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.
-
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.
-
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.
-
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
-
Node-Edge Structure
The simulation uses a node–edge graph, where nodes represent vacuum volumes with pressure states and edges model flow paths such as valves or pumps. This structure cleanly decouples system topology from behavior, allowing reconfigurations without altering the simulation logic.
-
Conductance
Inter-node flow is calculated using adjustable conductance values that approximate valve flow rates, restrictions, and pump characteristics. Pumps can be treated as conductance-driven sinks, enabling realistic pressure dynamics with minimal computational complexity.
-
Plug and Play
Built directly in CODESYS, the simulator reads valve and pump states from a centralized Plant variable while remaining independent of the state machine. This enables rapid and safe offline testing and debugging without the need for physical hardware.