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This paper deals with the practical aspects of the implementation of the balance-based adaptive control (B-BAC) technique. It gives the simple mathematical background of this methodology, shows the case-independent implementation concept as the ready-to-use flexible function block that results from the B-BAC generality, discusses how to embed the additional functionalities required in professional industrial control applications and finally presents three implementation examples for three different programming and hardware platforms. The control performance of each B-BAC function block is validated experimentally and compared with the performance of the corresponding platform-related standard PID function blocks. The comparative results and the potential accessibility of both the flexible function block and the simple tuning method put forward B-BAC methodology as a strong alternative for PID-based industrial control applications.

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This paper presents the flexible and ready-to-use function block for the implementation of the Balance-Based Adaptive Controller (B-BAC) embedded in the Siemens S7 PLCs. It is written according to the IEC-61131-3 programming standard using the SIMATIC software package STEP 7. The basic design principles are discussed in terms of ensuring the functionality similar to a PID function block and this functionality allows for direct B-BAC implementation to control a wide variety of different industrial SISO processes. Laboratory experimental tests were carried out in the laboratory water pumping system and the implementation aspects and control results are discussed in the paper.

Classical control applications with a centralized logic and distributed input/output system are being replaced by dynamic environments of cooperating components. Thus, the OPC (Object Linking and Embedding for Process Control) UA (Unified Architecture) is becoming more popular, because the OPC Data Access substandard is not well suited for distributed systems. Moreover, in many production systems, redundant data servers are preferred, for financial and legal reasons. Providing performance evaluation gives an estimate of the time required (and data samples lost) to switch to a backup data source for redundant OPC UA architecture, depending on the failure detection method, number of variables and redundancy mode.

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