The paper aimsto provide a convenient solution to the process of coolingcontrol via the pipes in a situation where the laying of cablesis not possible

2 Temperature Digital DataTransmission Approach

21 Mathematical Description of Digital Temperature ControlModel In this study each basic poured block temperaturecontrol unit has a fixed structure (see Figure 1) one electricsolenoid proportional valve one outlet water flow transmitterand two or more temperature sensors installed at the waterpipe inlet and outlet adjacent concrete temperature and soforthThemass concrete temperature control kernel collectedall the data and commanded the execution of individualcontrol actions indirectly via the PLC system which waseasily set up to handle the field bus

In this study a prerequisite signal processing techniquewas used [10 11] as the proposed closed-loop digital controlsystem for mass concrete cooling on a construction siteThe digital control system with analog sensors (flow sensorthermometer) included an analog prefilter placed betweenthe sensor and the sampler (AD converter) as antialiasingdevice shown in Figure 2The prefilters are low-pass and thesimplest transfer function is used

119867pf (119904) =119886

119904 + 119886 (1)

so that the noise above the prefilter breakpoint 119886 was attenu-ated The design goal is to provide enough attenuation at halfthe sample rate (120596

1199042) so that the noise above 120596

1199042 when

aliased into lower frequencies by the sampler will not bedetrimental to the control-system performance

Mathematical Problems in Engineering 3

Digital temperature and flow measuring device

Digital temperature and flow measuring device

Digital thermometer

Fresh concrete slab

Cooling pipe

Control server

Multichanneltemperature logger

Figure 1 The schematic diagram of temperature and flow acquisition collecting and analysing system

DACooling

controlled

SensorsAnalog prefilter

Manual control according to user needs

Server

Controlled output

ADsystem G(s)

H(s)

Command signal r(k)

D(z)

u(k)b(k)y(t)

Figure 2 Block diagram for control process

For this cooling control system the basic configurationand block diagram are shown in Figure 2 where

119866(119904) = transfer function of the controlled system(continuous-time system)119867(119904) = transfer function of the analogue sensor119863(119911) = transfer function of the digital control algo-rithm

The analogue and digital parts of the system are con-nected through DA and AD converters The server withits internal clock drives the DA and AD converters Itcompares the command signal 119903(119896) with the feedback signal119887(119896) and generates the control signal 119906(119896) to be sent to thefinal control elements of the cooling control system Thesesignals are computed fusing the digital control algorithm119863(119911) stored in the memory of the compute server

To suit the complications of a real construction sitethe field bus is designed to link the sensors and actuatorsthe Profibus network links all the analogue signal input and

output modules which are cyclically converting the ADor DA signals Mathematical models generally are used torepresent the digital control devices and the system TheAD converter model [14] used in this system is shownin Figure 3(a) For the field temperature control process acontinuous-time function119891(119905) 119905 ge 0 is the input and thesequence of real numbers 119891(119896) 119896 = 0 1 2 is the outputThe following relationship holds between input and output

119891 (119896) = 119891 (119905 = 119896119879) (2)

where 119879 is the sampler time interval between enquiring flowor temperature and acquiring the result The sequence 119891(119896)can be treated as a train of impulses represented by thecontinuous-time function 1198911015840(119905)

1198911015840

(119905) = 119891 (0) 120575 (119905) + 119891 (1) 120575 (119905 minus 119879)

+ 119891 (2) 120575 (119905 minus 2119879) + sdot sdot sdot =

infin

sum

119896=0

119891 (119896) 120575 (119905 minus 119896119879) (3)

4 Mathematical Problems in Engineering

Impulse modulator

AD converterf(t)

f(t)

Tf(k)

t0 0

120575T(t)

f998400(t) = f(t)120575T(t)k

(a)

DA converterZOH

T

f(k)

f(k)

t0 0k

gh0(s) = 1 minus eminussTs

f998400998400(t)

f998400998400(t)f998400(t)

(b)

Figure 3 A model of an AD or DA converter

The model of DA converter is shown in Figure 3(b) Asequence of numbers 119891(119896) 119896 = 0 1 2 is the input andthe continuous-time function 11989110158401015840(119905) 119905 ge 0 is the output Thefollowing relationship holds between input and output

11989110158401015840

(119905) = 119891 (119896) 119896119879 le 119905 lt (119896 + 1) 119879 (4)

Each sample of the sequence 119891(119896) may be treated as animpulse function of the form119891(119896)120575(119905 minus 119896119879) The zero-orderhold (ZOH) of Figure 3(b) can thus be viewed as a lineartime-invariant system that converts the impulse119891(119896)120575(119905minus119896119879)into a pulse of height 119891(119896) and width 119879 The DA convertermay therefore be modelled by Figure 3(b) where the ZOHis a system whose response to a unit impulse 120575(119905) is a unitpulse 119892

ℎ0(119905) of width 119879The Laplace transform of 119892

ℎ0(119905) is the

transfer function of the hold operation namely

119892ℎ0(119904) =1 minus 119890minus119904119879

119904 (5)

22 Temperature Digital Data Transmission For dam tem-perature control system shown in Figure 1 the temperaturesensors sampling time could be as long as one minute AProfibus network and corresponding modules would domi-nate the control cost unnecessarily and therefore a lower costfield bus called ITU was engaged An intelligent module cantransfer the ITU signals into RS485 protocol which mostkinds of PLC support The intelligent temperature modulewhich has 8 channels can link a maximum of 256 differentITU sensors usually via three core cables After initializationthe module can exchange the digital data with PLC basis ofRS485 protocol One RS485 master can communicate with127 slaves and this means one PLC CPU can acquire up to32512 ITU temperature sensors In this control system theSiemens Simatic S7-300 PLC was used as the data bridgebetween the control model computer and the field sensorsand actuators The specified PLC programming languageFBD (function block diagram) and standard function library

provided the software engineering basic environment Thesoftware tasks were condensed into the three parts of col-lecting the temperature and flow data communicating withthe model server and the water flow proportional integralderivative (PID) control

221 Data Inquiring and Acquiring There are a number ofcommands defined to fetch the status or data from the intel-ligent temperature module LTM8663 via the RS485 protocolwhich are in ASCII format The most important commandsfrom PLC to the intelligent module are as follows

(1) lowastAAN (CR)The command name to read all the sensorsrsquoID linked to the channel ldquo119873rdquo of the specified intelligentmodule ldquo119860119860rdquo (ranging from 00 h to FF h) here ldquoCRrdquo is thecarriage return character (ASCII code ldquo0Dhrdquo)

Each ID is preset by a handy tool or PC software to escapethe same numbering on the same channel

(2) AAN (CR) The command name similar to the aboveldquolowast119860119860119873rdquo this command tries to read all the sensorsrsquo datalinked to the channel ldquo119873rdquo of the specified intelligent moduleldquo119860119860rdquo

The above two frequently used commands enable PLC toget exactly the total numbers and numbering of linked sen-sors as well as their current temperature values

222 Data Handling Sorting and Filtering As long as thereis a valid response from the intelligent module the temper-ature digital data will be first transferred into a data bufferwhich is previously defined in the PLC and then analyzedaccording to the predefined data format The standard func-tion block for the PLC will copy the data from the RS485network to that buffer and generate a pulse indicating thatnew data is coming the user program will fetch the channelsrelated data and copy them to corresponding data blockaccording to the current counter

Since channel data sets are separated the PLC decideswhether they are valid or not on the basis of the receivedtelegramheader (here ldquogtrdquomeans data are valid)Theprogramwill then transfer the raw temperature data into standardizedformat (floating type) For the specific LTM8663module usedin this system the original temperature data format is 16 A(byte 1) B (byte 2) and the conversion formula is

119905 =[256 (119861amp167) + 119860]

16 (6)

According to the LTM8663 specification the RS485 com-munication protocol is ASCII and the parameters should beconfigured in the hardware interface as the speed transmis-sion rate is 9600 bps data bits are 8 stop bits is 1 and theoperating mode is half duplex (RS485) two-wire mode

After the PLC program has distinguished the total num-ber of sensors of the module each ID and actual data it isnot difficult to sort and copy them to the right offset locationin the summary data block Obviously each sensor ID inone module must be unique The summary data block is thetransmission information to the module control server

Mathematical Problems in Engineering 5

FB8DB8

Comment Comment

ENSF

M2002RREQ

512 LADDR20

05

DONE M2010ERROR M2011STATUS MW204

ENO

DB NODBB NO

R CPU NOR TYP

R OFFSETR CF BYTR CF BIT

The logic address of CP341 module

The telegram from PLC to the intelligent module

The telegram from the intelligent module to PLC

FB7DB7

EN

M2010

R

512 LADDR

30NDR M2020

ERROR M2021

LEN

STATUS MW206

ENO

EN R

DB NO

DBB NO

L TYP

L NO

L OFFSET

L CF BYT

L CF BITLEN

R NO

0

Network 16 Receiving from the intelligent module

Network 14 Sending to the intelligent module

Figure 4 Function blocks for communication between CP341 and LTM8663 modules

23 Management of Various Intelligent Modules On the damconstruction site thousands of sensors were installed on thecooling pipes or cast inside the concrete enabling variousidentified intelligent modules to be linked to PLC via RS485network PLC software autodecided the polling strategy forthe whole network to avoid data acquisition conflicts To polleach module and channel cyclically a counter is utilized todifferentiate the time frames for each task In addition thePLC sends twodifferent commands for each channel since thetime interval must be considered The brief polling sequenceis illustrated in [10]

To achieve communication between CP343-1 and themodule server the server must be configured in the Simaticmanager The module server is taken as ldquoanother stationrdquohere and in the net two connections should be establishedfor sending and receiving For the Transmission ControlProtocol (TCP) connection the port addresses of both partiesshould be fixed

The real-time data transmission from concrete construc-tion site to the remote module control server was achievedusing an industrial Ethernet communication board withTCPIP protocol Depending on the distance a fibre opticconverter or a wireless AP can be used for the data bridgeThe standard PLC Ethernet communication function blockcan easily transfer the data block contents to the target serverThe network structure is independent of the sensors If oneor several sensors fail the master can still read data fromother sensors After replacement the sensors can be accessedagain as the master collects the data on the whole networkrepeatedly

3 PLC Code Configuration

In this study the structured control language (SCL) was usedas the PLC codeThe FBD and the Standard Template Library(STL) included communication with the intelligent module

(RS485) temperature digital data treatment filtering andsorting communication with the module server (TCPIP)and the cooling water PID control

31 Communication with the Intelligent Module LTM8663The standard function block FB7 and FB8 (P SND RK)are designed for RS485 communication structure shown inFigure 4

The CP341 module is an extended communication pro-cessor which supports RS422 and RS485 protocol The datablock DB20 stores the inquiring command (5 bytes) to theintelligentmodule andDB30 is the receiving data buffer fromthe module The execution of FB7 and FB8 is separated bylogic

32 Temperature Digital Data Analysis When the specificchannel temperature digital data is recognized it is trans-ferred from DB30 to another data block for handling Forexample DB31 handles raw data coming from channel 1module 0 As the total number of sensors and each ID isknown by the program each temperature value can be con-verted into target floating formatThe source code below con-verts the data according to (6)

After the treatment the sensor actual values are copied toa summary data block (eg DB10 for module 0) The offsetin the data block will follow the ID For example the offsetaddress for the sensor ID 3 is 12 as in Table 1

33 Communication with the Module Server Two otherstandard functions (FC50 and FC60) are used for the TCPIPcommunicationwith themodule server as shown in Figure 5The Ethernet port is integrated in the CPU module The DB1is the sending buffer which collects all the sensor informationand telegram time stamp shown in Table 2

The telegram length is 2022 bytes including the title tele-gram label length telegram type sending time total circuit

6 Mathematical Problems in Engineering

Table 1 The PLC data structure of DB10 for communication with intelligent module

Number Address offset Name Data type Comments1 0 Module SN Integer Module serial number2 2 Total sensors Real Total sensors number3 4 Value ID1 Real SensorValue ID14 8 Value ID2 Real SensorValue ID25 12 Value ID3 Real SensorValue ID36 16 Value ID4 Real SensorValue ID4

256 1016 Value ID254 Real SensorValue ID254257 1020 Value ID255 Real SensorValue ID255258 1024 Value ID256 Real SensorValue ID256

Table 2 The PLC data structure of DB1 for sending telegram to module server

Number Address offset Name Data type Comments1 0 Label String(4) Fixed as ldquoEDAMrdquo2 4 Length Integer Telegram length3 6 Tel type INT Telegram type4 8 SendTime String(12) Format YYYYMMDDHHMM5 20 TotalNumber INT Total circuits6 22 Telegram1 UDT1 User defined data type

119899 + 5 (119899 minus 1) lowast 10 + 22 Telegram(119899) UDT1 User defined data type

Table 3 The user defined type (UDT) for each circuit value as a template

Number Address offset Name Data type Comments1 0 Number Integer The circuit number2 2 Mode Byte Mode 1 = auto 2 = manual3 3 AlarmWarnning Byte 0 = OK 1 = warning 2 = alarm4 4 InletTemp Integer Water inlet tmperature5 6 OutletTemp Integer Water outlet temperature6 8 ActFlow Integer Actual water flow

numbers and every item of circuit data Here a special UDT(user data type 10 bytes) is defined for each water coolingcircuit including the serial number auto- or manual modestatus inlet and outlet temperature and actual water flowshown in Table 3 Correspondingly the DB2 is the receivingbuffer containing the commands for each circuit from themodule serverrsquos control strategy system

Similarly the receiving telegram contains the labellength type and command for each circuit and the personal-ized control solution is then realized in this way Every circuitcan have its own cooling water flow target set point or fixedwater valve opening output

4 Application Case Study

41 Brief Introduction toDamSite Theproposedmethodwasapplied to the temperature control of the Xiluodu arch dam

during construction [28 29]The project is located on the Jin-shajiang River in the Leibo County of Sichuan province Theprincipal structures consist of a double-curvature arch dam2855 meters high crest length about 700 meters spillwayunderground powerhouse and logway A total of 6000000cubic meters of concrete were poured Because of the highstresses in an arch dam structure and the constructionprocess control difficulties the basic temperature controlprinciplewas tomaintain ultimately small temperature differ-ences betweenneighbouring areas of concrete by slow coolingand early cooling The cooling process should be based onthe concrete temperature measurement results taking intoconsideration the partitioning of the concrete pouringtemperature water pipes density of concrete and ambienttemperature The cooling water flow is adjusted in a timelymanner to meet the targeted temperature requirements

A flexible network structure for field temperature mon-itoring of the super high arch dam during construction was

Mathematical Problems in Engineering 7

Comment Comment

EN

ACT

ID

EN

M1000

M1001

MW102

M1040

M1041

MW106

MW108LADDRLADDR1

T32

SEND

ID

Network 7 Sending telegram to module server Network 8 Receiving telegram from module server

W163FFC

W163FFC

PDB1DBX00

PDB2DBX00

FC50 FC60NDR

RECV

2

BYTE 2048

BYTE 2048

2048

DONE

ERROR

ERROR

STATUS

STATUS

ENO

ENO

LEN

LEN

The logic address of CPU Ethernet port

Figure 5 The PLC functions for TCPIP communication with the module server

(1) BOX1

(2) PS307(3) CPU315

(4) CP341

(5) IM153(6) AI8

(7) AO8

Figure 6 The internal layout of the PLC control cubicle

developed based on the state of the art intelligence controltechnology [8] By employing flexible network structurearchitecture the bus was also connected to other typesof sensors such as dam strain measurement meters damcompressive stress measurement meters meters for moni-toring joint openings rock-deformations and piezometersfor seepage flow all of which were are designed to suitthis network specification Thus the measurement scopeutilized covered a wide spectrum as well as themany concretetemperature measurements sufficient for a super high archdam

42 Site Control System Arrangement The control cabinetswere prepared in the workshop Because of the complexelectromagnetic environment on the construction site wiringto the site flow valves and sensors were employed Figure 6shows a preassembled cabinet for digital data transmissionHere is the brief description of the main parts of PLC controlcubicle

BOX1 The intelligent temperature module The cir-cuit connection diagrams for connecting the temper-ature sensors to the module are shown in Figure 7PS307 The Simatic S7-300 PLC power moduleCPU315 The Simatic S7-300 PLC CPU with inte-grated Profibus and Ethernet interfacesCP341 The Simatic RS485 communication processorfor the intelligent temperature moduleIM153 The Simatic interface module which canextend the CPU control to remote areas by ProfibusnetworkAI8TheSimatic analog inputmodule which can read8 analogue signals (current voltage resistor or PT100sensors) The circuit diagram for connecting the flowmeters to the analogue input module is shown inFigure 8 The symbol ldquoSM331rdquo is the analogue inputmodule which is able to read 8 water flow transduc-ers please refer to ldquo(6) AI8rdquo of Figure 6AO8 The Simatic analogue output module whichcan drive 8 analog valves The circuit diagram forconnecting the electric valves to the analogue outputmodule is shown in Figure 9 The symbol ldquoSM332rdquo isthe analogue output module which is able to control8 proportional valves please refer to ldquo(7) AO8rdquo ofFigure 6

On the dam site the operators connect the valves flowmeters and temperature sensors into the PLC cabinets asrequired according to construction progress

43 Temperature Field Analysis Basis of Real-Time Temper-ature Data On the Xiluodu arch dam site the intelligentcooling control system used modern field bus technologyextensively and Siemens PLC devices to comprehensivelytrack the temperature data change at the pouring of everyblock in real time Adjustment of the valves and control ofwater flowwere performed using the PID algorithm based ontemperature control requirements and key factors such as thehighest temperature reached cooling rate and temperature

8 Mathematical Problems in Engineering

-BOX1

256 RS422LTM8663

GNDCH2

GNDCH1

GNDCH0

-X34

-X31

-X35

-X38

-X32-X33

-X36-X37

CH3GND

-X39-X310-X311-X312

CH4GND

CH5GND

CH6GND

CH7GND

-X316

-X313

-X317

-X320

-X314-X315

-X318-X319

-X321-X322-X323-X324

+5V+5V

+5V +5V

+5V+5V

+5V +5V

24V+ COM+

COMminus

CH2

CH0 5V

CH1 5V

CH0

CH0 GND

CH1 GNDCH2 5V

CH2 GNDCH3 5V

CH3

CH3 GNDBOX1

BOX1

BOX1BOX1

BOX1

BOX1BOX1

BOX1

BOX1

BOX1BOX1

BOX1

BOX1 CH5

BOX1 CH6

BOX1 CH4 5V

BOX1 CH5 5V

BOX1 CH4BOX1 CH4 GND

BOX1 CH5 GND

BOX1 CH6 5V

BOX1 CH6 GND

BOX1 CH7 5V

BOX1 CH7BOX1 CH7 GND

-XP1 1721-XM1 1728

CH1

GND(24V) = CC3 + CBL3-BOX1 COMminus

= CC3 + CBL3-BOX1 COM+

-RS422 COMminus+UR056

-RS422 COM++UR056

Figure 7 The circuit diagram for connecting the temperature sensors to the module

3 times 075

3 times 075

3 times 075

3 times 075

3 times 075

3 times 075

3 times 075

3 times 075

3 times 075 3 times 075

6ES7 331-1KF02-0AB0

SM 331

A

A

A

A

V

V

V

V

V

V

V

V

A

A

A

A

SIEMENS

8

Rack0Slot3

-A3

2

1

3

4

5

6

7

89

1112

13

1516

1718

1920

2122

2324

2526

2728

2930

3132

3334

3536

3738

3940

1

3

10

5

14

7

9

11

13

15

21

41-W501

1

21

41-W502

1

21

41-W503

1

21

41

1

12

47

1

12

12

12

47-W506

1

47-W507

1

47-W508

1

41-W401

148

-W402

1

The i

nlet

or o

utle

t w

ater

flow

tran

sduc

ers

AI 8 times 13 BIT

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

-FT501

-FT502

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

-FT503

-FT504

-W504

-FT505

-W505

-FT506

-FT507

-FT508

S+Sminus

S+Sminus

S+Sminus

S+Sminus

S+ Sminus

S+ Sminus

S+ Sminus

S+ Sminus +CBL1-XP2 2+CBL134+CBL1-XP2 1+CBL134

+CBL1-XM1 1+CBL124

CH0 I+

CH0 U+

CH0 Sminus

CH0 M+

CH0 Mminus

CH1 U+

CH1 I+

CH1 SminusCH1 M+

CH2 M+

CH2 U+

CH2 I+

CH2 Sminus

CH2 Mminus

CH1 Mminus

CH3 U+

CH3 I+CH3 Sminus

CH3 M+

CH3 Mminus

CH4 U+

CH4 I+

CH4 SminusCH4 M+

CH4 Mminus

CH5 U+

CH5 I+CH5 Sminus

CH5 M+

CH5 Mminus

CH6 U+

CH6 I+

CH6 SminusCH6 M+

CH6 Mminus

CH7 U+

CH7 I+CH7 Sminus

CH7 M+

CH7 Mminus

Figure 8 The circuit diagram for connecting the temperature sensors to the module

gradient A web graphical user interface (GUI) was providedfor integrated query analysis and prewarning [1]

Based on the proposed temperature data transmissionsystem the intelligent cooling system overcomes the short-comings in traditional manually collected data systemsproviding an effective dam concrete temperature control andcracking prevention technology both advanced and moreintelligent In particular the advances consist of (1) changingsimple manual data collection to real-time data acquisitionand feedback (2) automatically obtaining large quantitiesof thermodynamic parameters with respect to every blockof poured concrete enabling a more customized control

function and (3) enabling a 3D real-time temperature fieldanalysis be carried out as illustrated in Figure 10 Based onthe real-time temperature field analysis further stress fieldscan be analyzed to study alternative temperature controlplans not only limited to water flow but the whole pipeworkscheme can be adjusted to more optimal configurations

5 Conclusions

This paper presents a real-time temperature data transmis-sion approach for intelligent cooling control of early agemassconcrete based onAD convertermodel and PLC technology

Mathematical Problems in Engineering 9

6ES7 332-5HF00-0AB0

SM 332 SIEMENS

8

Rack0Slot4

-A4

1

2

3

4

5

66Mana0

7

8

9

1010Mana1

11

12

13

15

16

17

1818Mana3

19

20 20M20M

21

22

23

24

25

2626Mana4

27

28

29

3030Mana5

31

32

33

3434Mana6

35

36

37

3838Mana7

39

40

2

4

6

8

10

12

14

16

1414Mana2

-YVP5012

M

1

Y1

3

U

4

32-W501

2

-YVP5022

M

1

Y1

3

U

4

-YVP5032

M

1

Y1

3

U

4

-YVP5042

M

1

Y1

3

U

4

32-W502

2

-YVP5052

M

1

Y1

3

U

4

-YVP5062

M

1

Y1

3

U

4

-YVP5072

M

1

Y1

3

U

4

-YVP5082

M

1

Y1

3

U

4

32-W503

2

32-W504

2

37-W505

2

37-W506

2

37-W507

2

37-W508

2

31-W401

2 238

-W402

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

1L+1L+

CH0 QV+

CH0 S+

CH0 Sminus

CH0 Mana

CH1 QV+

CH1 S+

CH1 S-

CH1 Mana

CH2 QV+

CH2 S+

CH2 Sminus

CH3 QV+

CH3 S+

CH3 Sminus

CH3 Mana

CH2 Mana

CH4 QV+

CH4 S+

CH4 Sminus

CH4 Mana

CH5 QV+

CH5 S+

CH5 Sminus

CH5 Mana

CH6 QV+

CH6 S+

CH6 Sminus

CH6 Mana

CH7 QV+

CH7 S+

CH7 Sminus

CH7 Mana

24V

24V

24V

24V

24V

24V

24V

24V

+CBL1-XP1 1+CBL124

+CBL1-XM2 1+CBL135 +CBL1-XM2 2+CBL135

+CBL1-XM1 2+CBL125

The e

lect

ric so

leno

id

prop

ortio

nal v

alve

s

AO 8 times 12 BIT

3 times 075

Figure 9 The circuit diagram for connecting the electric valves to the analog output module

Y

X0 20 40 60 80 100 100120 140 160 180 200

0

10

20

30

40

50

50 1112131415161718192021

(∘C)

Figure 10 Real-time three-dimensional temperature field

The proposed approach offers an effective and efficient alter-native for acquiring temperature digital data useful for sup-porting the decision-making processes regarding the controlof cooling of just poured mass concrete in real time

A mathematical description of the digital temperaturecontrol model has been developed Use of this model fortemperature values acquisition filtering sorting treatingand their real-time transfer for cooling control purposes isproved effective A stable real-time high volume capacityof the temperature data transmission solution developedutilized an intelligent cooling control system

Using this system on the Xiluodu arch dam site enabledsome key problems to be solved including huge quantities ofraw data interchange with the module server personalizedand flexible control for each water cooling circuit andaccurate and punctual water conditional control data collec-tion instead of traditional manual checking The proposedapproach provides a convenient solution in process coolingcontrol pipes where cabling is not possible The systemalso has lower installation and maintenance costs operatesreliably and is of robust and flexible construction It is proved

suitable for heat of hydration control in dam constructionconcreting applications

Based on this study the future research will be focusedon the combination of real-time site monitoring analysis andnumerical simulation on thermal stress for control crackingof mass concrete in construction period

Conflict of Interests

The authors declare that there is no conflict of interestsregarding the publication of this paper

Acknowledgments

This research work was supported by National NaturalScience Foundation of China (nos 11272178 and 51339003)National Basic Research Program of China (973 Program)under Grants nos 2013CB035902 and 2011CB013503 andTsinghua University Initiative Scientific Research Program

References

[1] P Lin Q B Li S W Zhou and Y Hu ldquoIntelligent cooling con-trol method and system for mass concreterdquo Journal of HydraulicEngineering vol 44 no 8 pp 950ndash957 2013

[2] F A Branco and P Mendes ldquoNumerical simulations of heat ofhydration temperature in damsrdquo in Proceedings of the Interna-tional Workshop on Arch Dams pp 225ndash230 Coimbra Portu-gal April 1987

[3] B Zhu ldquoEffect of cooling by water flowing in nonmetal pipesembedded in mass concreterdquo Journal of Construction Engineer-ing and Management vol 125 no 1 pp 61ndash68 1999

[4] AMNevilleProperties of Concrete Longman Essex UK 1995

10 Mathematical Problems in Engineering

[5] H S Shang T H Yi and Y P Song ldquoBehavior of plain concreteof a highwater-cement ratio after freeze-thaw cyclesrdquoMaterialsvol 5 no 9 pp 1698ndash1707 2012

[6] H S Shang and T H Yi ldquoFreeze-thaw durability of air-entrained concreterdquo The Scientific World Journal vol 2013Article ID 650791 6 pages 2013

[7] H S Shang and T H Yi ldquoBehavior of HPC with fly ash afterelevated temperaturerdquo Advances in Materials Science and Engi-neering vol 2013 Article ID 478421 7 pages 2013

[8] G D Zhou and T H Yi ldquoThermal load in large-scale bridgesa state-of-the-art reviewrdquo International Journal of DistributedSensor Networks vol 2013 Article ID 217983 17 pages 2013

[9] Q Li G Li and G Wang ldquoElasto-plastic bond mechanics ofembeddedfiber optic sensors in concrete under uniaxial tensionwith strain localizationrdquo Smart Materials and Structures vol 12no 6 pp 851ndash858 2003

[10] P Lin Q B Li and H Hu ldquoA flexible network structure fortemperature monitoring of a super high arch damrdquo Interna-tional Journal of Distributed Sensor Networks vol 2012 ArticleID 917849 10 pages 2012

[11] Q B Li P Lin S W Zhou et al ldquoReal time online individu-ation and intelligent cooling control system for mass concreterdquoUtility Model Patent 2012204165226 2013

[12] P Lin Q B Li Y Hu et al ldquoA device of integrity flow and tem-perature controllingrdquo Patent Number(s) 2012204177149 2013

[13] Q B Li and P Lin ldquoDemonstration on intelligent damrdquo Journalof Hydroelectric Engineering vol 33 no 1 2014

[14] K J Astrom and T Hagglund PID Controllers Theory Designand Tuning International Society for Measurement and Con-trol Seattle Wash USA 2nd edition 1995

[15] A B Corripio Tuning of Industrial Control Systems InstrumentSociety of America Research Triangle Park NC USA 1990

[16] F D Petruzella Programmable Logic Controllers Mcgraw-HillNew York NY USA 3rd edition 2004

[17] M Gopal Digital Control and State Variable Methods Conven-tional and Intelligent Control Systems McGraw Hill Education4th edition 2012

[18] M S Santina A R Stubberud and G H Hostetter DigitalControl System Design International Thomson PublishingStamford Conn USA 2nd edition 1994

[19] F Italiano R Maugeri A Mastrolia and J Heinicke ldquoA newseafloor monitoring module for real-time data transmission anapplication to shallow hydrothermal ventsrdquo Procedia Earth andPlanetary Science vol 4 pp 93ndash98 2011

[20] R Bayindir and Y Cetinceviz ldquoAwater pumping control systemwith a Programmable Logic Controller (PLC) and industrialwireless modules for industrial plantsmdashan experimental setuprdquoISA Transactions vol 50 no 2 pp 321ndash328 2011

[21] J Flores B Arcay and J Arias ldquoAn intelligent system for dis-tributed control of an anaerobic wastewater treatment processrdquoEngineering Applications of Artificial Intelligence vol 13 no 4pp 485ndash494 2000

[22] P Marino M A Domınguez F Poza and F Vazquez ldquoUsingLOTOS in the specification of industrial bus communicationprotocolsrdquoComputerNetworks vol 45 no 6 pp 767ndash799 2004

[23] J L Posadas P Perez J E Simo G Benet and F BlanesldquoCommunications structure for sensory data in mobile robotsrdquoEngineering Applications of Artificial Intelligence vol 15 no 3-4pp 341ndash350 2002

[24] C Hennig T Bluhm P Heimann et al ldquoUsing the network asbus system for long discharge data acquisition and data process-ingrdquo Fusion Engineering and Design vol 81 no 15ndash17 pp 1735ndash1740 2006

[25] R Moraes F B Carreiro P Bartolomeu V Silva J A Fonsecaand F Vasques ldquoEnforcing the timing behavior of real-timestations in legacy bus-based industrial Ethernet networksrdquoComputer Standards and Interfaces vol 33 no 3 pp 249ndash2612011

[26] C Hennig K Kneupner and D Kinna ldquoConnecting Program-mable Logic Controllers (PLC) to control and data acquisition acomparison of the JET and Wendelstein 7-X approachrdquo FusionEngineering and Design vol 87 no 12 pp 1972ndash1976 2012

[27] J-N Dong G-H Qin and H Yu ldquoStudy on real-time sensorsignal transmission based on technology of polynomial predic-tive filteringrdquoMeasurement vol 42 no 7 pp 969ndash977 2009

[28] P Lin S Z KangQ B Li et al ldquoEvaluation on rockmass qualityand stability of xiluodu arch dam under construction phaserdquoJournal of Rock Mechanics and Engineering vol 31 no 10 pp2042ndash2052 2012

[29] P Lin X L Liu Y Hu Yu et al ldquoDeformation and stability anal-ysis on xiluodu arch dam under stress and seepage conditionrdquoJournal of Rock Mechanics and Engineering vol 32 no 6 pp1137ndash1144 2013

Submit your manuscripts athttpwwwhindawicom

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

MathematicsJournal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Mathematical Problems in Engineering

Hindawi Publishing Corporationhttpwwwhindawicom

Differential EquationsInternational Journal of

Volume 2014

Applied MathematicsJournal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Probability and StatisticsHindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Journal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Mathematical PhysicsAdvances in

Complex AnalysisJournal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

OptimizationJournal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

CombinatoricsHindawi Publishing Corporationhttpwwwhindawicom Volume 2014

International Journal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Operations ResearchAdvances in

Journal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Function Spaces

Abstract and Applied AnalysisHindawi Publishing Corporationhttpwwwhindawicom Volume 2014

International Journal of Mathematics and Mathematical Sciences

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

The Scientific World JournalHindawi Publishing Corporation httpwwwhindawicom Volume 2014

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Algebra

Discrete Dynamics in Nature and Society

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Decision SciencesAdvances in

Discrete MathematicsJournal of

Hindawi Publishing Corporationhttpwwwhindawicom

Volume 2014 Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Stochastic AnalysisInternational Journal of

2 Mathematical Problems in Engineering

the process directly In DDC systems analog controllers wereno longer used In 1970s microcomputers have already madea great impact on the process control fieldThey are replacinganalog hardware even as single loop controllers [15] Multipleloop single computer systems have variability interface andsoftware design The distributed computer control system(DCCS) was developed which is facilitated by adopting amultilevel or hierarchical viewpoint of control strategy Onthe lowest level of control main tasks handled acquisitionof process data and collection of data For complex processplant monitoring supervisory control and data acquisition(SCADA) systems are available The basic functions ofSCADA system include data acquisition and communicationevents and alarms reporting data processing and partialprocess control The other main and early application areaof digital methods was machine tool numerical controlwhich developed at about the same time as computer controlin process industries for example numerically controlled(NC) computerized numerical control (CNC) and directnumerical control (DNC) One of the most ingenious devicesever devised to advance the field of industrial automation isthe PLC The PLC a microprocessor-based general-purposedevice provides a ldquomenurdquo of basic operations that can beconfigured by programming to create logic control system forany application [16] Thus the recent appearance of powerfuland inexpensive microcomputers has made digital controlpractical for a wide variety of applications In fact now everyprocess is a candidate for digital control [17]

Digital data transmission technologies have attracted theattention of many researchers and engineers in recent years[18ndash27] For example Italiano et al [19] developed the SMMsea-floormonitoringmodule for real-time data transmissionfrom the sea bottom equipped with multidisciplinary sen-sors Bayindir and Cetinceviz [20] describe a water pumpingcontrol system designed for production plant and imple-mented experimentally in a laboratory An intelligent systemfor distributed control of an anaerobic wastewater treatmentprocess was developed by Flores et al [21] Language oftemporal ordering specification (LOTOS) was used in thespecification of industrial bus communication protocols [22]Communication structures have been used for sensory datainmobile robots [23] and the network is used as a bus systemfor long discharge data acquisition and data processing [24]The timing behaviour of real-time stations in legacy bus basedindustrial Ethernet networks has been enforced [25] A studyon real-time sensor signal transmission based on polynomialpredictive filtering technology has also been carried outby Dong et al [27] Connecting PLC to control and dataacquisition enabled a comparison of the Joint EuropeanTorus (JET) and Wendelstein 7-X approaches to be made[26] These studies have demonstrated convenient solutionsreliable operation and robust and flexible construction suit-able for industrial applications However few studies wereconcerned with the cooling control of mass concrete in adam under complex electromagnetic environment especiallythe problem of the large quantity of temperature digital data

to be transmitted in relation to temperature control duringconcrete block pouring

This paper relating to a real-time temperature data trans-mission approach at a super high arch dam site presents adetailed description of certain aspects of a control systemthat is intended to ensure the structural integrity of massiveconcrete structures during the construction process Thecooling control system prevents unwanted structural changeswithin massive concrete blocks by carrying away the heatgenerated by the exothermic processes of cement hydrationThe proposed temperature transmission approach collectstemperature data from many sensors and prevents the hard-ening concrete from overheating by controlling the waterflow inside the cooling pipes constructed within the concretestructure The temperature transmission system includesthe acquisition of temperature data management of vari-ous intelligent modules temperature data handling sortingand filtering and temperature data transfer to the modulecontrol server The detailed PLC software configuration andprogramming are also illustrated An application case oftemperature monitoring of the Xiluodu arch dam during theconstruction period is discussed in detail The paper aimsto provide a convenient solution to the process of coolingcontrol via the pipes in a situation where the laying of cablesis not possible

2 Temperature Digital DataTransmission Approach

21 Mathematical Description of Digital Temperature ControlModel In this study each basic poured block temperaturecontrol unit has a fixed structure (see Figure 1) one electricsolenoid proportional valve one outlet water flow transmitterand two or more temperature sensors installed at the waterpipe inlet and outlet adjacent concrete temperature and soforthThemass concrete temperature control kernel collectedall the data and commanded the execution of individualcontrol actions indirectly via the PLC system which waseasily set up to handle the field bus

In this study a prerequisite signal processing techniquewas used [10 11] as the proposed closed-loop digital controlsystem for mass concrete cooling on a construction siteThe digital control system with analog sensors (flow sensorthermometer) included an analog prefilter placed betweenthe sensor and the sampler (AD converter) as antialiasingdevice shown in Figure 2The prefilters are low-pass and thesimplest transfer function is used

119867pf (119904) =119886

119904 + 119886 (1)

so that the noise above the prefilter breakpoint 119886 was attenu-ated The design goal is to provide enough attenuation at halfthe sample rate (120596

1199042) so that the noise above 120596

1199042 when

aliased into lower frequencies by the sampler will not bedetrimental to the control-system performance

Mathematical Problems in Engineering 3

Digital temperature and flow measuring device

Digital temperature and flow measuring device

Digital thermometer

Fresh concrete slab

Cooling pipe

Control server

Multichanneltemperature logger

Figure 1 The schematic diagram of temperature and flow acquisition collecting and analysing system

DACooling

controlled

SensorsAnalog prefilter

Manual control according to user needs

Server

Controlled output

ADsystem G(s)

H(s)

Command signal r(k)

D(z)

u(k)b(k)y(t)

Figure 2 Block diagram for control process

For this cooling control system the basic configurationand block diagram are shown in Figure 2 where

119866(119904) = transfer function of the controlled system(continuous-time system)119867(119904) = transfer function of the analogue sensor119863(119911) = transfer function of the digital control algo-rithm

The analogue and digital parts of the system are con-nected through DA and AD converters The server withits internal clock drives the DA and AD converters Itcompares the command signal 119903(119896) with the feedback signal119887(119896) and generates the control signal 119906(119896) to be sent to thefinal control elements of the cooling control system Thesesignals are computed fusing the digital control algorithm119863(119911) stored in the memory of the compute server

To suit the complications of a real construction sitethe field bus is designed to link the sensors and actuatorsthe Profibus network links all the analogue signal input and

output modules which are cyclically converting the ADor DA signals Mathematical models generally are used torepresent the digital control devices and the system TheAD converter model [14] used in this system is shownin Figure 3(a) For the field temperature control process acontinuous-time function119891(119905) 119905 ge 0 is the input and thesequence of real numbers 119891(119896) 119896 = 0 1 2 is the outputThe following relationship holds between input and output

119891 (119896) = 119891 (119905 = 119896119879) (2)

where 119879 is the sampler time interval between enquiring flowor temperature and acquiring the result The sequence 119891(119896)can be treated as a train of impulses represented by thecontinuous-time function 1198911015840(119905)

1198911015840

(119905) = 119891 (0) 120575 (119905) + 119891 (1) 120575 (119905 minus 119879)

+ 119891 (2) 120575 (119905 minus 2119879) + sdot sdot sdot =

infin

sum

119896=0

119891 (119896) 120575 (119905 minus 119896119879) (3)

4 Mathematical Problems in Engineering

Impulse modulator

AD converterf(t)

f(t)

Tf(k)

t0 0

120575T(t)

f998400(t) = f(t)120575T(t)k

(a)

DA converterZOH

T

f(k)

f(k)

t0 0k

gh0(s) = 1 minus eminussTs

f998400998400(t)

f998400998400(t)f998400(t)

(b)

Figure 3 A model of an AD or DA converter

The model of DA converter is shown in Figure 3(b) Asequence of numbers 119891(119896) 119896 = 0 1 2 is the input andthe continuous-time function 11989110158401015840(119905) 119905 ge 0 is the output Thefollowing relationship holds between input and output

11989110158401015840

(119905) = 119891 (119896) 119896119879 le 119905 lt (119896 + 1) 119879 (4)

Each sample of the sequence 119891(119896) may be treated as animpulse function of the form119891(119896)120575(119905 minus 119896119879) The zero-orderhold (ZOH) of Figure 3(b) can thus be viewed as a lineartime-invariant system that converts the impulse119891(119896)120575(119905minus119896119879)into a pulse of height 119891(119896) and width 119879 The DA convertermay therefore be modelled by Figure 3(b) where the ZOHis a system whose response to a unit impulse 120575(119905) is a unitpulse 119892

ℎ0(119905) of width 119879The Laplace transform of 119892

ℎ0(119905) is the

transfer function of the hold operation namely

119892ℎ0(119904) =1 minus 119890minus119904119879

119904 (5)

22 Temperature Digital Data Transmission For dam tem-perature control system shown in Figure 1 the temperaturesensors sampling time could be as long as one minute AProfibus network and corresponding modules would domi-nate the control cost unnecessarily and therefore a lower costfield bus called ITU was engaged An intelligent module cantransfer the ITU signals into RS485 protocol which mostkinds of PLC support The intelligent temperature modulewhich has 8 channels can link a maximum of 256 differentITU sensors usually via three core cables After initializationthe module can exchange the digital data with PLC basis ofRS485 protocol One RS485 master can communicate with127 slaves and this means one PLC CPU can acquire up to32512 ITU temperature sensors In this control system theSiemens Simatic S7-300 PLC was used as the data bridgebetween the control model computer and the field sensorsand actuators The specified PLC programming languageFBD (function block diagram) and standard function library

provided the software engineering basic environment Thesoftware tasks were condensed into the three parts of col-lecting the temperature and flow data communicating withthe model server and the water flow proportional integralderivative (PID) control

221 Data Inquiring and Acquiring There are a number ofcommands defined to fetch the status or data from the intel-ligent temperature module LTM8663 via the RS485 protocolwhich are in ASCII format The most important commandsfrom PLC to the intelligent module are as follows

(1) lowastAAN (CR)The command name to read all the sensorsrsquoID linked to the channel ldquo119873rdquo of the specified intelligentmodule ldquo119860119860rdquo (ranging from 00 h to FF h) here ldquoCRrdquo is thecarriage return character (ASCII code ldquo0Dhrdquo)

Each ID is preset by a handy tool or PC software to escapethe same numbering on the same channel

(2) AAN (CR) The command name similar to the aboveldquolowast119860119860119873rdquo this command tries to read all the sensorsrsquo datalinked to the channel ldquo119873rdquo of the specified intelligent moduleldquo119860119860rdquo

The above two frequently used commands enable PLC toget exactly the total numbers and numbering of linked sen-sors as well as their current temperature values

222 Data Handling Sorting and Filtering As long as thereis a valid response from the intelligent module the temper-ature digital data will be first transferred into a data bufferwhich is previously defined in the PLC and then analyzedaccording to the predefined data format The standard func-tion block for the PLC will copy the data from the RS485network to that buffer and generate a pulse indicating thatnew data is coming the user program will fetch the channelsrelated data and copy them to corresponding data blockaccording to the current counter

Since channel data sets are separated the PLC decideswhether they are valid or not on the basis of the receivedtelegramheader (here ldquogtrdquomeans data are valid)Theprogramwill then transfer the raw temperature data into standardizedformat (floating type) For the specific LTM8663module usedin this system the original temperature data format is 16 A(byte 1) B (byte 2) and the conversion formula is

119905 =[256 (119861amp167) + 119860]

16 (6)

According to the LTM8663 specification the RS485 com-munication protocol is ASCII and the parameters should beconfigured in the hardware interface as the speed transmis-sion rate is 9600 bps data bits are 8 stop bits is 1 and theoperating mode is half duplex (RS485) two-wire mode

After the PLC program has distinguished the total num-ber of sensors of the module each ID and actual data it isnot difficult to sort and copy them to the right offset locationin the summary data block Obviously each sensor ID inone module must be unique The summary data block is thetransmission information to the module control server

Mathematical Problems in Engineering 5

FB8DB8

Comment Comment

ENSF

M2002RREQ

512 LADDR20

05

DONE M2010ERROR M2011STATUS MW204

ENO

DB NODBB NO

R CPU NOR TYP

R OFFSETR CF BYTR CF BIT

The logic address of CP341 module

The telegram from PLC to the intelligent module

The telegram from the intelligent module to PLC

FB7DB7

EN

M2010

R

512 LADDR

30NDR M2020

ERROR M2021

LEN

STATUS MW206

ENO

EN R

DB NO

DBB NO

L TYP

L NO

L OFFSET

L CF BYT

L CF BITLEN

R NO

0

Network 16 Receiving from the intelligent module

Network 14 Sending to the intelligent module

Figure 4 Function blocks for communication between CP341 and LTM8663 modules

23 Management of Various Intelligent Modules On the damconstruction site thousands of sensors were installed on thecooling pipes or cast inside the concrete enabling variousidentified intelligent modules to be linked to PLC via RS485network PLC software autodecided the polling strategy forthe whole network to avoid data acquisition conflicts To polleach module and channel cyclically a counter is utilized todifferentiate the time frames for each task In addition thePLC sends twodifferent commands for each channel since thetime interval must be considered The brief polling sequenceis illustrated in [10]

To achieve communication between CP343-1 and themodule server the server must be configured in the Simaticmanager The module server is taken as ldquoanother stationrdquohere and in the net two connections should be establishedfor sending and receiving For the Transmission ControlProtocol (TCP) connection the port addresses of both partiesshould be fixed

The real-time data transmission from concrete construc-tion site to the remote module control server was achievedusing an industrial Ethernet communication board withTCPIP protocol Depending on the distance a fibre opticconverter or a wireless AP can be used for the data bridgeThe standard PLC Ethernet communication function blockcan easily transfer the data block contents to the target serverThe network structure is independent of the sensors If oneor several sensors fail the master can still read data fromother sensors After replacement the sensors can be accessedagain as the master collects the data on the whole networkrepeatedly

3 PLC Code Configuration

In this study the structured control language (SCL) was usedas the PLC codeThe FBD and the Standard Template Library(STL) included communication with the intelligent module

(RS485) temperature digital data treatment filtering andsorting communication with the module server (TCPIP)and the cooling water PID control

31 Communication with the Intelligent Module LTM8663The standard function block FB7 and FB8 (P SND RK)are designed for RS485 communication structure shown inFigure 4

The CP341 module is an extended communication pro-cessor which supports RS422 and RS485 protocol The datablock DB20 stores the inquiring command (5 bytes) to theintelligentmodule andDB30 is the receiving data buffer fromthe module The execution of FB7 and FB8 is separated bylogic

32 Temperature Digital Data Analysis When the specificchannel temperature digital data is recognized it is trans-ferred from DB30 to another data block for handling Forexample DB31 handles raw data coming from channel 1module 0 As the total number of sensors and each ID isknown by the program each temperature value can be con-verted into target floating formatThe source code below con-verts the data according to (6)

After the treatment the sensor actual values are copied toa summary data block (eg DB10 for module 0) The offsetin the data block will follow the ID For example the offsetaddress for the sensor ID 3 is 12 as in Table 1

33 Communication with the Module Server Two otherstandard functions (FC50 and FC60) are used for the TCPIPcommunicationwith themodule server as shown in Figure 5The Ethernet port is integrated in the CPU module The DB1is the sending buffer which collects all the sensor informationand telegram time stamp shown in Table 2

The telegram length is 2022 bytes including the title tele-gram label length telegram type sending time total circuit

6 Mathematical Problems in Engineering

Table 1 The PLC data structure of DB10 for communication with intelligent module

Number Address offset Name Data type Comments1 0 Module SN Integer Module serial number2 2 Total sensors Real Total sensors number3 4 Value ID1 Real SensorValue ID14 8 Value ID2 Real SensorValue ID25 12 Value ID3 Real SensorValue ID36 16 Value ID4 Real SensorValue ID4

256 1016 Value ID254 Real SensorValue ID254257 1020 Value ID255 Real SensorValue ID255258 1024 Value ID256 Real SensorValue ID256

Table 2 The PLC data structure of DB1 for sending telegram to module server

Number Address offset Name Data type Comments1 0 Label String(4) Fixed as ldquoEDAMrdquo2 4 Length Integer Telegram length3 6 Tel type INT Telegram type4 8 SendTime String(12) Format YYYYMMDDHHMM5 20 TotalNumber INT Total circuits6 22 Telegram1 UDT1 User defined data type

119899 + 5 (119899 minus 1) lowast 10 + 22 Telegram(119899) UDT1 User defined data type

Table 3 The user defined type (UDT) for each circuit value as a template

Number Address offset Name Data type Comments1 0 Number Integer The circuit number2 2 Mode Byte Mode 1 = auto 2 = manual3 3 AlarmWarnning Byte 0 = OK 1 = warning 2 = alarm4 4 InletTemp Integer Water inlet tmperature5 6 OutletTemp Integer Water outlet temperature6 8 ActFlow Integer Actual water flow

numbers and every item of circuit data Here a special UDT(user data type 10 bytes) is defined for each water coolingcircuit including the serial number auto- or manual modestatus inlet and outlet temperature and actual water flowshown in Table 3 Correspondingly the DB2 is the receivingbuffer containing the commands for each circuit from themodule serverrsquos control strategy system

Similarly the receiving telegram contains the labellength type and command for each circuit and the personal-ized control solution is then realized in this way Every circuitcan have its own cooling water flow target set point or fixedwater valve opening output

4 Application Case Study

41 Brief Introduction toDamSite Theproposedmethodwasapplied to the temperature control of the Xiluodu arch dam

during construction [28 29]The project is located on the Jin-shajiang River in the Leibo County of Sichuan province Theprincipal structures consist of a double-curvature arch dam2855 meters high crest length about 700 meters spillwayunderground powerhouse and logway A total of 6000000cubic meters of concrete were poured Because of the highstresses in an arch dam structure and the constructionprocess control difficulties the basic temperature controlprinciplewas tomaintain ultimately small temperature differ-ences betweenneighbouring areas of concrete by slow coolingand early cooling The cooling process should be based onthe concrete temperature measurement results taking intoconsideration the partitioning of the concrete pouringtemperature water pipes density of concrete and ambienttemperature The cooling water flow is adjusted in a timelymanner to meet the targeted temperature requirements

A flexible network structure for field temperature mon-itoring of the super high arch dam during construction was

Mathematical Problems in Engineering 7

Comment Comment

EN

ACT

ID

EN

M1000

M1001

MW102

M1040

M1041

MW106

MW108LADDRLADDR1

T32

SEND

ID

Network 7 Sending telegram to module server Network 8 Receiving telegram from module server

W163FFC

W163FFC

PDB1DBX00

PDB2DBX00

FC50 FC60NDR

RECV

2

BYTE 2048

BYTE 2048

2048

DONE

ERROR

ERROR

STATUS

STATUS

ENO

ENO

LEN

LEN

The logic address of CPU Ethernet port

Figure 5 The PLC functions for TCPIP communication with the module server

(1) BOX1

(2) PS307(3) CPU315

(4) CP341

(5) IM153(6) AI8

(7) AO8

Figure 6 The internal layout of the PLC control cubicle

developed based on the state of the art intelligence controltechnology [8] By employing flexible network structurearchitecture the bus was also connected to other typesof sensors such as dam strain measurement meters damcompressive stress measurement meters meters for moni-toring joint openings rock-deformations and piezometersfor seepage flow all of which were are designed to suitthis network specification Thus the measurement scopeutilized covered a wide spectrum as well as themany concretetemperature measurements sufficient for a super high archdam

42 Site Control System Arrangement The control cabinetswere prepared in the workshop Because of the complexelectromagnetic environment on the construction site wiringto the site flow valves and sensors were employed Figure 6shows a preassembled cabinet for digital data transmissionHere is the brief description of the main parts of PLC controlcubicle

BOX1 The intelligent temperature module The cir-cuit connection diagrams for connecting the temper-ature sensors to the module are shown in Figure 7PS307 The Simatic S7-300 PLC power moduleCPU315 The Simatic S7-300 PLC CPU with inte-grated Profibus and Ethernet interfacesCP341 The Simatic RS485 communication processorfor the intelligent temperature moduleIM153 The Simatic interface module which canextend the CPU control to remote areas by ProfibusnetworkAI8TheSimatic analog inputmodule which can read8 analogue signals (current voltage resistor or PT100sensors) The circuit diagram for connecting the flowmeters to the analogue input module is shown inFigure 8 The symbol ldquoSM331rdquo is the analogue inputmodule which is able to read 8 water flow transduc-ers please refer to ldquo(6) AI8rdquo of Figure 6AO8 The Simatic analogue output module whichcan drive 8 analog valves The circuit diagram forconnecting the electric valves to the analogue outputmodule is shown in Figure 9 The symbol ldquoSM332rdquo isthe analogue output module which is able to control8 proportional valves please refer to ldquo(7) AO8rdquo ofFigure 6

On the dam site the operators connect the valves flowmeters and temperature sensors into the PLC cabinets asrequired according to construction progress

43 Temperature Field Analysis Basis of Real-Time Temper-ature Data On the Xiluodu arch dam site the intelligentcooling control system used modern field bus technologyextensively and Siemens PLC devices to comprehensivelytrack the temperature data change at the pouring of everyblock in real time Adjustment of the valves and control ofwater flowwere performed using the PID algorithm based ontemperature control requirements and key factors such as thehighest temperature reached cooling rate and temperature

8 Mathematical Problems in Engineering

-BOX1

256 RS422LTM8663

GNDCH2

GNDCH1

GNDCH0

-X34

-X31

-X35

-X38

-X32-X33

-X36-X37

CH3GND

-X39-X310-X311-X312

CH4GND

CH5GND

CH6GND

CH7GND

-X316

-X313

-X317

-X320

-X314-X315

-X318-X319

-X321-X322-X323-X324

+5V+5V

+5V +5V

+5V+5V

+5V +5V

24V+ COM+

COMminus

CH2

CH0 5V

CH1 5V

CH0

CH0 GND

CH1 GNDCH2 5V

CH2 GNDCH3 5V

CH3

CH3 GNDBOX1

BOX1

BOX1BOX1

BOX1

BOX1BOX1

BOX1

BOX1

BOX1BOX1

BOX1

BOX1 CH5

BOX1 CH6

BOX1 CH4 5V

BOX1 CH5 5V

BOX1 CH4BOX1 CH4 GND

BOX1 CH5 GND

BOX1 CH6 5V

BOX1 CH6 GND

BOX1 CH7 5V

BOX1 CH7BOX1 CH7 GND

-XP1 1721-XM1 1728

CH1

GND(24V) = CC3 + CBL3-BOX1 COMminus

= CC3 + CBL3-BOX1 COM+

-RS422 COMminus+UR056

-RS422 COM++UR056

Figure 7 The circuit diagram for connecting the temperature sensors to the module

3 times 075

3 times 075

3 times 075

3 times 075

3 times 075

3 times 075

3 times 075

3 times 075

3 times 075 3 times 075

6ES7 331-1KF02-0AB0

SM 331

A

A

A

A

V

V

V

V

V

V

V

V

A

A

A

A

SIEMENS

8

Rack0Slot3

-A3

2

1

3

4

5

6

7

89

1112

13

1516

1718

1920

2122

2324

2526

2728

2930

3132

3334

3536

3738

3940

1

3

10

5

14

7

9

11

13

15

21

41-W501

1

21

41-W502

1

21

41-W503

1

21

41

1

12

47

1

12

12

12

47-W506

1

47-W507

1

47-W508

1

41-W401

148

-W402

1

The i

nlet

or o

utle

t w

ater

flow

tran

sduc

ers

AI 8 times 13 BIT

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

-FT501

-FT502

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

-FT503

-FT504

-W504

-FT505

-W505

-FT506

-FT507

-FT508

S+Sminus

S+Sminus

S+Sminus

S+Sminus

S+ Sminus

S+ Sminus

S+ Sminus

S+ Sminus +CBL1-XP2 2+CBL134+CBL1-XP2 1+CBL134

+CBL1-XM1 1+CBL124

CH0 I+

CH0 U+

CH0 Sminus

CH0 M+

CH0 Mminus

CH1 U+

CH1 I+

CH1 SminusCH1 M+

CH2 M+

CH2 U+

CH2 I+

CH2 Sminus

CH2 Mminus

CH1 Mminus

CH3 U+

CH3 I+CH3 Sminus

CH3 M+

CH3 Mminus

CH4 U+

CH4 I+

CH4 SminusCH4 M+

CH4 Mminus

CH5 U+

CH5 I+CH5 Sminus

CH5 M+

CH5 Mminus

CH6 U+

CH6 I+

CH6 SminusCH6 M+

CH6 Mminus

CH7 U+

CH7 I+CH7 Sminus

CH7 M+

CH7 Mminus

Figure 8 The circuit diagram for connecting the temperature sensors to the module

gradient A web graphical user interface (GUI) was providedfor integrated query analysis and prewarning [1]

Based on the proposed temperature data transmissionsystem the intelligent cooling system overcomes the short-comings in traditional manually collected data systemsproviding an effective dam concrete temperature control andcracking prevention technology both advanced and moreintelligent In particular the advances consist of (1) changingsimple manual data collection to real-time data acquisitionand feedback (2) automatically obtaining large quantitiesof thermodynamic parameters with respect to every blockof poured concrete enabling a more customized control

function and (3) enabling a 3D real-time temperature fieldanalysis be carried out as illustrated in Figure 10 Based onthe real-time temperature field analysis further stress fieldscan be analyzed to study alternative temperature controlplans not only limited to water flow but the whole pipeworkscheme can be adjusted to more optimal configurations

5 Conclusions

This paper presents a real-time temperature data transmis-sion approach for intelligent cooling control of early agemassconcrete based onAD convertermodel and PLC technology

Mathematical Problems in Engineering 9

6ES7 332-5HF00-0AB0

SM 332 SIEMENS

8

Rack0Slot4

-A4

1

2

3

4

5

66Mana0

7

8

9

1010Mana1

11

12

13

15

16

17

1818Mana3

19

20 20M20M

21

22

23

24

25

2626Mana4

27

28

29

3030Mana5

31

32

33

3434Mana6

35

36

37

3838Mana7

39

40

2

4

6

8

10

12

14

16

1414Mana2

-YVP5012

M

1

Y1

3

U

4

32-W501

2

-YVP5022

M

1

Y1

3

U

4

-YVP5032

M

1

Y1

3

U

4

-YVP5042

M

1

Y1

3

U

4

32-W502

2

-YVP5052

M

1

Y1

3

U

4

-YVP5062

M

1

Y1

3

U

4

-YVP5072

M

1

Y1

3

U

4

-YVP5082

M

1

Y1

3

U

4

32-W503

2

32-W504

2

37-W505

2

37-W506

2

37-W507

2

37-W508

2

31-W401

2 238

-W402

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

1L+1L+

CH0 QV+

CH0 S+

CH0 Sminus

CH0 Mana

CH1 QV+

CH1 S+

CH1 S-

CH1 Mana

CH2 QV+

CH2 S+

CH2 Sminus

CH3 QV+

CH3 S+

CH3 Sminus

CH3 Mana

CH2 Mana

CH4 QV+

CH4 S+

CH4 Sminus

CH4 Mana

CH5 QV+

CH5 S+

CH5 Sminus

CH5 Mana

CH6 QV+

CH6 S+

CH6 Sminus

CH6 Mana

CH7 QV+

CH7 S+

CH7 Sminus

CH7 Mana

24V

24V

24V

24V

24V

24V

24V

24V

+CBL1-XP1 1+CBL124

+CBL1-XM2 1+CBL135 +CBL1-XM2 2+CBL135

+CBL1-XM1 2+CBL125

The e

lect

ric so

leno

id

prop

ortio

nal v

alve

s

AO 8 times 12 BIT

3 times 075

Figure 9 The circuit diagram for connecting the electric valves to the analog output module

Y

X0 20 40 60 80 100 100120 140 160 180 200

0

10

20

30

40

50

50 1112131415161718192021

(∘C)

Figure 10 Real-time three-dimensional temperature field

The proposed approach offers an effective and efficient alter-native for acquiring temperature digital data useful for sup-porting the decision-making processes regarding the controlof cooling of just poured mass concrete in real time

A mathematical description of the digital temperaturecontrol model has been developed Use of this model fortemperature values acquisition filtering sorting treatingand their real-time transfer for cooling control purposes isproved effective A stable real-time high volume capacityof the temperature data transmission solution developedutilized an intelligent cooling control system

Using this system on the Xiluodu arch dam site enabledsome key problems to be solved including huge quantities ofraw data interchange with the module server personalizedand flexible control for each water cooling circuit andaccurate and punctual water conditional control data collec-tion instead of traditional manual checking The proposedapproach provides a convenient solution in process coolingcontrol pipes where cabling is not possible The systemalso has lower installation and maintenance costs operatesreliably and is of robust and flexible construction It is proved

suitable for heat of hydration control in dam constructionconcreting applications

Based on this study the future research will be focusedon the combination of real-time site monitoring analysis andnumerical simulation on thermal stress for control crackingof mass concrete in construction period

Conflict of Interests

The authors declare that there is no conflict of interestsregarding the publication of this paper

Acknowledgments

This research work was supported by National NaturalScience Foundation of China (nos 11272178 and 51339003)National Basic Research Program of China (973 Program)under Grants nos 2013CB035902 and 2011CB013503 andTsinghua University Initiative Scientific Research Program

References

[1] P Lin Q B Li S W Zhou and Y Hu ldquoIntelligent cooling con-trol method and system for mass concreterdquo Journal of HydraulicEngineering vol 44 no 8 pp 950ndash957 2013

[2] F A Branco and P Mendes ldquoNumerical simulations of heat ofhydration temperature in damsrdquo in Proceedings of the Interna-tional Workshop on Arch Dams pp 225ndash230 Coimbra Portu-gal April 1987

[3] B Zhu ldquoEffect of cooling by water flowing in nonmetal pipesembedded in mass concreterdquo Journal of Construction Engineer-ing and Management vol 125 no 1 pp 61ndash68 1999

[4] AMNevilleProperties of Concrete Longman Essex UK 1995

10 Mathematical Problems in Engineering

[5] H S Shang T H Yi and Y P Song ldquoBehavior of plain concreteof a highwater-cement ratio after freeze-thaw cyclesrdquoMaterialsvol 5 no 9 pp 1698ndash1707 2012

[6] H S Shang and T H Yi ldquoFreeze-thaw durability of air-entrained concreterdquo The Scientific World Journal vol 2013Article ID 650791 6 pages 2013

[7] H S Shang and T H Yi ldquoBehavior of HPC with fly ash afterelevated temperaturerdquo Advances in Materials Science and Engi-neering vol 2013 Article ID 478421 7 pages 2013

[8] G D Zhou and T H Yi ldquoThermal load in large-scale bridgesa state-of-the-art reviewrdquo International Journal of DistributedSensor Networks vol 2013 Article ID 217983 17 pages 2013

[9] Q Li G Li and G Wang ldquoElasto-plastic bond mechanics ofembeddedfiber optic sensors in concrete under uniaxial tensionwith strain localizationrdquo Smart Materials and Structures vol 12no 6 pp 851ndash858 2003

[10] P Lin Q B Li and H Hu ldquoA flexible network structure fortemperature monitoring of a super high arch damrdquo Interna-tional Journal of Distributed Sensor Networks vol 2012 ArticleID 917849 10 pages 2012

[11] Q B Li P Lin S W Zhou et al ldquoReal time online individu-ation and intelligent cooling control system for mass concreterdquoUtility Model Patent 2012204165226 2013

[12] P Lin Q B Li Y Hu et al ldquoA device of integrity flow and tem-perature controllingrdquo Patent Number(s) 2012204177149 2013

[13] Q B Li and P Lin ldquoDemonstration on intelligent damrdquo Journalof Hydroelectric Engineering vol 33 no 1 2014

[14] K J Astrom and T Hagglund PID Controllers Theory Designand Tuning International Society for Measurement and Con-trol Seattle Wash USA 2nd edition 1995

[15] A B Corripio Tuning of Industrial Control Systems InstrumentSociety of America Research Triangle Park NC USA 1990

[16] F D Petruzella Programmable Logic Controllers Mcgraw-HillNew York NY USA 3rd edition 2004

[17] M Gopal Digital Control and State Variable Methods Conven-tional and Intelligent Control Systems McGraw Hill Education4th edition 2012

[18] M S Santina A R Stubberud and G H Hostetter DigitalControl System Design International Thomson PublishingStamford Conn USA 2nd edition 1994

[19] F Italiano R Maugeri A Mastrolia and J Heinicke ldquoA newseafloor monitoring module for real-time data transmission anapplication to shallow hydrothermal ventsrdquo Procedia Earth andPlanetary Science vol 4 pp 93ndash98 2011

[20] R Bayindir and Y Cetinceviz ldquoAwater pumping control systemwith a Programmable Logic Controller (PLC) and industrialwireless modules for industrial plantsmdashan experimental setuprdquoISA Transactions vol 50 no 2 pp 321ndash328 2011

[21] J Flores B Arcay and J Arias ldquoAn intelligent system for dis-tributed control of an anaerobic wastewater treatment processrdquoEngineering Applications of Artificial Intelligence vol 13 no 4pp 485ndash494 2000

[22] P Marino M A Domınguez F Poza and F Vazquez ldquoUsingLOTOS in the specification of industrial bus communicationprotocolsrdquoComputerNetworks vol 45 no 6 pp 767ndash799 2004

[23] J L Posadas P Perez J E Simo G Benet and F BlanesldquoCommunications structure for sensory data in mobile robotsrdquoEngineering Applications of Artificial Intelligence vol 15 no 3-4pp 341ndash350 2002

[24] C Hennig T Bluhm P Heimann et al ldquoUsing the network asbus system for long discharge data acquisition and data process-ingrdquo Fusion Engineering and Design vol 81 no 15ndash17 pp 1735ndash1740 2006

[25] R Moraes F B Carreiro P Bartolomeu V Silva J A Fonsecaand F Vasques ldquoEnforcing the timing behavior of real-timestations in legacy bus-based industrial Ethernet networksrdquoComputer Standards and Interfaces vol 33 no 3 pp 249ndash2612011

[26] C Hennig K Kneupner and D Kinna ldquoConnecting Program-mable Logic Controllers (PLC) to control and data acquisition acomparison of the JET and Wendelstein 7-X approachrdquo FusionEngineering and Design vol 87 no 12 pp 1972ndash1976 2012

[27] J-N Dong G-H Qin and H Yu ldquoStudy on real-time sensorsignal transmission based on technology of polynomial predic-tive filteringrdquoMeasurement vol 42 no 7 pp 969ndash977 2009

[28] P Lin S Z KangQ B Li et al ldquoEvaluation on rockmass qualityand stability of xiluodu arch dam under construction phaserdquoJournal of Rock Mechanics and Engineering vol 31 no 10 pp2042ndash2052 2012

[29] P Lin X L Liu Y Hu Yu et al ldquoDeformation and stability anal-ysis on xiluodu arch dam under stress and seepage conditionrdquoJournal of Rock Mechanics and Engineering vol 32 no 6 pp1137ndash1144 2013

Submit your manuscripts athttpwwwhindawicom

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

MathematicsJournal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Mathematical Problems in Engineering

Hindawi Publishing Corporationhttpwwwhindawicom

Differential EquationsInternational Journal of

Volume 2014

Applied MathematicsJournal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Probability and StatisticsHindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Journal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Mathematical PhysicsAdvances in

Complex AnalysisJournal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

OptimizationJournal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

CombinatoricsHindawi Publishing Corporationhttpwwwhindawicom Volume 2014

International Journal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Operations ResearchAdvances in

Journal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Function Spaces

Abstract and Applied AnalysisHindawi Publishing Corporationhttpwwwhindawicom Volume 2014

International Journal of Mathematics and Mathematical Sciences

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

The Scientific World JournalHindawi Publishing Corporation httpwwwhindawicom Volume 2014

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Algebra

Discrete Dynamics in Nature and Society

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Decision SciencesAdvances in

Discrete MathematicsJournal of

Hindawi Publishing Corporationhttpwwwhindawicom

Volume 2014 Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Stochastic AnalysisInternational Journal of

Mathematical Problems in Engineering 3

Digital temperature and flow measuring device

Digital temperature and flow measuring device

Digital thermometer

Fresh concrete slab

Cooling pipe

Control server

Multichanneltemperature logger

Figure 1 The schematic diagram of temperature and flow acquisition collecting and analysing system

DACooling

controlled

SensorsAnalog prefilter

Manual control according to user needs

Server

Controlled output

ADsystem G(s)

H(s)

Command signal r(k)

D(z)

u(k)b(k)y(t)

Figure 2 Block diagram for control process

For this cooling control system the basic configurationand block diagram are shown in Figure 2 where

119866(119904) = transfer function of the controlled system(continuous-time system)119867(119904) = transfer function of the analogue sensor119863(119911) = transfer function of the digital control algo-rithm

The analogue and digital parts of the system are con-nected through DA and AD converters The server withits internal clock drives the DA and AD converters Itcompares the command signal 119903(119896) with the feedback signal119887(119896) and generates the control signal 119906(119896) to be sent to thefinal control elements of the cooling control system Thesesignals are computed fusing the digital control algorithm119863(119911) stored in the memory of the compute server

To suit the complications of a real construction sitethe field bus is designed to link the sensors and actuatorsthe Profibus network links all the analogue signal input and

output modules which are cyclically converting the ADor DA signals Mathematical models generally are used torepresent the digital control devices and the system TheAD converter model [14] used in this system is shownin Figure 3(a) For the field temperature control process acontinuous-time function119891(119905) 119905 ge 0 is the input and thesequence of real numbers 119891(119896) 119896 = 0 1 2 is the outputThe following relationship holds between input and output

119891 (119896) = 119891 (119905 = 119896119879) (2)

where 119879 is the sampler time interval between enquiring flowor temperature and acquiring the result The sequence 119891(119896)can be treated as a train of impulses represented by thecontinuous-time function 1198911015840(119905)

1198911015840

(119905) = 119891 (0) 120575 (119905) + 119891 (1) 120575 (119905 minus 119879)

+ 119891 (2) 120575 (119905 minus 2119879) + sdot sdot sdot =

infin

sum

119896=0

119891 (119896) 120575 (119905 minus 119896119879) (3)

4 Mathematical Problems in Engineering

Impulse modulator

AD converterf(t)

f(t)

Tf(k)

t0 0

120575T(t)

f998400(t) = f(t)120575T(t)k

(a)

DA converterZOH

T

f(k)

f(k)

t0 0k

gh0(s) = 1 minus eminussTs

f998400998400(t)

f998400998400(t)f998400(t)

(b)

Figure 3 A model of an AD or DA converter

The model of DA converter is shown in Figure 3(b) Asequence of numbers 119891(119896) 119896 = 0 1 2 is the input andthe continuous-time function 11989110158401015840(119905) 119905 ge 0 is the output Thefollowing relationship holds between input and output

11989110158401015840

(119905) = 119891 (119896) 119896119879 le 119905 lt (119896 + 1) 119879 (4)

Each sample of the sequence 119891(119896) may be treated as animpulse function of the form119891(119896)120575(119905 minus 119896119879) The zero-orderhold (ZOH) of Figure 3(b) can thus be viewed as a lineartime-invariant system that converts the impulse119891(119896)120575(119905minus119896119879)into a pulse of height 119891(119896) and width 119879 The DA convertermay therefore be modelled by Figure 3(b) where the ZOHis a system whose response to a unit impulse 120575(119905) is a unitpulse 119892

ℎ0(119905) of width 119879The Laplace transform of 119892

ℎ0(119905) is the

transfer function of the hold operation namely

119892ℎ0(119904) =1 minus 119890minus119904119879

119904 (5)

22 Temperature Digital Data Transmission For dam tem-perature control system shown in Figure 1 the temperaturesensors sampling time could be as long as one minute AProfibus network and corresponding modules would domi-nate the control cost unnecessarily and therefore a lower costfield bus called ITU was engaged An intelligent module cantransfer the ITU signals into RS485 protocol which mostkinds of PLC support The intelligent temperature modulewhich has 8 channels can link a maximum of 256 differentITU sensors usually via three core cables After initializationthe module can exchange the digital data with PLC basis ofRS485 protocol One RS485 master can communicate with127 slaves and this means one PLC CPU can acquire up to32512 ITU temperature sensors In this control system theSiemens Simatic S7-300 PLC was used as the data bridgebetween the control model computer and the field sensorsand actuators The specified PLC programming languageFBD (function block diagram) and standard function library

provided the software engineering basic environment Thesoftware tasks were condensed into the three parts of col-lecting the temperature and flow data communicating withthe model server and the water flow proportional integralderivative (PID) control

221 Data Inquiring and Acquiring There are a number ofcommands defined to fetch the status or data from the intel-ligent temperature module LTM8663 via the RS485 protocolwhich are in ASCII format The most important commandsfrom PLC to the intelligent module are as follows

(1) lowastAAN (CR)The command name to read all the sensorsrsquoID linked to the channel ldquo119873rdquo of the specified intelligentmodule ldquo119860119860rdquo (ranging from 00 h to FF h) here ldquoCRrdquo is thecarriage return character (ASCII code ldquo0Dhrdquo)

Each ID is preset by a handy tool or PC software to escapethe same numbering on the same channel

(2) AAN (CR) The command name similar to the aboveldquolowast119860119860119873rdquo this command tries to read all the sensorsrsquo datalinked to the channel ldquo119873rdquo of the specified intelligent moduleldquo119860119860rdquo

The above two frequently used commands enable PLC toget exactly the total numbers and numbering of linked sen-sors as well as their current temperature values

222 Data Handling Sorting and Filtering As long as thereis a valid response from the intelligent module the temper-ature digital data will be first transferred into a data bufferwhich is previously defined in the PLC and then analyzedaccording to the predefined data format The standard func-tion block for the PLC will copy the data from the RS485network to that buffer and generate a pulse indicating thatnew data is coming the user program will fetch the channelsrelated data and copy them to corresponding data blockaccording to the current counter

Since channel data sets are separated the PLC decideswhether they are valid or not on the basis of the receivedtelegramheader (here ldquogtrdquomeans data are valid)Theprogramwill then transfer the raw temperature data into standardizedformat (floating type) For the specific LTM8663module usedin this system the original temperature data format is 16 A(byte 1) B (byte 2) and the conversion formula is

119905 =[256 (119861amp167) + 119860]

16 (6)

According to the LTM8663 specification the RS485 com-munication protocol is ASCII and the parameters should beconfigured in the hardware interface as the speed transmis-sion rate is 9600 bps data bits are 8 stop bits is 1 and theoperating mode is half duplex (RS485) two-wire mode

After the PLC program has distinguished the total num-ber of sensors of the module each ID and actual data it isnot difficult to sort and copy them to the right offset locationin the summary data block Obviously each sensor ID inone module must be unique The summary data block is thetransmission information to the module control server

Mathematical Problems in Engineering 5

FB8DB8

Comment Comment

ENSF

M2002RREQ

512 LADDR20

05

DONE M2010ERROR M2011STATUS MW204

ENO

DB NODBB NO

R CPU NOR TYP

R OFFSETR CF BYTR CF BIT

The logic address of CP341 module

The telegram from PLC to the intelligent module

The telegram from the intelligent module to PLC

FB7DB7

EN

M2010

R

512 LADDR

30NDR M2020

ERROR M2021

LEN

STATUS MW206

ENO

EN R

DB NO

DBB NO

L TYP

L NO

L OFFSET

L CF BYT

L CF BITLEN

R NO

0

Network 16 Receiving from the intelligent module

Network 14 Sending to the intelligent module

Figure 4 Function blocks for communication between CP341 and LTM8663 modules

23 Management of Various Intelligent Modules On the damconstruction site thousands of sensors were installed on thecooling pipes or cast inside the concrete enabling variousidentified intelligent modules to be linked to PLC via RS485network PLC software autodecided the polling strategy forthe whole network to avoid data acquisition conflicts To polleach module and channel cyclically a counter is utilized todifferentiate the time frames for each task In addition thePLC sends twodifferent commands for each channel since thetime interval must be considered The brief polling sequenceis illustrated in [10]

To achieve communication between CP343-1 and themodule server the server must be configured in the Simaticmanager The module server is taken as ldquoanother stationrdquohere and in the net two connections should be establishedfor sending and receiving For the Transmission ControlProtocol (TCP) connection the port addresses of both partiesshould be fixed

The real-time data transmission from concrete construc-tion site to the remote module control server was achievedusing an industrial Ethernet communication board withTCPIP protocol Depending on the distance a fibre opticconverter or a wireless AP can be used for the data bridgeThe standard PLC Ethernet communication function blockcan easily transfer the data block contents to the target serverThe network structure is independent of the sensors If oneor several sensors fail the master can still read data fromother sensors After replacement the sensors can be accessedagain as the master collects the data on the whole networkrepeatedly

3 PLC Code Configuration

In this study the structured control language (SCL) was usedas the PLC codeThe FBD and the Standard Template Library(STL) included communication with the intelligent module

(RS485) temperature digital data treatment filtering andsorting communication with the module server (TCPIP)and the cooling water PID control

31 Communication with the Intelligent Module LTM8663The standard function block FB7 and FB8 (P SND RK)are designed for RS485 communication structure shown inFigure 4

The CP341 module is an extended communication pro-cessor which supports RS422 and RS485 protocol The datablock DB20 stores the inquiring command (5 bytes) to theintelligentmodule andDB30 is the receiving data buffer fromthe module The execution of FB7 and FB8 is separated bylogic

32 Temperature Digital Data Analysis When the specificchannel temperature digital data is recognized it is trans-ferred from DB30 to another data block for handling Forexample DB31 handles raw data coming from channel 1module 0 As the total number of sensors and each ID isknown by the program each temperature value can be con-verted into target floating formatThe source code below con-verts the data according to (6)

After the treatment the sensor actual values are copied toa summary data block (eg DB10 for module 0) The offsetin the data block will follow the ID For example the offsetaddress for the sensor ID 3 is 12 as in Table 1

33 Communication with the Module Server Two otherstandard functions (FC50 and FC60) are used for the TCPIPcommunicationwith themodule server as shown in Figure 5The Ethernet port is integrated in the CPU module The DB1is the sending buffer which collects all the sensor informationand telegram time stamp shown in Table 2

The telegram length is 2022 bytes including the title tele-gram label length telegram type sending time total circuit

6 Mathematical Problems in Engineering

Table 1 The PLC data structure of DB10 for communication with intelligent module

Number Address offset Name Data type Comments1 0 Module SN Integer Module serial number2 2 Total sensors Real Total sensors number3 4 Value ID1 Real SensorValue ID14 8 Value ID2 Real SensorValue ID25 12 Value ID3 Real SensorValue ID36 16 Value ID4 Real SensorValue ID4

256 1016 Value ID254 Real SensorValue ID254257 1020 Value ID255 Real SensorValue ID255258 1024 Value ID256 Real SensorValue ID256

Table 2 The PLC data structure of DB1 for sending telegram to module server

Number Address offset Name Data type Comments1 0 Label String(4) Fixed as ldquoEDAMrdquo2 4 Length Integer Telegram length3 6 Tel type INT Telegram type4 8 SendTime String(12) Format YYYYMMDDHHMM5 20 TotalNumber INT Total circuits6 22 Telegram1 UDT1 User defined data type

119899 + 5 (119899 minus 1) lowast 10 + 22 Telegram(119899) UDT1 User defined data type

Table 3 The user defined type (UDT) for each circuit value as a template

Number Address offset Name Data type Comments1 0 Number Integer The circuit number2 2 Mode Byte Mode 1 = auto 2 = manual3 3 AlarmWarnning Byte 0 = OK 1 = warning 2 = alarm4 4 InletTemp Integer Water inlet tmperature5 6 OutletTemp Integer Water outlet temperature6 8 ActFlow Integer Actual water flow

numbers and every item of circuit data Here a special UDT(user data type 10 bytes) is defined for each water coolingcircuit including the serial number auto- or manual modestatus inlet and outlet temperature and actual water flowshown in Table 3 Correspondingly the DB2 is the receivingbuffer containing the commands for each circuit from themodule serverrsquos control strategy system

Similarly the receiving telegram contains the labellength type and command for each circuit and the personal-ized control solution is then realized in this way Every circuitcan have its own cooling water flow target set point or fixedwater valve opening output

4 Application Case Study

41 Brief Introduction toDamSite Theproposedmethodwasapplied to the temperature control of the Xiluodu arch dam

during construction [28 29]The project is located on the Jin-shajiang River in the Leibo County of Sichuan province Theprincipal structures consist of a double-curvature arch dam2855 meters high crest length about 700 meters spillwayunderground powerhouse and logway A total of 6000000cubic meters of concrete were poured Because of the highstresses in an arch dam structure and the constructionprocess control difficulties the basic temperature controlprinciplewas tomaintain ultimately small temperature differ-ences betweenneighbouring areas of concrete by slow coolingand early cooling The cooling process should be based onthe concrete temperature measurement results taking intoconsideration the partitioning of the concrete pouringtemperature water pipes density of concrete and ambienttemperature The cooling water flow is adjusted in a timelymanner to meet the targeted temperature requirements

A flexible network structure for field temperature mon-itoring of the super high arch dam during construction was

Mathematical Problems in Engineering 7

Comment Comment

EN

ACT

ID

EN

M1000

M1001

MW102

M1040

M1041

MW106

MW108LADDRLADDR1

T32

SEND

ID

Network 7 Sending telegram to module server Network 8 Receiving telegram from module server

W163FFC

W163FFC

PDB1DBX00

PDB2DBX00

FC50 FC60NDR

RECV

2

BYTE 2048

BYTE 2048

2048

DONE

ERROR

ERROR

STATUS

STATUS

ENO

ENO

LEN

LEN

The logic address of CPU Ethernet port

Figure 5 The PLC functions for TCPIP communication with the module server

(1) BOX1

(2) PS307(3) CPU315

(4) CP341

(5) IM153(6) AI8

(7) AO8

Figure 6 The internal layout of the PLC control cubicle

developed based on the state of the art intelligence controltechnology [8] By employing flexible network structurearchitecture the bus was also connected to other typesof sensors such as dam strain measurement meters damcompressive stress measurement meters meters for moni-toring joint openings rock-deformations and piezometersfor seepage flow all of which were are designed to suitthis network specification Thus the measurement scopeutilized covered a wide spectrum as well as themany concretetemperature measurements sufficient for a super high archdam

42 Site Control System Arrangement The control cabinetswere prepared in the workshop Because of the complexelectromagnetic environment on the construction site wiringto the site flow valves and sensors were employed Figure 6shows a preassembled cabinet for digital data transmissionHere is the brief description of the main parts of PLC controlcubicle

BOX1 The intelligent temperature module The cir-cuit connection diagrams for connecting the temper-ature sensors to the module are shown in Figure 7PS307 The Simatic S7-300 PLC power moduleCPU315 The Simatic S7-300 PLC CPU with inte-grated Profibus and Ethernet interfacesCP341 The Simatic RS485 communication processorfor the intelligent temperature moduleIM153 The Simatic interface module which canextend the CPU control to remote areas by ProfibusnetworkAI8TheSimatic analog inputmodule which can read8 analogue signals (current voltage resistor or PT100sensors) The circuit diagram for connecting the flowmeters to the analogue input module is shown inFigure 8 The symbol ldquoSM331rdquo is the analogue inputmodule which is able to read 8 water flow transduc-ers please refer to ldquo(6) AI8rdquo of Figure 6AO8 The Simatic analogue output module whichcan drive 8 analog valves The circuit diagram forconnecting the electric valves to the analogue outputmodule is shown in Figure 9 The symbol ldquoSM332rdquo isthe analogue output module which is able to control8 proportional valves please refer to ldquo(7) AO8rdquo ofFigure 6

On the dam site the operators connect the valves flowmeters and temperature sensors into the PLC cabinets asrequired according to construction progress

43 Temperature Field Analysis Basis of Real-Time Temper-ature Data On the Xiluodu arch dam site the intelligentcooling control system used modern field bus technologyextensively and Siemens PLC devices to comprehensivelytrack the temperature data change at the pouring of everyblock in real time Adjustment of the valves and control ofwater flowwere performed using the PID algorithm based ontemperature control requirements and key factors such as thehighest temperature reached cooling rate and temperature

8 Mathematical Problems in Engineering

-BOX1

256 RS422LTM8663

GNDCH2

GNDCH1

GNDCH0

-X34

-X31

-X35

-X38

-X32-X33

-X36-X37

CH3GND

-X39-X310-X311-X312

CH4GND

CH5GND

CH6GND

CH7GND

-X316

-X313

-X317

-X320

-X314-X315

-X318-X319

-X321-X322-X323-X324

+5V+5V

+5V +5V

+5V+5V

+5V +5V

24V+ COM+

COMminus

CH2

CH0 5V

CH1 5V

CH0

CH0 GND

CH1 GNDCH2 5V

CH2 GNDCH3 5V

CH3

CH3 GNDBOX1

BOX1

BOX1BOX1

BOX1

BOX1BOX1

BOX1

BOX1

BOX1BOX1

BOX1

BOX1 CH5

BOX1 CH6

BOX1 CH4 5V

BOX1 CH5 5V

BOX1 CH4BOX1 CH4 GND

BOX1 CH5 GND

BOX1 CH6 5V

BOX1 CH6 GND

BOX1 CH7 5V

BOX1 CH7BOX1 CH7 GND

-XP1 1721-XM1 1728

CH1

GND(24V) = CC3 + CBL3-BOX1 COMminus

= CC3 + CBL3-BOX1 COM+

-RS422 COMminus+UR056

-RS422 COM++UR056

Figure 7 The circuit diagram for connecting the temperature sensors to the module

3 times 075

3 times 075

3 times 075

3 times 075

3 times 075

3 times 075

3 times 075

3 times 075

3 times 075 3 times 075

6ES7 331-1KF02-0AB0

SM 331

A

A

A

A

V

V

V

V

V

V

V

V

A

A

A

A

SIEMENS

8

Rack0Slot3

-A3

2

1

3

4

5

6

7

89

1112

13

1516

1718

1920

2122

2324

2526

2728

2930

3132

3334

3536

3738

3940

1

3

10

5

14

7

9

11

13

15

21

41-W501

1

21

41-W502

1

21

41-W503

1

21

41

1

12

47

1

12

12

12

47-W506

1

47-W507

1

47-W508

1

41-W401

148

-W402

1

The i

nlet

or o

utle

t w

ater

flow

tran

sduc

ers

AI 8 times 13 BIT

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

-FT501

-FT502

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

-FT503

-FT504

-W504

-FT505

-W505

-FT506

-FT507

-FT508

S+Sminus

S+Sminus

S+Sminus

S+Sminus

S+ Sminus

S+ Sminus

S+ Sminus

S+ Sminus +CBL1-XP2 2+CBL134+CBL1-XP2 1+CBL134

+CBL1-XM1 1+CBL124

CH0 I+

CH0 U+

CH0 Sminus

CH0 M+

CH0 Mminus

CH1 U+

CH1 I+

CH1 SminusCH1 M+

CH2 M+

CH2 U+

CH2 I+

CH2 Sminus

CH2 Mminus

CH1 Mminus

CH3 U+

CH3 I+CH3 Sminus

CH3 M+

CH3 Mminus

CH4 U+

CH4 I+

CH4 SminusCH4 M+

CH4 Mminus

CH5 U+

CH5 I+CH5 Sminus

CH5 M+

CH5 Mminus

CH6 U+

CH6 I+

CH6 SminusCH6 M+

CH6 Mminus

CH7 U+

CH7 I+CH7 Sminus

CH7 M+

CH7 Mminus

Figure 8 The circuit diagram for connecting the temperature sensors to the module

gradient A web graphical user interface (GUI) was providedfor integrated query analysis and prewarning [1]

Based on the proposed temperature data transmissionsystem the intelligent cooling system overcomes the short-comings in traditional manually collected data systemsproviding an effective dam concrete temperature control andcracking prevention technology both advanced and moreintelligent In particular the advances consist of (1) changingsimple manual data collection to real-time data acquisitionand feedback (2) automatically obtaining large quantitiesof thermodynamic parameters with respect to every blockof poured concrete enabling a more customized control

function and (3) enabling a 3D real-time temperature fieldanalysis be carried out as illustrated in Figure 10 Based onthe real-time temperature field analysis further stress fieldscan be analyzed to study alternative temperature controlplans not only limited to water flow but the whole pipeworkscheme can be adjusted to more optimal configurations

5 Conclusions

This paper presents a real-time temperature data transmis-sion approach for intelligent cooling control of early agemassconcrete based onAD convertermodel and PLC technology

Mathematical Problems in Engineering 9

6ES7 332-5HF00-0AB0

SM 332 SIEMENS

8

Rack0Slot4

-A4

1

2

3

4

5

66Mana0

7

8

9

1010Mana1

11

12

13

15

16

17

1818Mana3

19

20 20M20M

21

22

23

24

25

2626Mana4

27

28

29

3030Mana5

31

32

33

3434Mana6

35

36

37

3838Mana7

39

40

2

4

6

8

10

12

14

16

1414Mana2

-YVP5012

M

1

Y1

3

U

4

32-W501

2

-YVP5022

M

1

Y1

3

U

4

-YVP5032

M

1

Y1

3

U

4

-YVP5042

M

1

Y1

3

U

4

32-W502

2

-YVP5052

M

1

Y1

3

U

4

-YVP5062

M

1

Y1

3

U

4

-YVP5072

M

1

Y1

3

U

4

-YVP5082

M

1

Y1

3

U

4

32-W503

2

32-W504

2

37-W505

2

37-W506

2

37-W507

2

37-W508

2

31-W401

2 238

-W402

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

1L+1L+

CH0 QV+

CH0 S+

CH0 Sminus

CH0 Mana

CH1 QV+

CH1 S+

CH1 S-

CH1 Mana

CH2 QV+

CH2 S+

CH2 Sminus

CH3 QV+

CH3 S+

CH3 Sminus

CH3 Mana

CH2 Mana

CH4 QV+

CH4 S+

CH4 Sminus

CH4 Mana

CH5 QV+

CH5 S+

CH5 Sminus

CH5 Mana

CH6 QV+

CH6 S+

CH6 Sminus

CH6 Mana

CH7 QV+

CH7 S+

CH7 Sminus

CH7 Mana

24V

24V

24V

24V

24V

24V

24V

24V

+CBL1-XP1 1+CBL124

+CBL1-XM2 1+CBL135 +CBL1-XM2 2+CBL135

+CBL1-XM1 2+CBL125

The e

lect

ric so

leno

id

prop

ortio

nal v

alve

s

AO 8 times 12 BIT

3 times 075

Figure 9 The circuit diagram for connecting the electric valves to the analog output module

Y

X0 20 40 60 80 100 100120 140 160 180 200

0

10

20

30

40

50

50 1112131415161718192021

(∘C)

Figure 10 Real-time three-dimensional temperature field

The proposed approach offers an effective and efficient alter-native for acquiring temperature digital data useful for sup-porting the decision-making processes regarding the controlof cooling of just poured mass concrete in real time

A mathematical description of the digital temperaturecontrol model has been developed Use of this model fortemperature values acquisition filtering sorting treatingand their real-time transfer for cooling control purposes isproved effective A stable real-time high volume capacityof the temperature data transmission solution developedutilized an intelligent cooling control system

Using this system on the Xiluodu arch dam site enabledsome key problems to be solved including huge quantities ofraw data interchange with the module server personalizedand flexible control for each water cooling circuit andaccurate and punctual water conditional control data collec-tion instead of traditional manual checking The proposedapproach provides a convenient solution in process coolingcontrol pipes where cabling is not possible The systemalso has lower installation and maintenance costs operatesreliably and is of robust and flexible construction It is proved

suitable for heat of hydration control in dam constructionconcreting applications

Based on this study the future research will be focusedon the combination of real-time site monitoring analysis andnumerical simulation on thermal stress for control crackingof mass concrete in construction period

Conflict of Interests

The authors declare that there is no conflict of interestsregarding the publication of this paper

Acknowledgments

This research work was supported by National NaturalScience Foundation of China (nos 11272178 and 51339003)National Basic Research Program of China (973 Program)under Grants nos 2013CB035902 and 2011CB013503 andTsinghua University Initiative Scientific Research Program

References

[1] P Lin Q B Li S W Zhou and Y Hu ldquoIntelligent cooling con-trol method and system for mass concreterdquo Journal of HydraulicEngineering vol 44 no 8 pp 950ndash957 2013

[2] F A Branco and P Mendes ldquoNumerical simulations of heat ofhydration temperature in damsrdquo in Proceedings of the Interna-tional Workshop on Arch Dams pp 225ndash230 Coimbra Portu-gal April 1987

[3] B Zhu ldquoEffect of cooling by water flowing in nonmetal pipesembedded in mass concreterdquo Journal of Construction Engineer-ing and Management vol 125 no 1 pp 61ndash68 1999

[4] AMNevilleProperties of Concrete Longman Essex UK 1995

10 Mathematical Problems in Engineering

[5] H S Shang T H Yi and Y P Song ldquoBehavior of plain concreteof a highwater-cement ratio after freeze-thaw cyclesrdquoMaterialsvol 5 no 9 pp 1698ndash1707 2012

[6] H S Shang and T H Yi ldquoFreeze-thaw durability of air-entrained concreterdquo The Scientific World Journal vol 2013Article ID 650791 6 pages 2013

[7] H S Shang and T H Yi ldquoBehavior of HPC with fly ash afterelevated temperaturerdquo Advances in Materials Science and Engi-neering vol 2013 Article ID 478421 7 pages 2013

[8] G D Zhou and T H Yi ldquoThermal load in large-scale bridgesa state-of-the-art reviewrdquo International Journal of DistributedSensor Networks vol 2013 Article ID 217983 17 pages 2013

[9] Q Li G Li and G Wang ldquoElasto-plastic bond mechanics ofembeddedfiber optic sensors in concrete under uniaxial tensionwith strain localizationrdquo Smart Materials and Structures vol 12no 6 pp 851ndash858 2003

[10] P Lin Q B Li and H Hu ldquoA flexible network structure fortemperature monitoring of a super high arch damrdquo Interna-tional Journal of Distributed Sensor Networks vol 2012 ArticleID 917849 10 pages 2012

[11] Q B Li P Lin S W Zhou et al ldquoReal time online individu-ation and intelligent cooling control system for mass concreterdquoUtility Model Patent 2012204165226 2013

[12] P Lin Q B Li Y Hu et al ldquoA device of integrity flow and tem-perature controllingrdquo Patent Number(s) 2012204177149 2013

[13] Q B Li and P Lin ldquoDemonstration on intelligent damrdquo Journalof Hydroelectric Engineering vol 33 no 1 2014

[14] K J Astrom and T Hagglund PID Controllers Theory Designand Tuning International Society for Measurement and Con-trol Seattle Wash USA 2nd edition 1995

[15] A B Corripio Tuning of Industrial Control Systems InstrumentSociety of America Research Triangle Park NC USA 1990

[16] F D Petruzella Programmable Logic Controllers Mcgraw-HillNew York NY USA 3rd edition 2004

[17] M Gopal Digital Control and State Variable Methods Conven-tional and Intelligent Control Systems McGraw Hill Education4th edition 2012

[18] M S Santina A R Stubberud and G H Hostetter DigitalControl System Design International Thomson PublishingStamford Conn USA 2nd edition 1994

[19] F Italiano R Maugeri A Mastrolia and J Heinicke ldquoA newseafloor monitoring module for real-time data transmission anapplication to shallow hydrothermal ventsrdquo Procedia Earth andPlanetary Science vol 4 pp 93ndash98 2011

[20] R Bayindir and Y Cetinceviz ldquoAwater pumping control systemwith a Programmable Logic Controller (PLC) and industrialwireless modules for industrial plantsmdashan experimental setuprdquoISA Transactions vol 50 no 2 pp 321ndash328 2011

[21] J Flores B Arcay and J Arias ldquoAn intelligent system for dis-tributed control of an anaerobic wastewater treatment processrdquoEngineering Applications of Artificial Intelligence vol 13 no 4pp 485ndash494 2000

[22] P Marino M A Domınguez F Poza and F Vazquez ldquoUsingLOTOS in the specification of industrial bus communicationprotocolsrdquoComputerNetworks vol 45 no 6 pp 767ndash799 2004

[23] J L Posadas P Perez J E Simo G Benet and F BlanesldquoCommunications structure for sensory data in mobile robotsrdquoEngineering Applications of Artificial Intelligence vol 15 no 3-4pp 341ndash350 2002

[24] C Hennig T Bluhm P Heimann et al ldquoUsing the network asbus system for long discharge data acquisition and data process-ingrdquo Fusion Engineering and Design vol 81 no 15ndash17 pp 1735ndash1740 2006

[25] R Moraes F B Carreiro P Bartolomeu V Silva J A Fonsecaand F Vasques ldquoEnforcing the timing behavior of real-timestations in legacy bus-based industrial Ethernet networksrdquoComputer Standards and Interfaces vol 33 no 3 pp 249ndash2612011

[26] C Hennig K Kneupner and D Kinna ldquoConnecting Program-mable Logic Controllers (PLC) to control and data acquisition acomparison of the JET and Wendelstein 7-X approachrdquo FusionEngineering and Design vol 87 no 12 pp 1972ndash1976 2012

[27] J-N Dong G-H Qin and H Yu ldquoStudy on real-time sensorsignal transmission based on technology of polynomial predic-tive filteringrdquoMeasurement vol 42 no 7 pp 969ndash977 2009

[28] P Lin S Z KangQ B Li et al ldquoEvaluation on rockmass qualityand stability of xiluodu arch dam under construction phaserdquoJournal of Rock Mechanics and Engineering vol 31 no 10 pp2042ndash2052 2012

[29] P Lin X L Liu Y Hu Yu et al ldquoDeformation and stability anal-ysis on xiluodu arch dam under stress and seepage conditionrdquoJournal of Rock Mechanics and Engineering vol 32 no 6 pp1137ndash1144 2013

Submit your manuscripts athttpwwwhindawicom

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

MathematicsJournal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Mathematical Problems in Engineering

Hindawi Publishing Corporationhttpwwwhindawicom

Differential EquationsInternational Journal of

Volume 2014

Applied MathematicsJournal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Probability and StatisticsHindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Journal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Mathematical PhysicsAdvances in

Complex AnalysisJournal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

OptimizationJournal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

CombinatoricsHindawi Publishing Corporationhttpwwwhindawicom Volume 2014

International Journal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Operations ResearchAdvances in

Journal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Function Spaces

Abstract and Applied AnalysisHindawi Publishing Corporationhttpwwwhindawicom Volume 2014

International Journal of Mathematics and Mathematical Sciences

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

The Scientific World JournalHindawi Publishing Corporation httpwwwhindawicom Volume 2014

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Algebra

Discrete Dynamics in Nature and Society

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Decision SciencesAdvances in

Discrete MathematicsJournal of

Hindawi Publishing Corporationhttpwwwhindawicom

Volume 2014 Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Stochastic AnalysisInternational Journal of

4 Mathematical Problems in Engineering

Impulse modulator

AD converterf(t)

f(t)

Tf(k)

t0 0

120575T(t)

f998400(t) = f(t)120575T(t)k

(a)

DA converterZOH

T

f(k)

f(k)

t0 0k

gh0(s) = 1 minus eminussTs

f998400998400(t)

f998400998400(t)f998400(t)

(b)

Figure 3 A model of an AD or DA converter

The model of DA converter is shown in Figure 3(b) Asequence of numbers 119891(119896) 119896 = 0 1 2 is the input andthe continuous-time function 11989110158401015840(119905) 119905 ge 0 is the output Thefollowing relationship holds between input and output

11989110158401015840

(119905) = 119891 (119896) 119896119879 le 119905 lt (119896 + 1) 119879 (4)

Each sample of the sequence 119891(119896) may be treated as animpulse function of the form119891(119896)120575(119905 minus 119896119879) The zero-orderhold (ZOH) of Figure 3(b) can thus be viewed as a lineartime-invariant system that converts the impulse119891(119896)120575(119905minus119896119879)into a pulse of height 119891(119896) and width 119879 The DA convertermay therefore be modelled by Figure 3(b) where the ZOHis a system whose response to a unit impulse 120575(119905) is a unitpulse 119892

ℎ0(119905) of width 119879The Laplace transform of 119892

ℎ0(119905) is the

transfer function of the hold operation namely

119892ℎ0(119904) =1 minus 119890minus119904119879

119904 (5)

22 Temperature Digital Data Transmission For dam tem-perature control system shown in Figure 1 the temperaturesensors sampling time could be as long as one minute AProfibus network and corresponding modules would domi-nate the control cost unnecessarily and therefore a lower costfield bus called ITU was engaged An intelligent module cantransfer the ITU signals into RS485 protocol which mostkinds of PLC support The intelligent temperature modulewhich has 8 channels can link a maximum of 256 differentITU sensors usually via three core cables After initializationthe module can exchange the digital data with PLC basis ofRS485 protocol One RS485 master can communicate with127 slaves and this means one PLC CPU can acquire up to32512 ITU temperature sensors In this control system theSiemens Simatic S7-300 PLC was used as the data bridgebetween the control model computer and the field sensorsand actuators The specified PLC programming languageFBD (function block diagram) and standard function library

provided the software engineering basic environment Thesoftware tasks were condensed into the three parts of col-lecting the temperature and flow data communicating withthe model server and the water flow proportional integralderivative (PID) control

221 Data Inquiring and Acquiring There are a number ofcommands defined to fetch the status or data from the intel-ligent temperature module LTM8663 via the RS485 protocolwhich are in ASCII format The most important commandsfrom PLC to the intelligent module are as follows

(1) lowastAAN (CR)The command name to read all the sensorsrsquoID linked to the channel ldquo119873rdquo of the specified intelligentmodule ldquo119860119860rdquo (ranging from 00 h to FF h) here ldquoCRrdquo is thecarriage return character (ASCII code ldquo0Dhrdquo)

Each ID is preset by a handy tool or PC software to escapethe same numbering on the same channel

(2) AAN (CR) The command name similar to the aboveldquolowast119860119860119873rdquo this command tries to read all the sensorsrsquo datalinked to the channel ldquo119873rdquo of the specified intelligent moduleldquo119860119860rdquo

The above two frequently used commands enable PLC toget exactly the total numbers and numbering of linked sen-sors as well as their current temperature values

222 Data Handling Sorting and Filtering As long as thereis a valid response from the intelligent module the temper-ature digital data will be first transferred into a data bufferwhich is previously defined in the PLC and then analyzedaccording to the predefined data format The standard func-tion block for the PLC will copy the data from the RS485network to that buffer and generate a pulse indicating thatnew data is coming the user program will fetch the channelsrelated data and copy them to corresponding data blockaccording to the current counter

Since channel data sets are separated the PLC decideswhether they are valid or not on the basis of the receivedtelegramheader (here ldquogtrdquomeans data are valid)Theprogramwill then transfer the raw temperature data into standardizedformat (floating type) For the specific LTM8663module usedin this system the original temperature data format is 16 A(byte 1) B (byte 2) and the conversion formula is

119905 =[256 (119861amp167) + 119860]

16 (6)

According to the LTM8663 specification the RS485 com-munication protocol is ASCII and the parameters should beconfigured in the hardware interface as the speed transmis-sion rate is 9600 bps data bits are 8 stop bits is 1 and theoperating mode is half duplex (RS485) two-wire mode

After the PLC program has distinguished the total num-ber of sensors of the module each ID and actual data it isnot difficult to sort and copy them to the right offset locationin the summary data block Obviously each sensor ID inone module must be unique The summary data block is thetransmission information to the module control server

Mathematical Problems in Engineering 5

FB8DB8

Comment Comment

ENSF

M2002RREQ

512 LADDR20

05

DONE M2010ERROR M2011STATUS MW204

ENO

DB NODBB NO

R CPU NOR TYP

R OFFSETR CF BYTR CF BIT

The logic address of CP341 module

The telegram from PLC to the intelligent module

The telegram from the intelligent module to PLC

FB7DB7

EN

M2010

R

512 LADDR

30NDR M2020

ERROR M2021

LEN

STATUS MW206

ENO

EN R

DB NO

DBB NO

L TYP

L NO

L OFFSET

L CF BYT

L CF BITLEN

R NO

0

Network 16 Receiving from the intelligent module

Network 14 Sending to the intelligent module

Figure 4 Function blocks for communication between CP341 and LTM8663 modules

23 Management of Various Intelligent Modules On the damconstruction site thousands of sensors were installed on thecooling pipes or cast inside the concrete enabling variousidentified intelligent modules to be linked to PLC via RS485network PLC software autodecided the polling strategy forthe whole network to avoid data acquisition conflicts To polleach module and channel cyclically a counter is utilized todifferentiate the time frames for each task In addition thePLC sends twodifferent commands for each channel since thetime interval must be considered The brief polling sequenceis illustrated in [10]

To achieve communication between CP343-1 and themodule server the server must be configured in the Simaticmanager The module server is taken as ldquoanother stationrdquohere and in the net two connections should be establishedfor sending and receiving For the Transmission ControlProtocol (TCP) connection the port addresses of both partiesshould be fixed

The real-time data transmission from concrete construc-tion site to the remote module control server was achievedusing an industrial Ethernet communication board withTCPIP protocol Depending on the distance a fibre opticconverter or a wireless AP can be used for the data bridgeThe standard PLC Ethernet communication function blockcan easily transfer the data block contents to the target serverThe network structure is independent of the sensors If oneor several sensors fail the master can still read data fromother sensors After replacement the sensors can be accessedagain as the master collects the data on the whole networkrepeatedly

3 PLC Code Configuration

In this study the structured control language (SCL) was usedas the PLC codeThe FBD and the Standard Template Library(STL) included communication with the intelligent module

(RS485) temperature digital data treatment filtering andsorting communication with the module server (TCPIP)and the cooling water PID control

31 Communication with the Intelligent Module LTM8663The standard function block FB7 and FB8 (P SND RK)are designed for RS485 communication structure shown inFigure 4

The CP341 module is an extended communication pro-cessor which supports RS422 and RS485 protocol The datablock DB20 stores the inquiring command (5 bytes) to theintelligentmodule andDB30 is the receiving data buffer fromthe module The execution of FB7 and FB8 is separated bylogic

32 Temperature Digital Data Analysis When the specificchannel temperature digital data is recognized it is trans-ferred from DB30 to another data block for handling Forexample DB31 handles raw data coming from channel 1module 0 As the total number of sensors and each ID isknown by the program each temperature value can be con-verted into target floating formatThe source code below con-verts the data according to (6)

After the treatment the sensor actual values are copied toa summary data block (eg DB10 for module 0) The offsetin the data block will follow the ID For example the offsetaddress for the sensor ID 3 is 12 as in Table 1

33 Communication with the Module Server Two otherstandard functions (FC50 and FC60) are used for the TCPIPcommunicationwith themodule server as shown in Figure 5The Ethernet port is integrated in the CPU module The DB1is the sending buffer which collects all the sensor informationand telegram time stamp shown in Table 2

The telegram length is 2022 bytes including the title tele-gram label length telegram type sending time total circuit

6 Mathematical Problems in Engineering

Table 1 The PLC data structure of DB10 for communication with intelligent module

Number Address offset Name Data type Comments1 0 Module SN Integer Module serial number2 2 Total sensors Real Total sensors number3 4 Value ID1 Real SensorValue ID14 8 Value ID2 Real SensorValue ID25 12 Value ID3 Real SensorValue ID36 16 Value ID4 Real SensorValue ID4

256 1016 Value ID254 Real SensorValue ID254257 1020 Value ID255 Real SensorValue ID255258 1024 Value ID256 Real SensorValue ID256

Table 2 The PLC data structure of DB1 for sending telegram to module server

Number Address offset Name Data type Comments1 0 Label String(4) Fixed as ldquoEDAMrdquo2 4 Length Integer Telegram length3 6 Tel type INT Telegram type4 8 SendTime String(12) Format YYYYMMDDHHMM5 20 TotalNumber INT Total circuits6 22 Telegram1 UDT1 User defined data type

119899 + 5 (119899 minus 1) lowast 10 + 22 Telegram(119899) UDT1 User defined data type

Table 3 The user defined type (UDT) for each circuit value as a template

Number Address offset Name Data type Comments1 0 Number Integer The circuit number2 2 Mode Byte Mode 1 = auto 2 = manual3 3 AlarmWarnning Byte 0 = OK 1 = warning 2 = alarm4 4 InletTemp Integer Water inlet tmperature5 6 OutletTemp Integer Water outlet temperature6 8 ActFlow Integer Actual water flow

numbers and every item of circuit data Here a special UDT(user data type 10 bytes) is defined for each water coolingcircuit including the serial number auto- or manual modestatus inlet and outlet temperature and actual water flowshown in Table 3 Correspondingly the DB2 is the receivingbuffer containing the commands for each circuit from themodule serverrsquos control strategy system

Similarly the receiving telegram contains the labellength type and command for each circuit and the personal-ized control solution is then realized in this way Every circuitcan have its own cooling water flow target set point or fixedwater valve opening output

4 Application Case Study

41 Brief Introduction toDamSite Theproposedmethodwasapplied to the temperature control of the Xiluodu arch dam

during construction [28 29]The project is located on the Jin-shajiang River in the Leibo County of Sichuan province Theprincipal structures consist of a double-curvature arch dam2855 meters high crest length about 700 meters spillwayunderground powerhouse and logway A total of 6000000cubic meters of concrete were poured Because of the highstresses in an arch dam structure and the constructionprocess control difficulties the basic temperature controlprinciplewas tomaintain ultimately small temperature differ-ences betweenneighbouring areas of concrete by slow coolingand early cooling The cooling process should be based onthe concrete temperature measurement results taking intoconsideration the partitioning of the concrete pouringtemperature water pipes density of concrete and ambienttemperature The cooling water flow is adjusted in a timelymanner to meet the targeted temperature requirements

A flexible network structure for field temperature mon-itoring of the super high arch dam during construction was

Mathematical Problems in Engineering 7

Comment Comment

EN

ACT

ID

EN

M1000

M1001

MW102

M1040

M1041

MW106

MW108LADDRLADDR1

T32

SEND

ID

Network 7 Sending telegram to module server Network 8 Receiving telegram from module server

W163FFC

W163FFC

PDB1DBX00

PDB2DBX00

FC50 FC60NDR

RECV

2

BYTE 2048

BYTE 2048

2048

DONE

ERROR

ERROR

STATUS

STATUS

ENO

ENO

LEN

LEN

The logic address of CPU Ethernet port

Figure 5 The PLC functions for TCPIP communication with the module server

(1) BOX1

(2) PS307(3) CPU315

(4) CP341

(5) IM153(6) AI8

(7) AO8

Figure 6 The internal layout of the PLC control cubicle

developed based on the state of the art intelligence controltechnology [8] By employing flexible network structurearchitecture the bus was also connected to other typesof sensors such as dam strain measurement meters damcompressive stress measurement meters meters for moni-toring joint openings rock-deformations and piezometersfor seepage flow all of which were are designed to suitthis network specification Thus the measurement scopeutilized covered a wide spectrum as well as themany concretetemperature measurements sufficient for a super high archdam

42 Site Control System Arrangement The control cabinetswere prepared in the workshop Because of the complexelectromagnetic environment on the construction site wiringto the site flow valves and sensors were employed Figure 6shows a preassembled cabinet for digital data transmissionHere is the brief description of the main parts of PLC controlcubicle

BOX1 The intelligent temperature module The cir-cuit connection diagrams for connecting the temper-ature sensors to the module are shown in Figure 7PS307 The Simatic S7-300 PLC power moduleCPU315 The Simatic S7-300 PLC CPU with inte-grated Profibus and Ethernet interfacesCP341 The Simatic RS485 communication processorfor the intelligent temperature moduleIM153 The Simatic interface module which canextend the CPU control to remote areas by ProfibusnetworkAI8TheSimatic analog inputmodule which can read8 analogue signals (current voltage resistor or PT100sensors) The circuit diagram for connecting the flowmeters to the analogue input module is shown inFigure 8 The symbol ldquoSM331rdquo is the analogue inputmodule which is able to read 8 water flow transduc-ers please refer to ldquo(6) AI8rdquo of Figure 6AO8 The Simatic analogue output module whichcan drive 8 analog valves The circuit diagram forconnecting the electric valves to the analogue outputmodule is shown in Figure 9 The symbol ldquoSM332rdquo isthe analogue output module which is able to control8 proportional valves please refer to ldquo(7) AO8rdquo ofFigure 6

On the dam site the operators connect the valves flowmeters and temperature sensors into the PLC cabinets asrequired according to construction progress

43 Temperature Field Analysis Basis of Real-Time Temper-ature Data On the Xiluodu arch dam site the intelligentcooling control system used modern field bus technologyextensively and Siemens PLC devices to comprehensivelytrack the temperature data change at the pouring of everyblock in real time Adjustment of the valves and control ofwater flowwere performed using the PID algorithm based ontemperature control requirements and key factors such as thehighest temperature reached cooling rate and temperature

8 Mathematical Problems in Engineering

-BOX1

256 RS422LTM8663

GNDCH2

GNDCH1

GNDCH0

-X34

-X31

-X35

-X38

-X32-X33

-X36-X37

CH3GND

-X39-X310-X311-X312

CH4GND

CH5GND

CH6GND

CH7GND

-X316

-X313

-X317

-X320

-X314-X315

-X318-X319

-X321-X322-X323-X324

+5V+5V

+5V +5V

+5V+5V

+5V +5V

24V+ COM+

COMminus

CH2

CH0 5V

CH1 5V

CH0

CH0 GND

CH1 GNDCH2 5V

CH2 GNDCH3 5V

CH3

CH3 GNDBOX1

BOX1

BOX1BOX1

BOX1

BOX1BOX1

BOX1

BOX1

BOX1BOX1

BOX1

BOX1 CH5

BOX1 CH6

BOX1 CH4 5V

BOX1 CH5 5V

BOX1 CH4BOX1 CH4 GND

BOX1 CH5 GND

BOX1 CH6 5V

BOX1 CH6 GND

BOX1 CH7 5V

BOX1 CH7BOX1 CH7 GND

-XP1 1721-XM1 1728

CH1

GND(24V) = CC3 + CBL3-BOX1 COMminus

= CC3 + CBL3-BOX1 COM+

-RS422 COMminus+UR056

-RS422 COM++UR056

Figure 7 The circuit diagram for connecting the temperature sensors to the module

3 times 075

3 times 075

3 times 075

3 times 075

3 times 075

3 times 075

3 times 075

3 times 075

3 times 075 3 times 075

6ES7 331-1KF02-0AB0

SM 331

A

A

A

A

V

V

V

V

V

V

V

V

A

A

A

A

SIEMENS

8

Rack0Slot3

-A3

2

1

3

4

5

6

7

89

1112

13

1516

1718

1920

2122

2324

2526

2728

2930

3132

3334

3536

3738

3940

1

3

10

5

14

7

9

11

13

15

21

41-W501

1

21

41-W502

1

21

41-W503

1

21

41

1

12

47

1

12

12

12

47-W506

1

47-W507

1

47-W508

1

41-W401

148

-W402

1

The i

nlet

or o

utle

t w

ater

flow

tran

sduc

ers

AI 8 times 13 BIT

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

-FT501

-FT502

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

-FT503

-FT504

-W504

-FT505

-W505

-FT506

-FT507

-FT508

S+Sminus

S+Sminus

S+Sminus

S+Sminus

S+ Sminus

S+ Sminus

S+ Sminus

S+ Sminus +CBL1-XP2 2+CBL134+CBL1-XP2 1+CBL134

+CBL1-XM1 1+CBL124

CH0 I+

CH0 U+

CH0 Sminus

CH0 M+

CH0 Mminus

CH1 U+

CH1 I+

CH1 SminusCH1 M+

CH2 M+

CH2 U+

CH2 I+

CH2 Sminus

CH2 Mminus

CH1 Mminus

CH3 U+

CH3 I+CH3 Sminus

CH3 M+

CH3 Mminus

CH4 U+

CH4 I+

CH4 SminusCH4 M+

CH4 Mminus

CH5 U+

CH5 I+CH5 Sminus

CH5 M+

CH5 Mminus

CH6 U+

CH6 I+

CH6 SminusCH6 M+

CH6 Mminus

CH7 U+

CH7 I+CH7 Sminus

CH7 M+

CH7 Mminus

Figure 8 The circuit diagram for connecting the temperature sensors to the module

gradient A web graphical user interface (GUI) was providedfor integrated query analysis and prewarning [1]

Based on the proposed temperature data transmissionsystem the intelligent cooling system overcomes the short-comings in traditional manually collected data systemsproviding an effective dam concrete temperature control andcracking prevention technology both advanced and moreintelligent In particular the advances consist of (1) changingsimple manual data collection to real-time data acquisitionand feedback (2) automatically obtaining large quantitiesof thermodynamic parameters with respect to every blockof poured concrete enabling a more customized control

function and (3) enabling a 3D real-time temperature fieldanalysis be carried out as illustrated in Figure 10 Based onthe real-time temperature field analysis further stress fieldscan be analyzed to study alternative temperature controlplans not only limited to water flow but the whole pipeworkscheme can be adjusted to more optimal configurations

5 Conclusions

This paper presents a real-time temperature data transmis-sion approach for intelligent cooling control of early agemassconcrete based onAD convertermodel and PLC technology

Mathematical Problems in Engineering 9

6ES7 332-5HF00-0AB0

SM 332 SIEMENS

8

Rack0Slot4

-A4

1

2

3

4

5

66Mana0

7

8

9

1010Mana1

11

12

13

15

16

17

1818Mana3

19

20 20M20M

21

22

23

24

25

2626Mana4

27

28

29

3030Mana5

31

32

33

3434Mana6

35

36

37

3838Mana7

39

40

2

4

6

8

10

12

14

16

1414Mana2

-YVP5012

M

1

Y1

3

U

4

32-W501

2

-YVP5022

M

1

Y1

3

U

4

-YVP5032

M

1

Y1

3

U

4

-YVP5042

M

1

Y1

3

U

4

32-W502

2

-YVP5052

M

1

Y1

3

U

4

-YVP5062

M

1

Y1

3

U

4

-YVP5072

M

1

Y1

3

U

4

-YVP5082

M

1

Y1

3

U

4

32-W503

2

32-W504

2

37-W505

2

37-W506

2

37-W507

2

37-W508

2

31-W401

2 238

-W402

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

1L+1L+

CH0 QV+

CH0 S+

CH0 Sminus

CH0 Mana

CH1 QV+

CH1 S+

CH1 S-

CH1 Mana

CH2 QV+

CH2 S+

CH2 Sminus

CH3 QV+

CH3 S+

CH3 Sminus

CH3 Mana

CH2 Mana

CH4 QV+

CH4 S+

CH4 Sminus

CH4 Mana

CH5 QV+

CH5 S+

CH5 Sminus

CH5 Mana

CH6 QV+

CH6 S+

CH6 Sminus

CH6 Mana

CH7 QV+

CH7 S+

CH7 Sminus

CH7 Mana

24V

24V

24V

24V

24V

24V

24V

24V

+CBL1-XP1 1+CBL124

+CBL1-XM2 1+CBL135 +CBL1-XM2 2+CBL135

+CBL1-XM1 2+CBL125

The e

lect

ric so

leno

id

prop

ortio

nal v

alve

s

AO 8 times 12 BIT

3 times 075

Figure 9 The circuit diagram for connecting the electric valves to the analog output module

Y

X0 20 40 60 80 100 100120 140 160 180 200

0

10

20

30

40

50

50 1112131415161718192021

(∘C)

Figure 10 Real-time three-dimensional temperature field

The proposed approach offers an effective and efficient alter-native for acquiring temperature digital data useful for sup-porting the decision-making processes regarding the controlof cooling of just poured mass concrete in real time

A mathematical description of the digital temperaturecontrol model has been developed Use of this model fortemperature values acquisition filtering sorting treatingand their real-time transfer for cooling control purposes isproved effective A stable real-time high volume capacityof the temperature data transmission solution developedutilized an intelligent cooling control system

Using this system on the Xiluodu arch dam site enabledsome key problems to be solved including huge quantities ofraw data interchange with the module server personalizedand flexible control for each water cooling circuit andaccurate and punctual water conditional control data collec-tion instead of traditional manual checking The proposedapproach provides a convenient solution in process coolingcontrol pipes where cabling is not possible The systemalso has lower installation and maintenance costs operatesreliably and is of robust and flexible construction It is proved

suitable for heat of hydration control in dam constructionconcreting applications

Based on this study the future research will be focusedon the combination of real-time site monitoring analysis andnumerical simulation on thermal stress for control crackingof mass concrete in construction period

Conflict of Interests

The authors declare that there is no conflict of interestsregarding the publication of this paper

Acknowledgments

This research work was supported by National NaturalScience Foundation of China (nos 11272178 and 51339003)National Basic Research Program of China (973 Program)under Grants nos 2013CB035902 and 2011CB013503 andTsinghua University Initiative Scientific Research Program

References

[1] P Lin Q B Li S W Zhou and Y Hu ldquoIntelligent cooling con-trol method and system for mass concreterdquo Journal of HydraulicEngineering vol 44 no 8 pp 950ndash957 2013

[2] F A Branco and P Mendes ldquoNumerical simulations of heat ofhydration temperature in damsrdquo in Proceedings of the Interna-tional Workshop on Arch Dams pp 225ndash230 Coimbra Portu-gal April 1987

[3] B Zhu ldquoEffect of cooling by water flowing in nonmetal pipesembedded in mass concreterdquo Journal of Construction Engineer-ing and Management vol 125 no 1 pp 61ndash68 1999

[4] AMNevilleProperties of Concrete Longman Essex UK 1995

10 Mathematical Problems in Engineering

[5] H S Shang T H Yi and Y P Song ldquoBehavior of plain concreteof a highwater-cement ratio after freeze-thaw cyclesrdquoMaterialsvol 5 no 9 pp 1698ndash1707 2012

[6] H S Shang and T H Yi ldquoFreeze-thaw durability of air-entrained concreterdquo The Scientific World Journal vol 2013Article ID 650791 6 pages 2013

[7] H S Shang and T H Yi ldquoBehavior of HPC with fly ash afterelevated temperaturerdquo Advances in Materials Science and Engi-neering vol 2013 Article ID 478421 7 pages 2013

[8] G D Zhou and T H Yi ldquoThermal load in large-scale bridgesa state-of-the-art reviewrdquo International Journal of DistributedSensor Networks vol 2013 Article ID 217983 17 pages 2013

[9] Q Li G Li and G Wang ldquoElasto-plastic bond mechanics ofembeddedfiber optic sensors in concrete under uniaxial tensionwith strain localizationrdquo Smart Materials and Structures vol 12no 6 pp 851ndash858 2003

[10] P Lin Q B Li and H Hu ldquoA flexible network structure fortemperature monitoring of a super high arch damrdquo Interna-tional Journal of Distributed Sensor Networks vol 2012 ArticleID 917849 10 pages 2012

[11] Q B Li P Lin S W Zhou et al ldquoReal time online individu-ation and intelligent cooling control system for mass concreterdquoUtility Model Patent 2012204165226 2013

[12] P Lin Q B Li Y Hu et al ldquoA device of integrity flow and tem-perature controllingrdquo Patent Number(s) 2012204177149 2013

[13] Q B Li and P Lin ldquoDemonstration on intelligent damrdquo Journalof Hydroelectric Engineering vol 33 no 1 2014

[14] K J Astrom and T Hagglund PID Controllers Theory Designand Tuning International Society for Measurement and Con-trol Seattle Wash USA 2nd edition 1995

[15] A B Corripio Tuning of Industrial Control Systems InstrumentSociety of America Research Triangle Park NC USA 1990

[16] F D Petruzella Programmable Logic Controllers Mcgraw-HillNew York NY USA 3rd edition 2004

[17] M Gopal Digital Control and State Variable Methods Conven-tional and Intelligent Control Systems McGraw Hill Education4th edition 2012

[18] M S Santina A R Stubberud and G H Hostetter DigitalControl System Design International Thomson PublishingStamford Conn USA 2nd edition 1994

[19] F Italiano R Maugeri A Mastrolia and J Heinicke ldquoA newseafloor monitoring module for real-time data transmission anapplication to shallow hydrothermal ventsrdquo Procedia Earth andPlanetary Science vol 4 pp 93ndash98 2011

[20] R Bayindir and Y Cetinceviz ldquoAwater pumping control systemwith a Programmable Logic Controller (PLC) and industrialwireless modules for industrial plantsmdashan experimental setuprdquoISA Transactions vol 50 no 2 pp 321ndash328 2011

[21] J Flores B Arcay and J Arias ldquoAn intelligent system for dis-tributed control of an anaerobic wastewater treatment processrdquoEngineering Applications of Artificial Intelligence vol 13 no 4pp 485ndash494 2000

[22] P Marino M A Domınguez F Poza and F Vazquez ldquoUsingLOTOS in the specification of industrial bus communicationprotocolsrdquoComputerNetworks vol 45 no 6 pp 767ndash799 2004

[23] J L Posadas P Perez J E Simo G Benet and F BlanesldquoCommunications structure for sensory data in mobile robotsrdquoEngineering Applications of Artificial Intelligence vol 15 no 3-4pp 341ndash350 2002

[24] C Hennig T Bluhm P Heimann et al ldquoUsing the network asbus system for long discharge data acquisition and data process-ingrdquo Fusion Engineering and Design vol 81 no 15ndash17 pp 1735ndash1740 2006

[25] R Moraes F B Carreiro P Bartolomeu V Silva J A Fonsecaand F Vasques ldquoEnforcing the timing behavior of real-timestations in legacy bus-based industrial Ethernet networksrdquoComputer Standards and Interfaces vol 33 no 3 pp 249ndash2612011

[26] C Hennig K Kneupner and D Kinna ldquoConnecting Program-mable Logic Controllers (PLC) to control and data acquisition acomparison of the JET and Wendelstein 7-X approachrdquo FusionEngineering and Design vol 87 no 12 pp 1972ndash1976 2012

[27] J-N Dong G-H Qin and H Yu ldquoStudy on real-time sensorsignal transmission based on technology of polynomial predic-tive filteringrdquoMeasurement vol 42 no 7 pp 969ndash977 2009

[28] P Lin S Z KangQ B Li et al ldquoEvaluation on rockmass qualityand stability of xiluodu arch dam under construction phaserdquoJournal of Rock Mechanics and Engineering vol 31 no 10 pp2042ndash2052 2012

[29] P Lin X L Liu Y Hu Yu et al ldquoDeformation and stability anal-ysis on xiluodu arch dam under stress and seepage conditionrdquoJournal of Rock Mechanics and Engineering vol 32 no 6 pp1137ndash1144 2013

Submit your manuscripts athttpwwwhindawicom

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

MathematicsJournal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Mathematical Problems in Engineering

Hindawi Publishing Corporationhttpwwwhindawicom

Differential EquationsInternational Journal of

Volume 2014

Applied MathematicsJournal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Probability and StatisticsHindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Journal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Mathematical PhysicsAdvances in

Complex AnalysisJournal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

OptimizationJournal of

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CombinatoricsHindawi Publishing Corporationhttpwwwhindawicom Volume 2014

International Journal of

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Operations ResearchAdvances in

Journal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Function Spaces

Abstract and Applied AnalysisHindawi Publishing Corporationhttpwwwhindawicom Volume 2014

International Journal of Mathematics and Mathematical Sciences

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

The Scientific World JournalHindawi Publishing Corporation httpwwwhindawicom Volume 2014

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Algebra

Discrete Dynamics in Nature and Society

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Decision SciencesAdvances in

Discrete MathematicsJournal of

Hindawi Publishing Corporationhttpwwwhindawicom

Volume 2014 Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Stochastic AnalysisInternational Journal of

Mathematical Problems in Engineering 5

FB8DB8

Comment Comment

ENSF

M2002RREQ

512 LADDR20

05

DONE M2010ERROR M2011STATUS MW204

ENO

DB NODBB NO

R CPU NOR TYP

R OFFSETR CF BYTR CF BIT

The logic address of CP341 module

The telegram from PLC to the intelligent module

The telegram from the intelligent module to PLC

FB7DB7

EN

M2010

R

512 LADDR

30NDR M2020

ERROR M2021

LEN

STATUS MW206

ENO

EN R

DB NO

DBB NO

L TYP

L NO

L OFFSET

L CF BYT

L CF BITLEN

R NO

0

Network 16 Receiving from the intelligent module

Network 14 Sending to the intelligent module

Figure 4 Function blocks for communication between CP341 and LTM8663 modules

23 Management of Various Intelligent Modules On the damconstruction site thousands of sensors were installed on thecooling pipes or cast inside the concrete enabling variousidentified intelligent modules to be linked to PLC via RS485network PLC software autodecided the polling strategy forthe whole network to avoid data acquisition conflicts To polleach module and channel cyclically a counter is utilized todifferentiate the time frames for each task In addition thePLC sends twodifferent commands for each channel since thetime interval must be considered The brief polling sequenceis illustrated in [10]

To achieve communication between CP343-1 and themodule server the server must be configured in the Simaticmanager The module server is taken as ldquoanother stationrdquohere and in the net two connections should be establishedfor sending and receiving For the Transmission ControlProtocol (TCP) connection the port addresses of both partiesshould be fixed

The real-time data transmission from concrete construc-tion site to the remote module control server was achievedusing an industrial Ethernet communication board withTCPIP protocol Depending on the distance a fibre opticconverter or a wireless AP can be used for the data bridgeThe standard PLC Ethernet communication function blockcan easily transfer the data block contents to the target serverThe network structure is independent of the sensors If oneor several sensors fail the master can still read data fromother sensors After replacement the sensors can be accessedagain as the master collects the data on the whole networkrepeatedly

3 PLC Code Configuration

In this study the structured control language (SCL) was usedas the PLC codeThe FBD and the Standard Template Library(STL) included communication with the intelligent module

(RS485) temperature digital data treatment filtering andsorting communication with the module server (TCPIP)and the cooling water PID control

31 Communication with the Intelligent Module LTM8663The standard function block FB7 and FB8 (P SND RK)are designed for RS485 communication structure shown inFigure 4

The CP341 module is an extended communication pro-cessor which supports RS422 and RS485 protocol The datablock DB20 stores the inquiring command (5 bytes) to theintelligentmodule andDB30 is the receiving data buffer fromthe module The execution of FB7 and FB8 is separated bylogic

32 Temperature Digital Data Analysis When the specificchannel temperature digital data is recognized it is trans-ferred from DB30 to another data block for handling Forexample DB31 handles raw data coming from channel 1module 0 As the total number of sensors and each ID isknown by the program each temperature value can be con-verted into target floating formatThe source code below con-verts the data according to (6)

After the treatment the sensor actual values are copied toa summary data block (eg DB10 for module 0) The offsetin the data block will follow the ID For example the offsetaddress for the sensor ID 3 is 12 as in Table 1

33 Communication with the Module Server Two otherstandard functions (FC50 and FC60) are used for the TCPIPcommunicationwith themodule server as shown in Figure 5The Ethernet port is integrated in the CPU module The DB1is the sending buffer which collects all the sensor informationand telegram time stamp shown in Table 2

The telegram length is 2022 bytes including the title tele-gram label length telegram type sending time total circuit

6 Mathematical Problems in Engineering

Table 1 The PLC data structure of DB10 for communication with intelligent module

Number Address offset Name Data type Comments1 0 Module SN Integer Module serial number2 2 Total sensors Real Total sensors number3 4 Value ID1 Real SensorValue ID14 8 Value ID2 Real SensorValue ID25 12 Value ID3 Real SensorValue ID36 16 Value ID4 Real SensorValue ID4

256 1016 Value ID254 Real SensorValue ID254257 1020 Value ID255 Real SensorValue ID255258 1024 Value ID256 Real SensorValue ID256

Table 2 The PLC data structure of DB1 for sending telegram to module server

Number Address offset Name Data type Comments1 0 Label String(4) Fixed as ldquoEDAMrdquo2 4 Length Integer Telegram length3 6 Tel type INT Telegram type4 8 SendTime String(12) Format YYYYMMDDHHMM5 20 TotalNumber INT Total circuits6 22 Telegram1 UDT1 User defined data type

119899 + 5 (119899 minus 1) lowast 10 + 22 Telegram(119899) UDT1 User defined data type

Table 3 The user defined type (UDT) for each circuit value as a template

Number Address offset Name Data type Comments1 0 Number Integer The circuit number2 2 Mode Byte Mode 1 = auto 2 = manual3 3 AlarmWarnning Byte 0 = OK 1 = warning 2 = alarm4 4 InletTemp Integer Water inlet tmperature5 6 OutletTemp Integer Water outlet temperature6 8 ActFlow Integer Actual water flow

numbers and every item of circuit data Here a special UDT(user data type 10 bytes) is defined for each water coolingcircuit including the serial number auto- or manual modestatus inlet and outlet temperature and actual water flowshown in Table 3 Correspondingly the DB2 is the receivingbuffer containing the commands for each circuit from themodule serverrsquos control strategy system

Similarly the receiving telegram contains the labellength type and command for each circuit and the personal-ized control solution is then realized in this way Every circuitcan have its own cooling water flow target set point or fixedwater valve opening output

4 Application Case Study

41 Brief Introduction toDamSite Theproposedmethodwasapplied to the temperature control of the Xiluodu arch dam

during construction [28 29]The project is located on the Jin-shajiang River in the Leibo County of Sichuan province Theprincipal structures consist of a double-curvature arch dam2855 meters high crest length about 700 meters spillwayunderground powerhouse and logway A total of 6000000cubic meters of concrete were poured Because of the highstresses in an arch dam structure and the constructionprocess control difficulties the basic temperature controlprinciplewas tomaintain ultimately small temperature differ-ences betweenneighbouring areas of concrete by slow coolingand early cooling The cooling process should be based onthe concrete temperature measurement results taking intoconsideration the partitioning of the concrete pouringtemperature water pipes density of concrete and ambienttemperature The cooling water flow is adjusted in a timelymanner to meet the targeted temperature requirements

A flexible network structure for field temperature mon-itoring of the super high arch dam during construction was

Mathematical Problems in Engineering 7

Comment Comment

EN

ACT

ID

EN

M1000

M1001

MW102

M1040

M1041

MW106

MW108LADDRLADDR1

T32

SEND

ID

Network 7 Sending telegram to module server Network 8 Receiving telegram from module server

W163FFC

W163FFC

PDB1DBX00

PDB2DBX00

FC50 FC60NDR

RECV

2

BYTE 2048

BYTE 2048

2048

DONE

ERROR

ERROR

STATUS

STATUS

ENO

ENO

LEN

LEN

The logic address of CPU Ethernet port

Figure 5 The PLC functions for TCPIP communication with the module server

(1) BOX1

(2) PS307(3) CPU315

(4) CP341

(5) IM153(6) AI8

(7) AO8

Figure 6 The internal layout of the PLC control cubicle

developed based on the state of the art intelligence controltechnology [8] By employing flexible network structurearchitecture the bus was also connected to other typesof sensors such as dam strain measurement meters damcompressive stress measurement meters meters for moni-toring joint openings rock-deformations and piezometersfor seepage flow all of which were are designed to suitthis network specification Thus the measurement scopeutilized covered a wide spectrum as well as themany concretetemperature measurements sufficient for a super high archdam

42 Site Control System Arrangement The control cabinetswere prepared in the workshop Because of the complexelectromagnetic environment on the construction site wiringto the site flow valves and sensors were employed Figure 6shows a preassembled cabinet for digital data transmissionHere is the brief description of the main parts of PLC controlcubicle

BOX1 The intelligent temperature module The cir-cuit connection diagrams for connecting the temper-ature sensors to the module are shown in Figure 7PS307 The Simatic S7-300 PLC power moduleCPU315 The Simatic S7-300 PLC CPU with inte-grated Profibus and Ethernet interfacesCP341 The Simatic RS485 communication processorfor the intelligent temperature moduleIM153 The Simatic interface module which canextend the CPU control to remote areas by ProfibusnetworkAI8TheSimatic analog inputmodule which can read8 analogue signals (current voltage resistor or PT100sensors) The circuit diagram for connecting the flowmeters to the analogue input module is shown inFigure 8 The symbol ldquoSM331rdquo is the analogue inputmodule which is able to read 8 water flow transduc-ers please refer to ldquo(6) AI8rdquo of Figure 6AO8 The Simatic analogue output module whichcan drive 8 analog valves The circuit diagram forconnecting the electric valves to the analogue outputmodule is shown in Figure 9 The symbol ldquoSM332rdquo isthe analogue output module which is able to control8 proportional valves please refer to ldquo(7) AO8rdquo ofFigure 6

On the dam site the operators connect the valves flowmeters and temperature sensors into the PLC cabinets asrequired according to construction progress

43 Temperature Field Analysis Basis of Real-Time Temper-ature Data On the Xiluodu arch dam site the intelligentcooling control system used modern field bus technologyextensively and Siemens PLC devices to comprehensivelytrack the temperature data change at the pouring of everyblock in real time Adjustment of the valves and control ofwater flowwere performed using the PID algorithm based ontemperature control requirements and key factors such as thehighest temperature reached cooling rate and temperature

8 Mathematical Problems in Engineering

-BOX1

256 RS422LTM8663

GNDCH2

GNDCH1

GNDCH0

-X34

-X31

-X35

-X38

-X32-X33

-X36-X37

CH3GND

-X39-X310-X311-X312

CH4GND

CH5GND

CH6GND

CH7GND

-X316

-X313

-X317

-X320

-X314-X315

-X318-X319

-X321-X322-X323-X324

+5V+5V

+5V +5V

+5V+5V

+5V +5V

24V+ COM+

COMminus

CH2

CH0 5V

CH1 5V

CH0

CH0 GND

CH1 GNDCH2 5V

CH2 GNDCH3 5V

CH3

CH3 GNDBOX1

BOX1

BOX1BOX1

BOX1

BOX1BOX1

BOX1

BOX1

BOX1BOX1

BOX1

BOX1 CH5

BOX1 CH6

BOX1 CH4 5V

BOX1 CH5 5V

BOX1 CH4BOX1 CH4 GND

BOX1 CH5 GND

BOX1 CH6 5V

BOX1 CH6 GND

BOX1 CH7 5V

BOX1 CH7BOX1 CH7 GND

-XP1 1721-XM1 1728

CH1

GND(24V) = CC3 + CBL3-BOX1 COMminus

= CC3 + CBL3-BOX1 COM+

-RS422 COMminus+UR056

-RS422 COM++UR056

Figure 7 The circuit diagram for connecting the temperature sensors to the module

3 times 075

3 times 075

3 times 075

3 times 075

3 times 075

3 times 075

3 times 075

3 times 075

3 times 075 3 times 075

6ES7 331-1KF02-0AB0

SM 331

A

A

A

A

V

V

V

V

V

V

V

V

A

A

A

A

SIEMENS

8

Rack0Slot3

-A3

2

1

3

4

5

6

7

89

1112

13

1516

1718

1920

2122

2324

2526

2728

2930

3132

3334

3536

3738

3940

1

3

10

5

14

7

9

11

13

15

21

41-W501

1

21

41-W502

1

21

41-W503

1

21

41

1

12

47

1

12

12

12

47-W506

1

47-W507

1

47-W508

1

41-W401

148

-W402

1

The i

nlet

or o

utle

t w

ater

flow

tran

sduc

ers

AI 8 times 13 BIT

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

-FT501

-FT502

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

-FT503

-FT504

-W504

-FT505

-W505

-FT506

-FT507

-FT508

S+Sminus

S+Sminus

S+Sminus

S+Sminus

S+ Sminus

S+ Sminus

S+ Sminus

S+ Sminus +CBL1-XP2 2+CBL134+CBL1-XP2 1+CBL134

+CBL1-XM1 1+CBL124

CH0 I+

CH0 U+

CH0 Sminus

CH0 M+

CH0 Mminus

CH1 U+

CH1 I+

CH1 SminusCH1 M+

CH2 M+

CH2 U+

CH2 I+

CH2 Sminus

CH2 Mminus

CH1 Mminus

CH3 U+

CH3 I+CH3 Sminus

CH3 M+

CH3 Mminus

CH4 U+

CH4 I+

CH4 SminusCH4 M+

CH4 Mminus

CH5 U+

CH5 I+CH5 Sminus

CH5 M+

CH5 Mminus

CH6 U+

CH6 I+

CH6 SminusCH6 M+

CH6 Mminus

CH7 U+

CH7 I+CH7 Sminus

CH7 M+

CH7 Mminus

Figure 8 The circuit diagram for connecting the temperature sensors to the module

gradient A web graphical user interface (GUI) was providedfor integrated query analysis and prewarning [1]

Based on the proposed temperature data transmissionsystem the intelligent cooling system overcomes the short-comings in traditional manually collected data systemsproviding an effective dam concrete temperature control andcracking prevention technology both advanced and moreintelligent In particular the advances consist of (1) changingsimple manual data collection to real-time data acquisitionand feedback (2) automatically obtaining large quantitiesof thermodynamic parameters with respect to every blockof poured concrete enabling a more customized control

function and (3) enabling a 3D real-time temperature fieldanalysis be carried out as illustrated in Figure 10 Based onthe real-time temperature field analysis further stress fieldscan be analyzed to study alternative temperature controlplans not only limited to water flow but the whole pipeworkscheme can be adjusted to more optimal configurations

5 Conclusions

This paper presents a real-time temperature data transmis-sion approach for intelligent cooling control of early agemassconcrete based onAD convertermodel and PLC technology

Mathematical Problems in Engineering 9

6ES7 332-5HF00-0AB0

SM 332 SIEMENS

8

Rack0Slot4

-A4

1

2

3

4

5

66Mana0

7

8

9

1010Mana1

11

12

13

15

16

17

1818Mana3

19

20 20M20M

21

22

23

24

25

2626Mana4

27

28

29

3030Mana5

31

32

33

3434Mana6

35

36

37

3838Mana7

39

40

2

4

6

8

10

12

14

16

1414Mana2

-YVP5012

M

1

Y1

3

U

4

32-W501

2

-YVP5022

M

1

Y1

3

U

4

-YVP5032

M

1

Y1

3

U

4

-YVP5042

M

1

Y1

3

U

4

32-W502

2

-YVP5052

M

1

Y1

3

U

4

-YVP5062

M

1

Y1

3

U

4

-YVP5072

M

1

Y1

3

U

4

-YVP5082

M

1

Y1

3

U

4

32-W503

2

32-W504

2

37-W505

2

37-W506

2

37-W507

2

37-W508

2

31-W401

2 238

-W402

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

1L+1L+

CH0 QV+

CH0 S+

CH0 Sminus

CH0 Mana

CH1 QV+

CH1 S+

CH1 S-

CH1 Mana

CH2 QV+

CH2 S+

CH2 Sminus

CH3 QV+

CH3 S+

CH3 Sminus

CH3 Mana

CH2 Mana

CH4 QV+

CH4 S+

CH4 Sminus

CH4 Mana

CH5 QV+

CH5 S+

CH5 Sminus

CH5 Mana

CH6 QV+

CH6 S+

CH6 Sminus

CH6 Mana

CH7 QV+

CH7 S+

CH7 Sminus

CH7 Mana

24V

24V

24V

24V

24V

24V

24V

24V

+CBL1-XP1 1+CBL124

+CBL1-XM2 1+CBL135 +CBL1-XM2 2+CBL135

+CBL1-XM1 2+CBL125

The e

lect

ric so

leno

id

prop

ortio

nal v

alve

s

AO 8 times 12 BIT

3 times 075

Figure 9 The circuit diagram for connecting the electric valves to the analog output module

Y

X0 20 40 60 80 100 100120 140 160 180 200

0

10

20

30

40

50

50 1112131415161718192021

(∘C)

Figure 10 Real-time three-dimensional temperature field

The proposed approach offers an effective and efficient alter-native for acquiring temperature digital data useful for sup-porting the decision-making processes regarding the controlof cooling of just poured mass concrete in real time

A mathematical description of the digital temperaturecontrol model has been developed Use of this model fortemperature values acquisition filtering sorting treatingand their real-time transfer for cooling control purposes isproved effective A stable real-time high volume capacityof the temperature data transmission solution developedutilized an intelligent cooling control system

Using this system on the Xiluodu arch dam site enabledsome key problems to be solved including huge quantities ofraw data interchange with the module server personalizedand flexible control for each water cooling circuit andaccurate and punctual water conditional control data collec-tion instead of traditional manual checking The proposedapproach provides a convenient solution in process coolingcontrol pipes where cabling is not possible The systemalso has lower installation and maintenance costs operatesreliably and is of robust and flexible construction It is proved

suitable for heat of hydration control in dam constructionconcreting applications

Based on this study the future research will be focusedon the combination of real-time site monitoring analysis andnumerical simulation on thermal stress for control crackingof mass concrete in construction period

Conflict of Interests

The authors declare that there is no conflict of interestsregarding the publication of this paper

Acknowledgments

This research work was supported by National NaturalScience Foundation of China (nos 11272178 and 51339003)National Basic Research Program of China (973 Program)under Grants nos 2013CB035902 and 2011CB013503 andTsinghua University Initiative Scientific Research Program

References

[1] P Lin Q B Li S W Zhou and Y Hu ldquoIntelligent cooling con-trol method and system for mass concreterdquo Journal of HydraulicEngineering vol 44 no 8 pp 950ndash957 2013

[2] F A Branco and P Mendes ldquoNumerical simulations of heat ofhydration temperature in damsrdquo in Proceedings of the Interna-tional Workshop on Arch Dams pp 225ndash230 Coimbra Portu-gal April 1987

[3] B Zhu ldquoEffect of cooling by water flowing in nonmetal pipesembedded in mass concreterdquo Journal of Construction Engineer-ing and Management vol 125 no 1 pp 61ndash68 1999

[4] AMNevilleProperties of Concrete Longman Essex UK 1995

10 Mathematical Problems in Engineering

[5] H S Shang T H Yi and Y P Song ldquoBehavior of plain concreteof a highwater-cement ratio after freeze-thaw cyclesrdquoMaterialsvol 5 no 9 pp 1698ndash1707 2012

[6] H S Shang and T H Yi ldquoFreeze-thaw durability of air-entrained concreterdquo The Scientific World Journal vol 2013Article ID 650791 6 pages 2013

[7] H S Shang and T H Yi ldquoBehavior of HPC with fly ash afterelevated temperaturerdquo Advances in Materials Science and Engi-neering vol 2013 Article ID 478421 7 pages 2013

[8] G D Zhou and T H Yi ldquoThermal load in large-scale bridgesa state-of-the-art reviewrdquo International Journal of DistributedSensor Networks vol 2013 Article ID 217983 17 pages 2013

[9] Q Li G Li and G Wang ldquoElasto-plastic bond mechanics ofembeddedfiber optic sensors in concrete under uniaxial tensionwith strain localizationrdquo Smart Materials and Structures vol 12no 6 pp 851ndash858 2003

[10] P Lin Q B Li and H Hu ldquoA flexible network structure fortemperature monitoring of a super high arch damrdquo Interna-tional Journal of Distributed Sensor Networks vol 2012 ArticleID 917849 10 pages 2012

[11] Q B Li P Lin S W Zhou et al ldquoReal time online individu-ation and intelligent cooling control system for mass concreterdquoUtility Model Patent 2012204165226 2013

[12] P Lin Q B Li Y Hu et al ldquoA device of integrity flow and tem-perature controllingrdquo Patent Number(s) 2012204177149 2013

[13] Q B Li and P Lin ldquoDemonstration on intelligent damrdquo Journalof Hydroelectric Engineering vol 33 no 1 2014

[14] K J Astrom and T Hagglund PID Controllers Theory Designand Tuning International Society for Measurement and Con-trol Seattle Wash USA 2nd edition 1995

[15] A B Corripio Tuning of Industrial Control Systems InstrumentSociety of America Research Triangle Park NC USA 1990

[16] F D Petruzella Programmable Logic Controllers Mcgraw-HillNew York NY USA 3rd edition 2004

[17] M Gopal Digital Control and State Variable Methods Conven-tional and Intelligent Control Systems McGraw Hill Education4th edition 2012

[18] M S Santina A R Stubberud and G H Hostetter DigitalControl System Design International Thomson PublishingStamford Conn USA 2nd edition 1994

[19] F Italiano R Maugeri A Mastrolia and J Heinicke ldquoA newseafloor monitoring module for real-time data transmission anapplication to shallow hydrothermal ventsrdquo Procedia Earth andPlanetary Science vol 4 pp 93ndash98 2011

[20] R Bayindir and Y Cetinceviz ldquoAwater pumping control systemwith a Programmable Logic Controller (PLC) and industrialwireless modules for industrial plantsmdashan experimental setuprdquoISA Transactions vol 50 no 2 pp 321ndash328 2011

[21] J Flores B Arcay and J Arias ldquoAn intelligent system for dis-tributed control of an anaerobic wastewater treatment processrdquoEngineering Applications of Artificial Intelligence vol 13 no 4pp 485ndash494 2000

[22] P Marino M A Domınguez F Poza and F Vazquez ldquoUsingLOTOS in the specification of industrial bus communicationprotocolsrdquoComputerNetworks vol 45 no 6 pp 767ndash799 2004

[23] J L Posadas P Perez J E Simo G Benet and F BlanesldquoCommunications structure for sensory data in mobile robotsrdquoEngineering Applications of Artificial Intelligence vol 15 no 3-4pp 341ndash350 2002

[24] C Hennig T Bluhm P Heimann et al ldquoUsing the network asbus system for long discharge data acquisition and data process-ingrdquo Fusion Engineering and Design vol 81 no 15ndash17 pp 1735ndash1740 2006

[25] R Moraes F B Carreiro P Bartolomeu V Silva J A Fonsecaand F Vasques ldquoEnforcing the timing behavior of real-timestations in legacy bus-based industrial Ethernet networksrdquoComputer Standards and Interfaces vol 33 no 3 pp 249ndash2612011

[26] C Hennig K Kneupner and D Kinna ldquoConnecting Program-mable Logic Controllers (PLC) to control and data acquisition acomparison of the JET and Wendelstein 7-X approachrdquo FusionEngineering and Design vol 87 no 12 pp 1972ndash1976 2012

[27] J-N Dong G-H Qin and H Yu ldquoStudy on real-time sensorsignal transmission based on technology of polynomial predic-tive filteringrdquoMeasurement vol 42 no 7 pp 969ndash977 2009

[28] P Lin S Z KangQ B Li et al ldquoEvaluation on rockmass qualityand stability of xiluodu arch dam under construction phaserdquoJournal of Rock Mechanics and Engineering vol 31 no 10 pp2042ndash2052 2012

[29] P Lin X L Liu Y Hu Yu et al ldquoDeformation and stability anal-ysis on xiluodu arch dam under stress and seepage conditionrdquoJournal of Rock Mechanics and Engineering vol 32 no 6 pp1137ndash1144 2013

Submit your manuscripts athttpwwwhindawicom

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

MathematicsJournal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Mathematical Problems in Engineering

Hindawi Publishing Corporationhttpwwwhindawicom

Differential EquationsInternational Journal of

Volume 2014

Applied MathematicsJournal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Probability and StatisticsHindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Journal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Mathematical PhysicsAdvances in

Complex AnalysisJournal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

OptimizationJournal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

CombinatoricsHindawi Publishing Corporationhttpwwwhindawicom Volume 2014

International Journal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Operations ResearchAdvances in

Journal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Function Spaces

Abstract and Applied AnalysisHindawi Publishing Corporationhttpwwwhindawicom Volume 2014

International Journal of Mathematics and Mathematical Sciences

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

The Scientific World JournalHindawi Publishing Corporation httpwwwhindawicom Volume 2014

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Algebra

Discrete Dynamics in Nature and Society

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Decision SciencesAdvances in

Discrete MathematicsJournal of

Hindawi Publishing Corporationhttpwwwhindawicom

Volume 2014 Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Stochastic AnalysisInternational Journal of

6 Mathematical Problems in Engineering

Table 1 The PLC data structure of DB10 for communication with intelligent module

Number Address offset Name Data type Comments1 0 Module SN Integer Module serial number2 2 Total sensors Real Total sensors number3 4 Value ID1 Real SensorValue ID14 8 Value ID2 Real SensorValue ID25 12 Value ID3 Real SensorValue ID36 16 Value ID4 Real SensorValue ID4

256 1016 Value ID254 Real SensorValue ID254257 1020 Value ID255 Real SensorValue ID255258 1024 Value ID256 Real SensorValue ID256

Table 2 The PLC data structure of DB1 for sending telegram to module server

Number Address offset Name Data type Comments1 0 Label String(4) Fixed as ldquoEDAMrdquo2 4 Length Integer Telegram length3 6 Tel type INT Telegram type4 8 SendTime String(12) Format YYYYMMDDHHMM5 20 TotalNumber INT Total circuits6 22 Telegram1 UDT1 User defined data type

119899 + 5 (119899 minus 1) lowast 10 + 22 Telegram(119899) UDT1 User defined data type

Table 3 The user defined type (UDT) for each circuit value as a template

Number Address offset Name Data type Comments1 0 Number Integer The circuit number2 2 Mode Byte Mode 1 = auto 2 = manual3 3 AlarmWarnning Byte 0 = OK 1 = warning 2 = alarm4 4 InletTemp Integer Water inlet tmperature5 6 OutletTemp Integer Water outlet temperature6 8 ActFlow Integer Actual water flow

numbers and every item of circuit data Here a special UDT(user data type 10 bytes) is defined for each water coolingcircuit including the serial number auto- or manual modestatus inlet and outlet temperature and actual water flowshown in Table 3 Correspondingly the DB2 is the receivingbuffer containing the commands for each circuit from themodule serverrsquos control strategy system

Similarly the receiving telegram contains the labellength type and command for each circuit and the personal-ized control solution is then realized in this way Every circuitcan have its own cooling water flow target set point or fixedwater valve opening output

4 Application Case Study

41 Brief Introduction toDamSite Theproposedmethodwasapplied to the temperature control of the Xiluodu arch dam

during construction [28 29]The project is located on the Jin-shajiang River in the Leibo County of Sichuan province Theprincipal structures consist of a double-curvature arch dam2855 meters high crest length about 700 meters spillwayunderground powerhouse and logway A total of 6000000cubic meters of concrete were poured Because of the highstresses in an arch dam structure and the constructionprocess control difficulties the basic temperature controlprinciplewas tomaintain ultimately small temperature differ-ences betweenneighbouring areas of concrete by slow coolingand early cooling The cooling process should be based onthe concrete temperature measurement results taking intoconsideration the partitioning of the concrete pouringtemperature water pipes density of concrete and ambienttemperature The cooling water flow is adjusted in a timelymanner to meet the targeted temperature requirements

A flexible network structure for field temperature mon-itoring of the super high arch dam during construction was

Mathematical Problems in Engineering 7

Comment Comment

EN

ACT

ID

EN

M1000

M1001

MW102

M1040

M1041

MW106

MW108LADDRLADDR1

T32

SEND

ID

Network 7 Sending telegram to module server Network 8 Receiving telegram from module server

W163FFC

W163FFC

PDB1DBX00

PDB2DBX00

FC50 FC60NDR

RECV

2

BYTE 2048

BYTE 2048

2048

DONE

ERROR

ERROR

STATUS

STATUS

ENO

ENO

LEN

LEN

The logic address of CPU Ethernet port

Figure 5 The PLC functions for TCPIP communication with the module server

(1) BOX1

(2) PS307(3) CPU315

(4) CP341

(5) IM153(6) AI8

(7) AO8

Figure 6 The internal layout of the PLC control cubicle

developed based on the state of the art intelligence controltechnology [8] By employing flexible network structurearchitecture the bus was also connected to other typesof sensors such as dam strain measurement meters damcompressive stress measurement meters meters for moni-toring joint openings rock-deformations and piezometersfor seepage flow all of which were are designed to suitthis network specification Thus the measurement scopeutilized covered a wide spectrum as well as themany concretetemperature measurements sufficient for a super high archdam

42 Site Control System Arrangement The control cabinetswere prepared in the workshop Because of the complexelectromagnetic environment on the construction site wiringto the site flow valves and sensors were employed Figure 6shows a preassembled cabinet for digital data transmissionHere is the brief description of the main parts of PLC controlcubicle

BOX1 The intelligent temperature module The cir-cuit connection diagrams for connecting the temper-ature sensors to the module are shown in Figure 7PS307 The Simatic S7-300 PLC power moduleCPU315 The Simatic S7-300 PLC CPU with inte-grated Profibus and Ethernet interfacesCP341 The Simatic RS485 communication processorfor the intelligent temperature moduleIM153 The Simatic interface module which canextend the CPU control to remote areas by ProfibusnetworkAI8TheSimatic analog inputmodule which can read8 analogue signals (current voltage resistor or PT100sensors) The circuit diagram for connecting the flowmeters to the analogue input module is shown inFigure 8 The symbol ldquoSM331rdquo is the analogue inputmodule which is able to read 8 water flow transduc-ers please refer to ldquo(6) AI8rdquo of Figure 6AO8 The Simatic analogue output module whichcan drive 8 analog valves The circuit diagram forconnecting the electric valves to the analogue outputmodule is shown in Figure 9 The symbol ldquoSM332rdquo isthe analogue output module which is able to control8 proportional valves please refer to ldquo(7) AO8rdquo ofFigure 6

On the dam site the operators connect the valves flowmeters and temperature sensors into the PLC cabinets asrequired according to construction progress

43 Temperature Field Analysis Basis of Real-Time Temper-ature Data On the Xiluodu arch dam site the intelligentcooling control system used modern field bus technologyextensively and Siemens PLC devices to comprehensivelytrack the temperature data change at the pouring of everyblock in real time Adjustment of the valves and control ofwater flowwere performed using the PID algorithm based ontemperature control requirements and key factors such as thehighest temperature reached cooling rate and temperature

8 Mathematical Problems in Engineering

-BOX1

256 RS422LTM8663

GNDCH2

GNDCH1

GNDCH0

-X34

-X31

-X35

-X38

-X32-X33

-X36-X37

CH3GND

-X39-X310-X311-X312

CH4GND

CH5GND

CH6GND

CH7GND

-X316

-X313

-X317

-X320

-X314-X315

-X318-X319

-X321-X322-X323-X324

+5V+5V

+5V +5V

+5V+5V

+5V +5V

24V+ COM+

COMminus

CH2

CH0 5V

CH1 5V

CH0

CH0 GND

CH1 GNDCH2 5V

CH2 GNDCH3 5V

CH3

CH3 GNDBOX1

BOX1

BOX1BOX1

BOX1

BOX1BOX1

BOX1

BOX1

BOX1BOX1

BOX1

BOX1 CH5

BOX1 CH6

BOX1 CH4 5V

BOX1 CH5 5V

BOX1 CH4BOX1 CH4 GND

BOX1 CH5 GND

BOX1 CH6 5V

BOX1 CH6 GND

BOX1 CH7 5V

BOX1 CH7BOX1 CH7 GND

-XP1 1721-XM1 1728

CH1

GND(24V) = CC3 + CBL3-BOX1 COMminus

= CC3 + CBL3-BOX1 COM+

-RS422 COMminus+UR056

-RS422 COM++UR056

Figure 7 The circuit diagram for connecting the temperature sensors to the module

3 times 075

3 times 075

3 times 075

3 times 075

3 times 075

3 times 075

3 times 075

3 times 075

3 times 075 3 times 075

6ES7 331-1KF02-0AB0

SM 331

A

A

A

A

V

V

V

V

V

V

V

V

A

A

A

A

SIEMENS

8

Rack0Slot3

-A3

2

1

3

4

5

6

7

89

1112

13

1516

1718

1920

2122

2324

2526

2728

2930

3132

3334

3536

3738

3940

1

3

10

5

14

7

9

11

13

15

21

41-W501

1

21

41-W502

1

21

41-W503

1

21

41

1

12

47

1

12

12

12

47-W506

1

47-W507

1

47-W508

1

41-W401

148

-W402

1

The i

nlet

or o

utle

t w

ater

flow

tran

sduc

ers

AI 8 times 13 BIT

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

-FT501

-FT502

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

-FT503

-FT504

-W504

-FT505

-W505

-FT506

-FT507

-FT508

S+Sminus

S+Sminus

S+Sminus

S+Sminus

S+ Sminus

S+ Sminus

S+ Sminus

S+ Sminus +CBL1-XP2 2+CBL134+CBL1-XP2 1+CBL134

+CBL1-XM1 1+CBL124

CH0 I+

CH0 U+

CH0 Sminus

CH0 M+

CH0 Mminus

CH1 U+

CH1 I+

CH1 SminusCH1 M+

CH2 M+

CH2 U+

CH2 I+

CH2 Sminus

CH2 Mminus

CH1 Mminus

CH3 U+

CH3 I+CH3 Sminus

CH3 M+

CH3 Mminus

CH4 U+

CH4 I+

CH4 SminusCH4 M+

CH4 Mminus

CH5 U+

CH5 I+CH5 Sminus

CH5 M+

CH5 Mminus

CH6 U+

CH6 I+

CH6 SminusCH6 M+

CH6 Mminus

CH7 U+

CH7 I+CH7 Sminus

CH7 M+

CH7 Mminus

Figure 8 The circuit diagram for connecting the temperature sensors to the module

gradient A web graphical user interface (GUI) was providedfor integrated query analysis and prewarning [1]

Based on the proposed temperature data transmissionsystem the intelligent cooling system overcomes the short-comings in traditional manually collected data systemsproviding an effective dam concrete temperature control andcracking prevention technology both advanced and moreintelligent In particular the advances consist of (1) changingsimple manual data collection to real-time data acquisitionand feedback (2) automatically obtaining large quantitiesof thermodynamic parameters with respect to every blockof poured concrete enabling a more customized control

function and (3) enabling a 3D real-time temperature fieldanalysis be carried out as illustrated in Figure 10 Based onthe real-time temperature field analysis further stress fieldscan be analyzed to study alternative temperature controlplans not only limited to water flow but the whole pipeworkscheme can be adjusted to more optimal configurations

5 Conclusions

This paper presents a real-time temperature data transmis-sion approach for intelligent cooling control of early agemassconcrete based onAD convertermodel and PLC technology

Mathematical Problems in Engineering 9

6ES7 332-5HF00-0AB0

SM 332 SIEMENS

8

Rack0Slot4

-A4

1

2

3

4

5

66Mana0

7

8

9

1010Mana1

11

12

13

15

16

17

1818Mana3

19

20 20M20M

21

22

23

24

25

2626Mana4

27

28

29

3030Mana5

31

32

33

3434Mana6

35

36

37

3838Mana7

39

40

2

4

6

8

10

12

14

16

1414Mana2

-YVP5012

M

1

Y1

3

U

4

32-W501

2

-YVP5022

M

1

Y1

3

U

4

-YVP5032

M

1

Y1

3

U

4

-YVP5042

M

1

Y1

3

U

4

32-W502

2

-YVP5052

M

1

Y1

3

U

4

-YVP5062

M

1

Y1

3

U

4

-YVP5072

M

1

Y1

3

U

4

-YVP5082

M

1

Y1

3

U

4

32-W503

2

32-W504

2

37-W505

2

37-W506

2

37-W507

2

37-W508

2

31-W401

2 238

-W402

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

1L+1L+

CH0 QV+

CH0 S+

CH0 Sminus

CH0 Mana

CH1 QV+

CH1 S+

CH1 S-

CH1 Mana

CH2 QV+

CH2 S+

CH2 Sminus

CH3 QV+

CH3 S+

CH3 Sminus

CH3 Mana

CH2 Mana

CH4 QV+

CH4 S+

CH4 Sminus

CH4 Mana

CH5 QV+

CH5 S+

CH5 Sminus

CH5 Mana

CH6 QV+

CH6 S+

CH6 Sminus

CH6 Mana

CH7 QV+

CH7 S+

CH7 Sminus

CH7 Mana

24V

24V

24V

24V

24V

24V

24V

24V

+CBL1-XP1 1+CBL124

+CBL1-XM2 1+CBL135 +CBL1-XM2 2+CBL135

+CBL1-XM1 2+CBL125

The e

lect

ric so

leno

id

prop

ortio

nal v

alve

s

AO 8 times 12 BIT

3 times 075

Figure 9 The circuit diagram for connecting the electric valves to the analog output module

Y

X0 20 40 60 80 100 100120 140 160 180 200

0

10

20

30

40

50

50 1112131415161718192021

(∘C)

Figure 10 Real-time three-dimensional temperature field

The proposed approach offers an effective and efficient alter-native for acquiring temperature digital data useful for sup-porting the decision-making processes regarding the controlof cooling of just poured mass concrete in real time

A mathematical description of the digital temperaturecontrol model has been developed Use of this model fortemperature values acquisition filtering sorting treatingand their real-time transfer for cooling control purposes isproved effective A stable real-time high volume capacityof the temperature data transmission solution developedutilized an intelligent cooling control system

Using this system on the Xiluodu arch dam site enabledsome key problems to be solved including huge quantities ofraw data interchange with the module server personalizedand flexible control for each water cooling circuit andaccurate and punctual water conditional control data collec-tion instead of traditional manual checking The proposedapproach provides a convenient solution in process coolingcontrol pipes where cabling is not possible The systemalso has lower installation and maintenance costs operatesreliably and is of robust and flexible construction It is proved

suitable for heat of hydration control in dam constructionconcreting applications

Based on this study the future research will be focusedon the combination of real-time site monitoring analysis andnumerical simulation on thermal stress for control crackingof mass concrete in construction period

Conflict of Interests

The authors declare that there is no conflict of interestsregarding the publication of this paper

Acknowledgments

This research work was supported by National NaturalScience Foundation of China (nos 11272178 and 51339003)National Basic Research Program of China (973 Program)under Grants nos 2013CB035902 and 2011CB013503 andTsinghua University Initiative Scientific Research Program

References

[1] P Lin Q B Li S W Zhou and Y Hu ldquoIntelligent cooling con-trol method and system for mass concreterdquo Journal of HydraulicEngineering vol 44 no 8 pp 950ndash957 2013

[2] F A Branco and P Mendes ldquoNumerical simulations of heat ofhydration temperature in damsrdquo in Proceedings of the Interna-tional Workshop on Arch Dams pp 225ndash230 Coimbra Portu-gal April 1987

[3] B Zhu ldquoEffect of cooling by water flowing in nonmetal pipesembedded in mass concreterdquo Journal of Construction Engineer-ing and Management vol 125 no 1 pp 61ndash68 1999

[4] AMNevilleProperties of Concrete Longman Essex UK 1995

10 Mathematical Problems in Engineering

[5] H S Shang T H Yi and Y P Song ldquoBehavior of plain concreteof a highwater-cement ratio after freeze-thaw cyclesrdquoMaterialsvol 5 no 9 pp 1698ndash1707 2012

[6] H S Shang and T H Yi ldquoFreeze-thaw durability of air-entrained concreterdquo The Scientific World Journal vol 2013Article ID 650791 6 pages 2013

[7] H S Shang and T H Yi ldquoBehavior of HPC with fly ash afterelevated temperaturerdquo Advances in Materials Science and Engi-neering vol 2013 Article ID 478421 7 pages 2013

[8] G D Zhou and T H Yi ldquoThermal load in large-scale bridgesa state-of-the-art reviewrdquo International Journal of DistributedSensor Networks vol 2013 Article ID 217983 17 pages 2013

[9] Q Li G Li and G Wang ldquoElasto-plastic bond mechanics ofembeddedfiber optic sensors in concrete under uniaxial tensionwith strain localizationrdquo Smart Materials and Structures vol 12no 6 pp 851ndash858 2003

[10] P Lin Q B Li and H Hu ldquoA flexible network structure fortemperature monitoring of a super high arch damrdquo Interna-tional Journal of Distributed Sensor Networks vol 2012 ArticleID 917849 10 pages 2012

[11] Q B Li P Lin S W Zhou et al ldquoReal time online individu-ation and intelligent cooling control system for mass concreterdquoUtility Model Patent 2012204165226 2013

[12] P Lin Q B Li Y Hu et al ldquoA device of integrity flow and tem-perature controllingrdquo Patent Number(s) 2012204177149 2013

[13] Q B Li and P Lin ldquoDemonstration on intelligent damrdquo Journalof Hydroelectric Engineering vol 33 no 1 2014

[14] K J Astrom and T Hagglund PID Controllers Theory Designand Tuning International Society for Measurement and Con-trol Seattle Wash USA 2nd edition 1995

[15] A B Corripio Tuning of Industrial Control Systems InstrumentSociety of America Research Triangle Park NC USA 1990

[16] F D Petruzella Programmable Logic Controllers Mcgraw-HillNew York NY USA 3rd edition 2004

[17] M Gopal Digital Control and State Variable Methods Conven-tional and Intelligent Control Systems McGraw Hill Education4th edition 2012

[18] M S Santina A R Stubberud and G H Hostetter DigitalControl System Design International Thomson PublishingStamford Conn USA 2nd edition 1994

[19] F Italiano R Maugeri A Mastrolia and J Heinicke ldquoA newseafloor monitoring module for real-time data transmission anapplication to shallow hydrothermal ventsrdquo Procedia Earth andPlanetary Science vol 4 pp 93ndash98 2011

[20] R Bayindir and Y Cetinceviz ldquoAwater pumping control systemwith a Programmable Logic Controller (PLC) and industrialwireless modules for industrial plantsmdashan experimental setuprdquoISA Transactions vol 50 no 2 pp 321ndash328 2011

[21] J Flores B Arcay and J Arias ldquoAn intelligent system for dis-tributed control of an anaerobic wastewater treatment processrdquoEngineering Applications of Artificial Intelligence vol 13 no 4pp 485ndash494 2000

[22] P Marino M A Domınguez F Poza and F Vazquez ldquoUsingLOTOS in the specification of industrial bus communicationprotocolsrdquoComputerNetworks vol 45 no 6 pp 767ndash799 2004

[23] J L Posadas P Perez J E Simo G Benet and F BlanesldquoCommunications structure for sensory data in mobile robotsrdquoEngineering Applications of Artificial Intelligence vol 15 no 3-4pp 341ndash350 2002

[24] C Hennig T Bluhm P Heimann et al ldquoUsing the network asbus system for long discharge data acquisition and data process-ingrdquo Fusion Engineering and Design vol 81 no 15ndash17 pp 1735ndash1740 2006

[25] R Moraes F B Carreiro P Bartolomeu V Silva J A Fonsecaand F Vasques ldquoEnforcing the timing behavior of real-timestations in legacy bus-based industrial Ethernet networksrdquoComputer Standards and Interfaces vol 33 no 3 pp 249ndash2612011

[26] C Hennig K Kneupner and D Kinna ldquoConnecting Program-mable Logic Controllers (PLC) to control and data acquisition acomparison of the JET and Wendelstein 7-X approachrdquo FusionEngineering and Design vol 87 no 12 pp 1972ndash1976 2012

[27] J-N Dong G-H Qin and H Yu ldquoStudy on real-time sensorsignal transmission based on technology of polynomial predic-tive filteringrdquoMeasurement vol 42 no 7 pp 969ndash977 2009

[28] P Lin S Z KangQ B Li et al ldquoEvaluation on rockmass qualityand stability of xiluodu arch dam under construction phaserdquoJournal of Rock Mechanics and Engineering vol 31 no 10 pp2042ndash2052 2012

[29] P Lin X L Liu Y Hu Yu et al ldquoDeformation and stability anal-ysis on xiluodu arch dam under stress and seepage conditionrdquoJournal of Rock Mechanics and Engineering vol 32 no 6 pp1137ndash1144 2013

Submit your manuscripts athttpwwwhindawicom

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

MathematicsJournal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Mathematical Problems in Engineering

Hindawi Publishing Corporationhttpwwwhindawicom

Differential EquationsInternational Journal of

Volume 2014

Applied MathematicsJournal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Probability and StatisticsHindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Journal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Mathematical PhysicsAdvances in

Complex AnalysisJournal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

OptimizationJournal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

CombinatoricsHindawi Publishing Corporationhttpwwwhindawicom Volume 2014

International Journal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Operations ResearchAdvances in

Journal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Function Spaces

Abstract and Applied AnalysisHindawi Publishing Corporationhttpwwwhindawicom Volume 2014

International Journal of Mathematics and Mathematical Sciences

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

The Scientific World JournalHindawi Publishing Corporation httpwwwhindawicom Volume 2014

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Algebra

Discrete Dynamics in Nature and Society

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Decision SciencesAdvances in

Discrete MathematicsJournal of

Hindawi Publishing Corporationhttpwwwhindawicom

Volume 2014 Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Stochastic AnalysisInternational Journal of

Mathematical Problems in Engineering 7

Comment Comment

EN

ACT

ID

EN

M1000

M1001

MW102

M1040

M1041

MW106

MW108LADDRLADDR1

T32

SEND

ID

Network 7 Sending telegram to module server Network 8 Receiving telegram from module server

W163FFC

W163FFC

PDB1DBX00

PDB2DBX00

FC50 FC60NDR

RECV

2

BYTE 2048

BYTE 2048

2048

DONE

ERROR

ERROR

STATUS

STATUS

ENO

ENO

LEN

LEN

The logic address of CPU Ethernet port

Figure 5 The PLC functions for TCPIP communication with the module server

(1) BOX1

(2) PS307(3) CPU315

(4) CP341

(5) IM153(6) AI8

(7) AO8

Figure 6 The internal layout of the PLC control cubicle

developed based on the state of the art intelligence controltechnology [8] By employing flexible network structurearchitecture the bus was also connected to other typesof sensors such as dam strain measurement meters damcompressive stress measurement meters meters for moni-toring joint openings rock-deformations and piezometersfor seepage flow all of which were are designed to suitthis network specification Thus the measurement scopeutilized covered a wide spectrum as well as themany concretetemperature measurements sufficient for a super high archdam

42 Site Control System Arrangement The control cabinetswere prepared in the workshop Because of the complexelectromagnetic environment on the construction site wiringto the site flow valves and sensors were employed Figure 6shows a preassembled cabinet for digital data transmissionHere is the brief description of the main parts of PLC controlcubicle

BOX1 The intelligent temperature module The cir-cuit connection diagrams for connecting the temper-ature sensors to the module are shown in Figure 7PS307 The Simatic S7-300 PLC power moduleCPU315 The Simatic S7-300 PLC CPU with inte-grated Profibus and Ethernet interfacesCP341 The Simatic RS485 communication processorfor the intelligent temperature moduleIM153 The Simatic interface module which canextend the CPU control to remote areas by ProfibusnetworkAI8TheSimatic analog inputmodule which can read8 analogue signals (current voltage resistor or PT100sensors) The circuit diagram for connecting the flowmeters to the analogue input module is shown inFigure 8 The symbol ldquoSM331rdquo is the analogue inputmodule which is able to read 8 water flow transduc-ers please refer to ldquo(6) AI8rdquo of Figure 6AO8 The Simatic analogue output module whichcan drive 8 analog valves The circuit diagram forconnecting the electric valves to the analogue outputmodule is shown in Figure 9 The symbol ldquoSM332rdquo isthe analogue output module which is able to control8 proportional valves please refer to ldquo(7) AO8rdquo ofFigure 6

On the dam site the operators connect the valves flowmeters and temperature sensors into the PLC cabinets asrequired according to construction progress

43 Temperature Field Analysis Basis of Real-Time Temper-ature Data On the Xiluodu arch dam site the intelligentcooling control system used modern field bus technologyextensively and Siemens PLC devices to comprehensivelytrack the temperature data change at the pouring of everyblock in real time Adjustment of the valves and control ofwater flowwere performed using the PID algorithm based ontemperature control requirements and key factors such as thehighest temperature reached cooling rate and temperature

8 Mathematical Problems in Engineering

-BOX1

256 RS422LTM8663

GNDCH2

GNDCH1

GNDCH0

-X34

-X31

-X35

-X38

-X32-X33

-X36-X37

CH3GND

-X39-X310-X311-X312

CH4GND

CH5GND

CH6GND

CH7GND

-X316

-X313

-X317

-X320

-X314-X315

-X318-X319

-X321-X322-X323-X324

+5V+5V

+5V +5V

+5V+5V

+5V +5V

24V+ COM+

COMminus

CH2

CH0 5V

CH1 5V

CH0

CH0 GND

CH1 GNDCH2 5V

CH2 GNDCH3 5V

CH3

CH3 GNDBOX1

BOX1

BOX1BOX1

BOX1

BOX1BOX1

BOX1

BOX1

BOX1BOX1

BOX1

BOX1 CH5

BOX1 CH6

BOX1 CH4 5V

BOX1 CH5 5V

BOX1 CH4BOX1 CH4 GND

BOX1 CH5 GND

BOX1 CH6 5V

BOX1 CH6 GND

BOX1 CH7 5V

BOX1 CH7BOX1 CH7 GND

-XP1 1721-XM1 1728

CH1

GND(24V) = CC3 + CBL3-BOX1 COMminus

= CC3 + CBL3-BOX1 COM+

-RS422 COMminus+UR056

-RS422 COM++UR056

Figure 7 The circuit diagram for connecting the temperature sensors to the module

3 times 075

3 times 075

3 times 075

3 times 075

3 times 075

3 times 075

3 times 075

3 times 075

3 times 075 3 times 075

6ES7 331-1KF02-0AB0

SM 331

A

A

A

A

V

V

V

V

V

V

V

V

A

A

A

A

SIEMENS

8

Rack0Slot3

-A3

2

1

3

4

5

6

7

89

1112

13

1516

1718

1920

2122

2324

2526

2728

2930

3132

3334

3536

3738

3940

1

3

10

5

14

7

9

11

13

15

21

41-W501

1

21

41-W502

1

21

41-W503

1

21

41

1

12

47

1

12

12

12

47-W506

1

47-W507

1

47-W508

1

41-W401

148

-W402

1

The i

nlet

or o

utle

t w

ater

flow

tran

sduc

ers

AI 8 times 13 BIT

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

-FT501

-FT502

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

-FT503

-FT504

-W504

-FT505

-W505

-FT506

-FT507

-FT508

S+Sminus

S+Sminus

S+Sminus

S+Sminus

S+ Sminus

S+ Sminus

S+ Sminus

S+ Sminus +CBL1-XP2 2+CBL134+CBL1-XP2 1+CBL134

+CBL1-XM1 1+CBL124

CH0 I+

CH0 U+

CH0 Sminus

CH0 M+

CH0 Mminus

CH1 U+

CH1 I+

CH1 SminusCH1 M+

CH2 M+

CH2 U+

CH2 I+

CH2 Sminus

CH2 Mminus

CH1 Mminus

CH3 U+

CH3 I+CH3 Sminus

CH3 M+

CH3 Mminus

CH4 U+

CH4 I+

CH4 SminusCH4 M+

CH4 Mminus

CH5 U+

CH5 I+CH5 Sminus

CH5 M+

CH5 Mminus

CH6 U+

CH6 I+

CH6 SminusCH6 M+

CH6 Mminus

CH7 U+

CH7 I+CH7 Sminus

CH7 M+

CH7 Mminus

Figure 8 The circuit diagram for connecting the temperature sensors to the module

gradient A web graphical user interface (GUI) was providedfor integrated query analysis and prewarning [1]

Based on the proposed temperature data transmissionsystem the intelligent cooling system overcomes the short-comings in traditional manually collected data systemsproviding an effective dam concrete temperature control andcracking prevention technology both advanced and moreintelligent In particular the advances consist of (1) changingsimple manual data collection to real-time data acquisitionand feedback (2) automatically obtaining large quantitiesof thermodynamic parameters with respect to every blockof poured concrete enabling a more customized control

function and (3) enabling a 3D real-time temperature fieldanalysis be carried out as illustrated in Figure 10 Based onthe real-time temperature field analysis further stress fieldscan be analyzed to study alternative temperature controlplans not only limited to water flow but the whole pipeworkscheme can be adjusted to more optimal configurations

5 Conclusions

This paper presents a real-time temperature data transmis-sion approach for intelligent cooling control of early agemassconcrete based onAD convertermodel and PLC technology

Mathematical Problems in Engineering 9

6ES7 332-5HF00-0AB0

SM 332 SIEMENS

8

Rack0Slot4

-A4

1

2

3

4

5

66Mana0

7

8

9

1010Mana1

11

12

13

15

16

17

1818Mana3

19

20 20M20M

21

22

23

24

25

2626Mana4

27

28

29

3030Mana5

31

32

33

3434Mana6

35

36

37

3838Mana7

39

40

2

4

6

8

10

12

14

16

1414Mana2

-YVP5012

M

1

Y1

3

U

4

32-W501

2

-YVP5022

M

1

Y1

3

U

4

-YVP5032

M

1

Y1

3

U

4

-YVP5042

M

1

Y1

3

U

4

32-W502

2

-YVP5052

M

1

Y1

3

U

4

-YVP5062

M

1

Y1

3

U

4

-YVP5072

M

1

Y1

3

U

4

-YVP5082

M

1

Y1

3

U

4

32-W503

2

32-W504

2

37-W505

2

37-W506

2

37-W507

2

37-W508

2

31-W401

2 238

-W402

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

1L+1L+

CH0 QV+

CH0 S+

CH0 Sminus

CH0 Mana

CH1 QV+

CH1 S+

CH1 S-

CH1 Mana

CH2 QV+

CH2 S+

CH2 Sminus

CH3 QV+

CH3 S+

CH3 Sminus

CH3 Mana

CH2 Mana

CH4 QV+

CH4 S+

CH4 Sminus

CH4 Mana

CH5 QV+

CH5 S+

CH5 Sminus

CH5 Mana

CH6 QV+

CH6 S+

CH6 Sminus

CH6 Mana

CH7 QV+

CH7 S+

CH7 Sminus

CH7 Mana

24V

24V

24V

24V

24V

24V

24V

24V

+CBL1-XP1 1+CBL124

+CBL1-XM2 1+CBL135 +CBL1-XM2 2+CBL135

+CBL1-XM1 2+CBL125

The e

lect

ric so

leno

id

prop

ortio

nal v

alve

s

AO 8 times 12 BIT

3 times 075

Figure 9 The circuit diagram for connecting the electric valves to the analog output module

Y

X0 20 40 60 80 100 100120 140 160 180 200

0

10

20

30

40

50

50 1112131415161718192021

(∘C)

Figure 10 Real-time three-dimensional temperature field

The proposed approach offers an effective and efficient alter-native for acquiring temperature digital data useful for sup-porting the decision-making processes regarding the controlof cooling of just poured mass concrete in real time

A mathematical description of the digital temperaturecontrol model has been developed Use of this model fortemperature values acquisition filtering sorting treatingand their real-time transfer for cooling control purposes isproved effective A stable real-time high volume capacityof the temperature data transmission solution developedutilized an intelligent cooling control system

Using this system on the Xiluodu arch dam site enabledsome key problems to be solved including huge quantities ofraw data interchange with the module server personalizedand flexible control for each water cooling circuit andaccurate and punctual water conditional control data collec-tion instead of traditional manual checking The proposedapproach provides a convenient solution in process coolingcontrol pipes where cabling is not possible The systemalso has lower installation and maintenance costs operatesreliably and is of robust and flexible construction It is proved

suitable for heat of hydration control in dam constructionconcreting applications

Based on this study the future research will be focusedon the combination of real-time site monitoring analysis andnumerical simulation on thermal stress for control crackingof mass concrete in construction period

Conflict of Interests

The authors declare that there is no conflict of interestsregarding the publication of this paper

Acknowledgments

This research work was supported by National NaturalScience Foundation of China (nos 11272178 and 51339003)National Basic Research Program of China (973 Program)under Grants nos 2013CB035902 and 2011CB013503 andTsinghua University Initiative Scientific Research Program

References

[1] P Lin Q B Li S W Zhou and Y Hu ldquoIntelligent cooling con-trol method and system for mass concreterdquo Journal of HydraulicEngineering vol 44 no 8 pp 950ndash957 2013

[2] F A Branco and P Mendes ldquoNumerical simulations of heat ofhydration temperature in damsrdquo in Proceedings of the Interna-tional Workshop on Arch Dams pp 225ndash230 Coimbra Portu-gal April 1987

[3] B Zhu ldquoEffect of cooling by water flowing in nonmetal pipesembedded in mass concreterdquo Journal of Construction Engineer-ing and Management vol 125 no 1 pp 61ndash68 1999

[4] AMNevilleProperties of Concrete Longman Essex UK 1995

10 Mathematical Problems in Engineering

[5] H S Shang T H Yi and Y P Song ldquoBehavior of plain concreteof a highwater-cement ratio after freeze-thaw cyclesrdquoMaterialsvol 5 no 9 pp 1698ndash1707 2012

[6] H S Shang and T H Yi ldquoFreeze-thaw durability of air-entrained concreterdquo The Scientific World Journal vol 2013Article ID 650791 6 pages 2013

[7] H S Shang and T H Yi ldquoBehavior of HPC with fly ash afterelevated temperaturerdquo Advances in Materials Science and Engi-neering vol 2013 Article ID 478421 7 pages 2013

[8] G D Zhou and T H Yi ldquoThermal load in large-scale bridgesa state-of-the-art reviewrdquo International Journal of DistributedSensor Networks vol 2013 Article ID 217983 17 pages 2013

[9] Q Li G Li and G Wang ldquoElasto-plastic bond mechanics ofembeddedfiber optic sensors in concrete under uniaxial tensionwith strain localizationrdquo Smart Materials and Structures vol 12no 6 pp 851ndash858 2003

[10] P Lin Q B Li and H Hu ldquoA flexible network structure fortemperature monitoring of a super high arch damrdquo Interna-tional Journal of Distributed Sensor Networks vol 2012 ArticleID 917849 10 pages 2012

[11] Q B Li P Lin S W Zhou et al ldquoReal time online individu-ation and intelligent cooling control system for mass concreterdquoUtility Model Patent 2012204165226 2013

[12] P Lin Q B Li Y Hu et al ldquoA device of integrity flow and tem-perature controllingrdquo Patent Number(s) 2012204177149 2013

[13] Q B Li and P Lin ldquoDemonstration on intelligent damrdquo Journalof Hydroelectric Engineering vol 33 no 1 2014

[14] K J Astrom and T Hagglund PID Controllers Theory Designand Tuning International Society for Measurement and Con-trol Seattle Wash USA 2nd edition 1995

[15] A B Corripio Tuning of Industrial Control Systems InstrumentSociety of America Research Triangle Park NC USA 1990

[16] F D Petruzella Programmable Logic Controllers Mcgraw-HillNew York NY USA 3rd edition 2004

[17] M Gopal Digital Control and State Variable Methods Conven-tional and Intelligent Control Systems McGraw Hill Education4th edition 2012

[18] M S Santina A R Stubberud and G H Hostetter DigitalControl System Design International Thomson PublishingStamford Conn USA 2nd edition 1994

[19] F Italiano R Maugeri A Mastrolia and J Heinicke ldquoA newseafloor monitoring module for real-time data transmission anapplication to shallow hydrothermal ventsrdquo Procedia Earth andPlanetary Science vol 4 pp 93ndash98 2011

[20] R Bayindir and Y Cetinceviz ldquoAwater pumping control systemwith a Programmable Logic Controller (PLC) and industrialwireless modules for industrial plantsmdashan experimental setuprdquoISA Transactions vol 50 no 2 pp 321ndash328 2011

[21] J Flores B Arcay and J Arias ldquoAn intelligent system for dis-tributed control of an anaerobic wastewater treatment processrdquoEngineering Applications of Artificial Intelligence vol 13 no 4pp 485ndash494 2000

[22] P Marino M A Domınguez F Poza and F Vazquez ldquoUsingLOTOS in the specification of industrial bus communicationprotocolsrdquoComputerNetworks vol 45 no 6 pp 767ndash799 2004

[23] J L Posadas P Perez J E Simo G Benet and F BlanesldquoCommunications structure for sensory data in mobile robotsrdquoEngineering Applications of Artificial Intelligence vol 15 no 3-4pp 341ndash350 2002

[24] C Hennig T Bluhm P Heimann et al ldquoUsing the network asbus system for long discharge data acquisition and data process-ingrdquo Fusion Engineering and Design vol 81 no 15ndash17 pp 1735ndash1740 2006

[25] R Moraes F B Carreiro P Bartolomeu V Silva J A Fonsecaand F Vasques ldquoEnforcing the timing behavior of real-timestations in legacy bus-based industrial Ethernet networksrdquoComputer Standards and Interfaces vol 33 no 3 pp 249ndash2612011

[26] C Hennig K Kneupner and D Kinna ldquoConnecting Program-mable Logic Controllers (PLC) to control and data acquisition acomparison of the JET and Wendelstein 7-X approachrdquo FusionEngineering and Design vol 87 no 12 pp 1972ndash1976 2012

[27] J-N Dong G-H Qin and H Yu ldquoStudy on real-time sensorsignal transmission based on technology of polynomial predic-tive filteringrdquoMeasurement vol 42 no 7 pp 969ndash977 2009

[28] P Lin S Z KangQ B Li et al ldquoEvaluation on rockmass qualityand stability of xiluodu arch dam under construction phaserdquoJournal of Rock Mechanics and Engineering vol 31 no 10 pp2042ndash2052 2012

[29] P Lin X L Liu Y Hu Yu et al ldquoDeformation and stability anal-ysis on xiluodu arch dam under stress and seepage conditionrdquoJournal of Rock Mechanics and Engineering vol 32 no 6 pp1137ndash1144 2013

Submit your manuscripts athttpwwwhindawicom

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

MathematicsJournal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Mathematical Problems in Engineering

Hindawi Publishing Corporationhttpwwwhindawicom

Differential EquationsInternational Journal of

Volume 2014

Applied MathematicsJournal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Probability and StatisticsHindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Journal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Mathematical PhysicsAdvances in

Complex AnalysisJournal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

OptimizationJournal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

CombinatoricsHindawi Publishing Corporationhttpwwwhindawicom Volume 2014

International Journal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Operations ResearchAdvances in

Journal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Function Spaces

Abstract and Applied AnalysisHindawi Publishing Corporationhttpwwwhindawicom Volume 2014

International Journal of Mathematics and Mathematical Sciences

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

The Scientific World JournalHindawi Publishing Corporation httpwwwhindawicom Volume 2014

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Algebra

Discrete Dynamics in Nature and Society

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Decision SciencesAdvances in

Discrete MathematicsJournal of

Hindawi Publishing Corporationhttpwwwhindawicom

Volume 2014 Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Stochastic AnalysisInternational Journal of

8 Mathematical Problems in Engineering

-BOX1

256 RS422LTM8663

GNDCH2

GNDCH1

GNDCH0

-X34

-X31

-X35

-X38

-X32-X33

-X36-X37

CH3GND

-X39-X310-X311-X312

CH4GND

CH5GND

CH6GND

CH7GND

-X316

-X313

-X317

-X320

-X314-X315

-X318-X319

-X321-X322-X323-X324

+5V+5V

+5V +5V

+5V+5V

+5V +5V

24V+ COM+

COMminus

CH2

CH0 5V

CH1 5V

CH0

CH0 GND

CH1 GNDCH2 5V

CH2 GNDCH3 5V

CH3

CH3 GNDBOX1

BOX1

BOX1BOX1

BOX1

BOX1BOX1

BOX1

BOX1

BOX1BOX1

BOX1

BOX1 CH5

BOX1 CH6

BOX1 CH4 5V

BOX1 CH5 5V

BOX1 CH4BOX1 CH4 GND

BOX1 CH5 GND

BOX1 CH6 5V

BOX1 CH6 GND

BOX1 CH7 5V

BOX1 CH7BOX1 CH7 GND

-XP1 1721-XM1 1728

CH1

GND(24V) = CC3 + CBL3-BOX1 COMminus

= CC3 + CBL3-BOX1 COM+

-RS422 COMminus+UR056

-RS422 COM++UR056

Figure 7 The circuit diagram for connecting the temperature sensors to the module

3 times 075

3 times 075

3 times 075

3 times 075

3 times 075

3 times 075

3 times 075

3 times 075

3 times 075 3 times 075

6ES7 331-1KF02-0AB0

SM 331

A

A

A

A

V

V

V

V

V

V

V

V

A

A

A

A

SIEMENS

8

Rack0Slot3

-A3

2

1

3

4

5

6

7

89

1112

13

1516

1718

1920

2122

2324

2526

2728

2930

3132

3334

3536

3738

3940

1

3

10

5

14

7

9

11

13

15

21

41-W501

1

21

41-W502

1

21

41-W503

1

21

41

1

12

47

1

12

12

12

47-W506

1

47-W507

1

47-W508

1

41-W401

148

-W402

1

The i

nlet

or o

utle

t w

ater

flow

tran

sduc

ers

AI 8 times 13 BIT

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

-FT501

-FT502

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

-FT503

-FT504

-W504

-FT505

-W505

-FT506

-FT507

-FT508

S+Sminus

S+Sminus

S+Sminus

S+Sminus

S+ Sminus

S+ Sminus

S+ Sminus

S+ Sminus +CBL1-XP2 2+CBL134+CBL1-XP2 1+CBL134

+CBL1-XM1 1+CBL124

CH0 I+

CH0 U+

CH0 Sminus

CH0 M+

CH0 Mminus

CH1 U+

CH1 I+

CH1 SminusCH1 M+

CH2 M+

CH2 U+

CH2 I+

CH2 Sminus

CH2 Mminus

CH1 Mminus

CH3 U+

CH3 I+CH3 Sminus

CH3 M+

CH3 Mminus

CH4 U+

CH4 I+

CH4 SminusCH4 M+

CH4 Mminus

CH5 U+

CH5 I+CH5 Sminus

CH5 M+

CH5 Mminus

CH6 U+

CH6 I+

CH6 SminusCH6 M+

CH6 Mminus

CH7 U+

CH7 I+CH7 Sminus

CH7 M+

CH7 Mminus

Figure 8 The circuit diagram for connecting the temperature sensors to the module

gradient A web graphical user interface (GUI) was providedfor integrated query analysis and prewarning [1]

Based on the proposed temperature data transmissionsystem the intelligent cooling system overcomes the short-comings in traditional manually collected data systemsproviding an effective dam concrete temperature control andcracking prevention technology both advanced and moreintelligent In particular the advances consist of (1) changingsimple manual data collection to real-time data acquisitionand feedback (2) automatically obtaining large quantitiesof thermodynamic parameters with respect to every blockof poured concrete enabling a more customized control

function and (3) enabling a 3D real-time temperature fieldanalysis be carried out as illustrated in Figure 10 Based onthe real-time temperature field analysis further stress fieldscan be analyzed to study alternative temperature controlplans not only limited to water flow but the whole pipeworkscheme can be adjusted to more optimal configurations

5 Conclusions

This paper presents a real-time temperature data transmis-sion approach for intelligent cooling control of early agemassconcrete based onAD convertermodel and PLC technology

Mathematical Problems in Engineering 9

6ES7 332-5HF00-0AB0

SM 332 SIEMENS

8

Rack0Slot4

-A4

1

2

3

4

5

66Mana0

7

8

9

1010Mana1

11

12

13

15

16

17

1818Mana3

19

20 20M20M

21

22

23

24

25

2626Mana4

27

28

29

3030Mana5

31

32

33

3434Mana6

35

36

37

3838Mana7

39

40

2

4

6

8

10

12

14

16

1414Mana2

-YVP5012

M

1

Y1

3

U

4

32-W501

2

-YVP5022

M

1

Y1

3

U

4

-YVP5032

M

1

Y1

3

U

4

-YVP5042

M

1

Y1

3

U

4

32-W502

2

-YVP5052

M

1

Y1

3

U

4

-YVP5062

M

1

Y1

3

U

4

-YVP5072

M

1

Y1

3

U

4

-YVP5082

M

1

Y1

3

U

4

32-W503

2

32-W504

2

37-W505

2

37-W506

2

37-W507

2

37-W508

2

31-W401

2 238

-W402

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

1L+1L+

CH0 QV+

CH0 S+

CH0 Sminus

CH0 Mana

CH1 QV+

CH1 S+

CH1 S-

CH1 Mana

CH2 QV+

CH2 S+

CH2 Sminus

CH3 QV+

CH3 S+

CH3 Sminus

CH3 Mana

CH2 Mana

CH4 QV+

CH4 S+

CH4 Sminus

CH4 Mana

CH5 QV+

CH5 S+

CH5 Sminus

CH5 Mana

CH6 QV+

CH6 S+

CH6 Sminus

CH6 Mana

CH7 QV+

CH7 S+

CH7 Sminus

CH7 Mana

24V

24V

24V

24V

24V

24V

24V

24V

+CBL1-XP1 1+CBL124

+CBL1-XM2 1+CBL135 +CBL1-XM2 2+CBL135

+CBL1-XM1 2+CBL125

The e

lect

ric so

leno

id

prop

ortio

nal v

alve

s

AO 8 times 12 BIT

3 times 075

Figure 9 The circuit diagram for connecting the electric valves to the analog output module

Y

X0 20 40 60 80 100 100120 140 160 180 200

0

10

20

30

40

50

50 1112131415161718192021

(∘C)

Figure 10 Real-time three-dimensional temperature field

The proposed approach offers an effective and efficient alter-native for acquiring temperature digital data useful for sup-porting the decision-making processes regarding the controlof cooling of just poured mass concrete in real time

A mathematical description of the digital temperaturecontrol model has been developed Use of this model fortemperature values acquisition filtering sorting treatingand their real-time transfer for cooling control purposes isproved effective A stable real-time high volume capacityof the temperature data transmission solution developedutilized an intelligent cooling control system

Using this system on the Xiluodu arch dam site enabledsome key problems to be solved including huge quantities ofraw data interchange with the module server personalizedand flexible control for each water cooling circuit andaccurate and punctual water conditional control data collec-tion instead of traditional manual checking The proposedapproach provides a convenient solution in process coolingcontrol pipes where cabling is not possible The systemalso has lower installation and maintenance costs operatesreliably and is of robust and flexible construction It is proved

suitable for heat of hydration control in dam constructionconcreting applications

Based on this study the future research will be focusedon the combination of real-time site monitoring analysis andnumerical simulation on thermal stress for control crackingof mass concrete in construction period

Conflict of Interests

The authors declare that there is no conflict of interestsregarding the publication of this paper

Acknowledgments

This research work was supported by National NaturalScience Foundation of China (nos 11272178 and 51339003)National Basic Research Program of China (973 Program)under Grants nos 2013CB035902 and 2011CB013503 andTsinghua University Initiative Scientific Research Program

References

[1] P Lin Q B Li S W Zhou and Y Hu ldquoIntelligent cooling con-trol method and system for mass concreterdquo Journal of HydraulicEngineering vol 44 no 8 pp 950ndash957 2013

[2] F A Branco and P Mendes ldquoNumerical simulations of heat ofhydration temperature in damsrdquo in Proceedings of the Interna-tional Workshop on Arch Dams pp 225ndash230 Coimbra Portu-gal April 1987

[3] B Zhu ldquoEffect of cooling by water flowing in nonmetal pipesembedded in mass concreterdquo Journal of Construction Engineer-ing and Management vol 125 no 1 pp 61ndash68 1999

[4] AMNevilleProperties of Concrete Longman Essex UK 1995

10 Mathematical Problems in Engineering

[5] H S Shang T H Yi and Y P Song ldquoBehavior of plain concreteof a highwater-cement ratio after freeze-thaw cyclesrdquoMaterialsvol 5 no 9 pp 1698ndash1707 2012

[6] H S Shang and T H Yi ldquoFreeze-thaw durability of air-entrained concreterdquo The Scientific World Journal vol 2013Article ID 650791 6 pages 2013

[7] H S Shang and T H Yi ldquoBehavior of HPC with fly ash afterelevated temperaturerdquo Advances in Materials Science and Engi-neering vol 2013 Article ID 478421 7 pages 2013

[8] G D Zhou and T H Yi ldquoThermal load in large-scale bridgesa state-of-the-art reviewrdquo International Journal of DistributedSensor Networks vol 2013 Article ID 217983 17 pages 2013

[9] Q Li G Li and G Wang ldquoElasto-plastic bond mechanics ofembeddedfiber optic sensors in concrete under uniaxial tensionwith strain localizationrdquo Smart Materials and Structures vol 12no 6 pp 851ndash858 2003

[10] P Lin Q B Li and H Hu ldquoA flexible network structure fortemperature monitoring of a super high arch damrdquo Interna-tional Journal of Distributed Sensor Networks vol 2012 ArticleID 917849 10 pages 2012

[11] Q B Li P Lin S W Zhou et al ldquoReal time online individu-ation and intelligent cooling control system for mass concreterdquoUtility Model Patent 2012204165226 2013

[12] P Lin Q B Li Y Hu et al ldquoA device of integrity flow and tem-perature controllingrdquo Patent Number(s) 2012204177149 2013

[13] Q B Li and P Lin ldquoDemonstration on intelligent damrdquo Journalof Hydroelectric Engineering vol 33 no 1 2014

[14] K J Astrom and T Hagglund PID Controllers Theory Designand Tuning International Society for Measurement and Con-trol Seattle Wash USA 2nd edition 1995

[15] A B Corripio Tuning of Industrial Control Systems InstrumentSociety of America Research Triangle Park NC USA 1990

[16] F D Petruzella Programmable Logic Controllers Mcgraw-HillNew York NY USA 3rd edition 2004

[17] M Gopal Digital Control and State Variable Methods Conven-tional and Intelligent Control Systems McGraw Hill Education4th edition 2012

[18] M S Santina A R Stubberud and G H Hostetter DigitalControl System Design International Thomson PublishingStamford Conn USA 2nd edition 1994

[19] F Italiano R Maugeri A Mastrolia and J Heinicke ldquoA newseafloor monitoring module for real-time data transmission anapplication to shallow hydrothermal ventsrdquo Procedia Earth andPlanetary Science vol 4 pp 93ndash98 2011

[20] R Bayindir and Y Cetinceviz ldquoAwater pumping control systemwith a Programmable Logic Controller (PLC) and industrialwireless modules for industrial plantsmdashan experimental setuprdquoISA Transactions vol 50 no 2 pp 321ndash328 2011

[21] J Flores B Arcay and J Arias ldquoAn intelligent system for dis-tributed control of an anaerobic wastewater treatment processrdquoEngineering Applications of Artificial Intelligence vol 13 no 4pp 485ndash494 2000

[22] P Marino M A Domınguez F Poza and F Vazquez ldquoUsingLOTOS in the specification of industrial bus communicationprotocolsrdquoComputerNetworks vol 45 no 6 pp 767ndash799 2004

[23] J L Posadas P Perez J E Simo G Benet and F BlanesldquoCommunications structure for sensory data in mobile robotsrdquoEngineering Applications of Artificial Intelligence vol 15 no 3-4pp 341ndash350 2002

[24] C Hennig T Bluhm P Heimann et al ldquoUsing the network asbus system for long discharge data acquisition and data process-ingrdquo Fusion Engineering and Design vol 81 no 15ndash17 pp 1735ndash1740 2006

[25] R Moraes F B Carreiro P Bartolomeu V Silva J A Fonsecaand F Vasques ldquoEnforcing the timing behavior of real-timestations in legacy bus-based industrial Ethernet networksrdquoComputer Standards and Interfaces vol 33 no 3 pp 249ndash2612011

[26] C Hennig K Kneupner and D Kinna ldquoConnecting Program-mable Logic Controllers (PLC) to control and data acquisition acomparison of the JET and Wendelstein 7-X approachrdquo FusionEngineering and Design vol 87 no 12 pp 1972ndash1976 2012

[27] J-N Dong G-H Qin and H Yu ldquoStudy on real-time sensorsignal transmission based on technology of polynomial predic-tive filteringrdquoMeasurement vol 42 no 7 pp 969ndash977 2009

[28] P Lin S Z KangQ B Li et al ldquoEvaluation on rockmass qualityand stability of xiluodu arch dam under construction phaserdquoJournal of Rock Mechanics and Engineering vol 31 no 10 pp2042ndash2052 2012

[29] P Lin X L Liu Y Hu Yu et al ldquoDeformation and stability anal-ysis on xiluodu arch dam under stress and seepage conditionrdquoJournal of Rock Mechanics and Engineering vol 32 no 6 pp1137ndash1144 2013

Submit your manuscripts athttpwwwhindawicom

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

MathematicsJournal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Mathematical Problems in Engineering

Hindawi Publishing Corporationhttpwwwhindawicom

Differential EquationsInternational Journal of

Volume 2014

Applied MathematicsJournal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Probability and StatisticsHindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Journal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Mathematical PhysicsAdvances in

Complex AnalysisJournal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

OptimizationJournal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

CombinatoricsHindawi Publishing Corporationhttpwwwhindawicom Volume 2014

International Journal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Operations ResearchAdvances in

Journal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Function Spaces

Abstract and Applied AnalysisHindawi Publishing Corporationhttpwwwhindawicom Volume 2014

International Journal of Mathematics and Mathematical Sciences

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

The Scientific World JournalHindawi Publishing Corporation httpwwwhindawicom Volume 2014

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Algebra

Discrete Dynamics in Nature and Society

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Decision SciencesAdvances in

Discrete MathematicsJournal of

Hindawi Publishing Corporationhttpwwwhindawicom

Volume 2014 Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Stochastic AnalysisInternational Journal of

Mathematical Problems in Engineering 9

6ES7 332-5HF00-0AB0

SM 332 SIEMENS

8

Rack0Slot4

-A4

1

2

3

4

5

66Mana0

7

8

9

1010Mana1

11

12

13

15

16

17

1818Mana3

19

20 20M20M

21

22

23

24

25

2626Mana4

27

28

29

3030Mana5

31

32

33

3434Mana6

35

36

37

3838Mana7

39

40

2

4

6

8

10

12

14

16

1414Mana2

-YVP5012

M

1

Y1

3

U

4

32-W501

2

-YVP5022

M

1

Y1

3

U

4

-YVP5032

M

1

Y1

3

U

4

-YVP5042

M

1

Y1

3

U

4

32-W502

2

-YVP5052

M

1

Y1

3

U

4

-YVP5062

M

1

Y1

3

U

4

-YVP5072

M

1

Y1

3

U

4

-YVP5082

M

1

Y1

3

U

4

32-W503

2

32-W504

2

37-W505

2

37-W506

2

37-W507

2

37-W508

2

31-W401

2 238

-W402

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

4ndash20mA

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

+CBL1-X1

1L+1L+

CH0 QV+

CH0 S+

CH0 Sminus

CH0 Mana

CH1 QV+

CH1 S+

CH1 S-

CH1 Mana

CH2 QV+

CH2 S+

CH2 Sminus

CH3 QV+

CH3 S+

CH3 Sminus

CH3 Mana

CH2 Mana

CH4 QV+

CH4 S+

CH4 Sminus

CH4 Mana

CH5 QV+

CH5 S+

CH5 Sminus

CH5 Mana

CH6 QV+

CH6 S+

CH6 Sminus

CH6 Mana

CH7 QV+

CH7 S+

CH7 Sminus

CH7 Mana

24V

24V

24V

24V

24V

24V

24V

24V

+CBL1-XP1 1+CBL124

+CBL1-XM2 1+CBL135 +CBL1-XM2 2+CBL135

+CBL1-XM1 2+CBL125

The e

lect

ric so

leno

id

prop

ortio

nal v

alve

s

AO 8 times 12 BIT

3 times 075

Figure 9 The circuit diagram for connecting the electric valves to the analog output module

Y

X0 20 40 60 80 100 100120 140 160 180 200

0

10

20

30

40

50

50 1112131415161718192021

(∘C)

Figure 10 Real-time three-dimensional temperature field

The proposed approach offers an effective and efficient alter-native for acquiring temperature digital data useful for sup-porting the decision-making processes regarding the controlof cooling of just poured mass concrete in real time

A mathematical description of the digital temperaturecontrol model has been developed Use of this model fortemperature values acquisition filtering sorting treatingand their real-time transfer for cooling control purposes isproved effective A stable real-time high volume capacityof the temperature data transmission solution developedutilized an intelligent cooling control system

Using this system on the Xiluodu arch dam site enabledsome key problems to be solved including huge quantities ofraw data interchange with the module server personalizedand flexible control for each water cooling circuit andaccurate and punctual water conditional control data collec-tion instead of traditional manual checking The proposedapproach provides a convenient solution in process coolingcontrol pipes where cabling is not possible The systemalso has lower installation and maintenance costs operatesreliably and is of robust and flexible construction It is proved

suitable for heat of hydration control in dam constructionconcreting applications

Based on this study the future research will be focusedon the combination of real-time site monitoring analysis andnumerical simulation on thermal stress for control crackingof mass concrete in construction period

Conflict of Interests

The authors declare that there is no conflict of interestsregarding the publication of this paper

Acknowledgments

This research work was supported by National NaturalScience Foundation of China (nos 11272178 and 51339003)National Basic Research Program of China (973 Program)under Grants nos 2013CB035902 and 2011CB013503 andTsinghua University Initiative Scientific Research Program

References

[1] P Lin Q B Li S W Zhou and Y Hu ldquoIntelligent cooling con-trol method and system for mass concreterdquo Journal of HydraulicEngineering vol 44 no 8 pp 950ndash957 2013

[2] F A Branco and P Mendes ldquoNumerical simulations of heat ofhydration temperature in damsrdquo in Proceedings of the Interna-tional Workshop on Arch Dams pp 225ndash230 Coimbra Portu-gal April 1987

[3] B Zhu ldquoEffect of cooling by water flowing in nonmetal pipesembedded in mass concreterdquo Journal of Construction Engineer-ing and Management vol 125 no 1 pp 61ndash68 1999

[4] AMNevilleProperties of Concrete Longman Essex UK 1995

10 Mathematical Problems in Engineering

[5] H S Shang T H Yi and Y P Song ldquoBehavior of plain concreteof a highwater-cement ratio after freeze-thaw cyclesrdquoMaterialsvol 5 no 9 pp 1698ndash1707 2012

[6] H S Shang and T H Yi ldquoFreeze-thaw durability of air-entrained concreterdquo The Scientific World Journal vol 2013Article ID 650791 6 pages 2013

[7] H S Shang and T H Yi ldquoBehavior of HPC with fly ash afterelevated temperaturerdquo Advances in Materials Science and Engi-neering vol 2013 Article ID 478421 7 pages 2013

[8] G D Zhou and T H Yi ldquoThermal load in large-scale bridgesa state-of-the-art reviewrdquo International Journal of DistributedSensor Networks vol 2013 Article ID 217983 17 pages 2013

[9] Q Li G Li and G Wang ldquoElasto-plastic bond mechanics ofembeddedfiber optic sensors in concrete under uniaxial tensionwith strain localizationrdquo Smart Materials and Structures vol 12no 6 pp 851ndash858 2003

[10] P Lin Q B Li and H Hu ldquoA flexible network structure fortemperature monitoring of a super high arch damrdquo Interna-tional Journal of Distributed Sensor Networks vol 2012 ArticleID 917849 10 pages 2012

[11] Q B Li P Lin S W Zhou et al ldquoReal time online individu-ation and intelligent cooling control system for mass concreterdquoUtility Model Patent 2012204165226 2013

[12] P Lin Q B Li Y Hu et al ldquoA device of integrity flow and tem-perature controllingrdquo Patent Number(s) 2012204177149 2013

[13] Q B Li and P Lin ldquoDemonstration on intelligent damrdquo Journalof Hydroelectric Engineering vol 33 no 1 2014

[14] K J Astrom and T Hagglund PID Controllers Theory Designand Tuning International Society for Measurement and Con-trol Seattle Wash USA 2nd edition 1995

[15] A B Corripio Tuning of Industrial Control Systems InstrumentSociety of America Research Triangle Park NC USA 1990

[16] F D Petruzella Programmable Logic Controllers Mcgraw-HillNew York NY USA 3rd edition 2004

[17] M Gopal Digital Control and State Variable Methods Conven-tional and Intelligent Control Systems McGraw Hill Education4th edition 2012

[18] M S Santina A R Stubberud and G H Hostetter DigitalControl System Design International Thomson PublishingStamford Conn USA 2nd edition 1994

[19] F Italiano R Maugeri A Mastrolia and J Heinicke ldquoA newseafloor monitoring module for real-time data transmission anapplication to shallow hydrothermal ventsrdquo Procedia Earth andPlanetary Science vol 4 pp 93ndash98 2011

[20] R Bayindir and Y Cetinceviz ldquoAwater pumping control systemwith a Programmable Logic Controller (PLC) and industrialwireless modules for industrial plantsmdashan experimental setuprdquoISA Transactions vol 50 no 2 pp 321ndash328 2011

[21] J Flores B Arcay and J Arias ldquoAn intelligent system for dis-tributed control of an anaerobic wastewater treatment processrdquoEngineering Applications of Artificial Intelligence vol 13 no 4pp 485ndash494 2000

[22] P Marino M A Domınguez F Poza and F Vazquez ldquoUsingLOTOS in the specification of industrial bus communicationprotocolsrdquoComputerNetworks vol 45 no 6 pp 767ndash799 2004

[23] J L Posadas P Perez J E Simo G Benet and F BlanesldquoCommunications structure for sensory data in mobile robotsrdquoEngineering Applications of Artificial Intelligence vol 15 no 3-4pp 341ndash350 2002

[24] C Hennig T Bluhm P Heimann et al ldquoUsing the network asbus system for long discharge data acquisition and data process-ingrdquo Fusion Engineering and Design vol 81 no 15ndash17 pp 1735ndash1740 2006

[25] R Moraes F B Carreiro P Bartolomeu V Silva J A Fonsecaand F Vasques ldquoEnforcing the timing behavior of real-timestations in legacy bus-based industrial Ethernet networksrdquoComputer Standards and Interfaces vol 33 no 3 pp 249ndash2612011

[26] C Hennig K Kneupner and D Kinna ldquoConnecting Program-mable Logic Controllers (PLC) to control and data acquisition acomparison of the JET and Wendelstein 7-X approachrdquo FusionEngineering and Design vol 87 no 12 pp 1972ndash1976 2012

[27] J-N Dong G-H Qin and H Yu ldquoStudy on real-time sensorsignal transmission based on technology of polynomial predic-tive filteringrdquoMeasurement vol 42 no 7 pp 969ndash977 2009

[28] P Lin S Z KangQ B Li et al ldquoEvaluation on rockmass qualityand stability of xiluodu arch dam under construction phaserdquoJournal of Rock Mechanics and Engineering vol 31 no 10 pp2042ndash2052 2012

[29] P Lin X L Liu Y Hu Yu et al ldquoDeformation and stability anal-ysis on xiluodu arch dam under stress and seepage conditionrdquoJournal of Rock Mechanics and Engineering vol 32 no 6 pp1137ndash1144 2013

Submit your manuscripts athttpwwwhindawicom

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

MathematicsJournal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Mathematical Problems in Engineering

Hindawi Publishing Corporationhttpwwwhindawicom

Differential EquationsInternational Journal of

Volume 2014

Applied MathematicsJournal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Probability and StatisticsHindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Journal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Mathematical PhysicsAdvances in

Complex AnalysisJournal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

OptimizationJournal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

CombinatoricsHindawi Publishing Corporationhttpwwwhindawicom Volume 2014

International Journal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Operations ResearchAdvances in

Journal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Function Spaces

Abstract and Applied AnalysisHindawi Publishing Corporationhttpwwwhindawicom Volume 2014

International Journal of Mathematics and Mathematical Sciences

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

The Scientific World JournalHindawi Publishing Corporation httpwwwhindawicom Volume 2014

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Algebra

Discrete Dynamics in Nature and Society

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Decision SciencesAdvances in

Discrete MathematicsJournal of

Hindawi Publishing Corporationhttpwwwhindawicom

Volume 2014 Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Stochastic AnalysisInternational Journal of

10 Mathematical Problems in Engineering

[5] H S Shang T H Yi and Y P Song ldquoBehavior of plain concreteof a highwater-cement ratio after freeze-thaw cyclesrdquoMaterialsvol 5 no 9 pp 1698ndash1707 2012

[6] H S Shang and T H Yi ldquoFreeze-thaw durability of air-entrained concreterdquo The Scientific World Journal vol 2013Article ID 650791 6 pages 2013

[7] H S Shang and T H Yi ldquoBehavior of HPC with fly ash afterelevated temperaturerdquo Advances in Materials Science and Engi-neering vol 2013 Article ID 478421 7 pages 2013

[8] G D Zhou and T H Yi ldquoThermal load in large-scale bridgesa state-of-the-art reviewrdquo International Journal of DistributedSensor Networks vol 2013 Article ID 217983 17 pages 2013

[9] Q Li G Li and G Wang ldquoElasto-plastic bond mechanics ofembeddedfiber optic sensors in concrete under uniaxial tensionwith strain localizationrdquo Smart Materials and Structures vol 12no 6 pp 851ndash858 2003

[10] P Lin Q B Li and H Hu ldquoA flexible network structure fortemperature monitoring of a super high arch damrdquo Interna-tional Journal of Distributed Sensor Networks vol 2012 ArticleID 917849 10 pages 2012

[11] Q B Li P Lin S W Zhou et al ldquoReal time online individu-ation and intelligent cooling control system for mass concreterdquoUtility Model Patent 2012204165226 2013

[12] P Lin Q B Li Y Hu et al ldquoA device of integrity flow and tem-perature controllingrdquo Patent Number(s) 2012204177149 2013

[13] Q B Li and P Lin ldquoDemonstration on intelligent damrdquo Journalof Hydroelectric Engineering vol 33 no 1 2014

[14] K J Astrom and T Hagglund PID Controllers Theory Designand Tuning International Society for Measurement and Con-trol Seattle Wash USA 2nd edition 1995

[15] A B Corripio Tuning of Industrial Control Systems InstrumentSociety of America Research Triangle Park NC USA 1990

[16] F D Petruzella Programmable Logic Controllers Mcgraw-HillNew York NY USA 3rd edition 2004

[17] M Gopal Digital Control and State Variable Methods Conven-tional and Intelligent Control Systems McGraw Hill Education4th edition 2012

[18] M S Santina A R Stubberud and G H Hostetter DigitalControl System Design International Thomson PublishingStamford Conn USA 2nd edition 1994

[19] F Italiano R Maugeri A Mastrolia and J Heinicke ldquoA newseafloor monitoring module for real-time data transmission anapplication to shallow hydrothermal ventsrdquo Procedia Earth andPlanetary Science vol 4 pp 93ndash98 2011

[20] R Bayindir and Y Cetinceviz ldquoAwater pumping control systemwith a Programmable Logic Controller (PLC) and industrialwireless modules for industrial plantsmdashan experimental setuprdquoISA Transactions vol 50 no 2 pp 321ndash328 2011

[21] J Flores B Arcay and J Arias ldquoAn intelligent system for dis-tributed control of an anaerobic wastewater treatment processrdquoEngineering Applications of Artificial Intelligence vol 13 no 4pp 485ndash494 2000

[22] P Marino M A Domınguez F Poza and F Vazquez ldquoUsingLOTOS in the specification of industrial bus communicationprotocolsrdquoComputerNetworks vol 45 no 6 pp 767ndash799 2004

[23] J L Posadas P Perez J E Simo G Benet and F BlanesldquoCommunications structure for sensory data in mobile robotsrdquoEngineering Applications of Artificial Intelligence vol 15 no 3-4pp 341ndash350 2002

[24] C Hennig T Bluhm P Heimann et al ldquoUsing the network asbus system for long discharge data acquisition and data process-ingrdquo Fusion Engineering and Design vol 81 no 15ndash17 pp 1735ndash1740 2006

[25] R Moraes F B Carreiro P Bartolomeu V Silva J A Fonsecaand F Vasques ldquoEnforcing the timing behavior of real-timestations in legacy bus-based industrial Ethernet networksrdquoComputer Standards and Interfaces vol 33 no 3 pp 249ndash2612011

[26] C Hennig K Kneupner and D Kinna ldquoConnecting Program-mable Logic Controllers (PLC) to control and data acquisition acomparison of the JET and Wendelstein 7-X approachrdquo FusionEngineering and Design vol 87 no 12 pp 1972ndash1976 2012

[27] J-N Dong G-H Qin and H Yu ldquoStudy on real-time sensorsignal transmission based on technology of polynomial predic-tive filteringrdquoMeasurement vol 42 no 7 pp 969ndash977 2009

[28] P Lin S Z KangQ B Li et al ldquoEvaluation on rockmass qualityand stability of xiluodu arch dam under construction phaserdquoJournal of Rock Mechanics and Engineering vol 31 no 10 pp2042ndash2052 2012

[29] P Lin X L Liu Y Hu Yu et al ldquoDeformation and stability anal-ysis on xiluodu arch dam under stress and seepage conditionrdquoJournal of Rock Mechanics and Engineering vol 32 no 6 pp1137ndash1144 2013

Submit your manuscripts athttpwwwhindawicom

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

MathematicsJournal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Mathematical Problems in Engineering

Hindawi Publishing Corporationhttpwwwhindawicom

Differential EquationsInternational Journal of

Volume 2014

Applied MathematicsJournal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Probability and StatisticsHindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Journal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Mathematical PhysicsAdvances in

Complex AnalysisJournal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

OptimizationJournal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

CombinatoricsHindawi Publishing Corporationhttpwwwhindawicom Volume 2014

International Journal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Operations ResearchAdvances in

Journal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Function Spaces

Abstract and Applied AnalysisHindawi Publishing Corporationhttpwwwhindawicom Volume 2014

International Journal of Mathematics and Mathematical Sciences

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

The Scientific World JournalHindawi Publishing Corporation httpwwwhindawicom Volume 2014

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Algebra

Discrete Dynamics in Nature and Society

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Decision SciencesAdvances in

Discrete MathematicsJournal of

Hindawi Publishing Corporationhttpwwwhindawicom

Volume 2014 Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Stochastic AnalysisInternational Journal of

Submit your manuscripts athttpwwwhindawicom

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

MathematicsJournal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Mathematical Problems in Engineering

Hindawi Publishing Corporationhttpwwwhindawicom

Differential EquationsInternational Journal of

Volume 2014

Applied MathematicsJournal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Probability and StatisticsHindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Journal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Mathematical PhysicsAdvances in

Complex AnalysisJournal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

OptimizationJournal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

CombinatoricsHindawi Publishing Corporationhttpwwwhindawicom Volume 2014

International Journal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Operations ResearchAdvances in

Journal of

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Function Spaces

Abstract and Applied AnalysisHindawi Publishing Corporationhttpwwwhindawicom Volume 2014

International Journal of Mathematics and Mathematical Sciences

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

The Scientific World JournalHindawi Publishing Corporation httpwwwhindawicom Volume 2014

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Algebra

Discrete Dynamics in Nature and Society

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Decision SciencesAdvances in

Discrete MathematicsJournal of

Hindawi Publishing Corporationhttpwwwhindawicom

Volume 2014 Hindawi Publishing Corporationhttpwwwhindawicom Volume 2014

Stochastic AnalysisInternational Journal of