Vacuum Chamber State Machine
This project develops the control algorithm for a vacuum pump–chamber system, including a state machine that will interface with a PLC to manage the full pump–evac–vent cycle. It also includes a pressure simulation to reduce debugging time and provide a safer way to test the sequence before running it on hardware.
The goal isn’t mere functionality, but long-term reliability.
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The architecture is designed so components can be added, removed, or rearranged with minimal effort. This mirrors real-world vacuum configurations and allows the system to adapt to different hardware setups without rewriting core logic.
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since the project migrated from PAC Control to CODESYS using Structured Text (IEC 61131-3), it remains platform-agnostic and can integrate with a wide range of PLCs and industrial controllers. The control logic is not tied to a single vendor or hardware family.
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The OOP structure enables the system to be reused, extended, and adapted across multiple products or vacuum configurations. New chambers, pumps, or workflows can be added without structural changes, making the system future-ready.
Virtual Testing Simulation
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Node-Edge Structure
The simulation is implemented as a node–edge graph, where nodes represent discrete control volumes with their own pressure states, and edges represent mass-flow paths such as valves, restrictions, or pumps. This abstraction cleanly separates system topology from flow behavior and allows chambers and connections to be reconfigured without modifying the core simulation logic.
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Conductance
Mass flow between nodes is computed using configurable conductance parameters driven by pressure differentials. These values approximate valve flow characteristics, geometric restrictions, and effective pumping speeds. Pumps are modeled as high-conductance sinks or sources, enabling realistic transient and steady-state pressure behavior while keeping the overall computation lightweight.
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Plug and Play
The simulator runs directly inside the CODESYS environment and interfaces with a centralized Plant structure that mirrors real I/O signals. It reads valve states, pump commands, and chamber configurations while remaining independent of the state machine, enabling safe offline testing, faster iteration, and debugging without relying on physical hardware. This separation allows the simulation to function as a drop-in tool for validation across different PLC platforms and system configurations.