PLCopen: changing the world of industrial automation. Overview of the current activities and working groups

Transcription

1 PLCopen: changing the world of industrial automation Overview of the current activities and working groups Eelco van der Wal Managing Director PLCopen Page 1 printed at 9/14/2011

2 PLCopen tagline PLCopen Why and How Page 2 printed at 9/14/2011

3 Percentage of Software development costs in production systems (source: McKinsey) 100% 80% 60% 40% 20% 0% Mechanic Electric Software Page 3 printed at 9/14/2011

4 Managing Complexity ,000 1mio 100mio Lines of Code Page 4 printed at 9/14/2011

5 A hierarchy of abstraction Page 5 printed at 9/14/2011

6 Abstraction via Function Blocks MC_MoveAbsolute AXIS_REF Axis Axis BOOL Execute Done BOOL ContinuousUpdate Busy REAL Position Active REAL Velocity CommandAborted REAL Acceleration Error REAL Deceleration ErrorID REAL Jerk MC_DIRECTION Direction MC_BUFFER_MODE BufferMode AXIS_REF BOOL BOOL BOOL BOOL BOOL WORD Page 6 printed at 9/14/2011

7 Function Block example REAL REAL REAL Hysterisis XIN1 Q XIN2 EPS BOOL FUNCTION_BLOCK HYSTERISIS VAR_INPUT XIN1, XIN2 : REAL; EPS : REAL; (* Hysterisis band *) END_VAR VAR_OUTPUT Q : BOOL := 0 END_VAR Q IF Q THEN IF XIN1 < (XIN2-EPS) THEN 1 Q := 0 (* XIN1 decreasing *) END_IF; 0 ELSIF XIN1 > (XIN2 + EPS ) THEN EPS EPS Q := 1; (* XIN1 increasing *) END_IF; XIN2 END_FUNCTION_BLOCK Page 7 printed at 9/14/2011

8 Information hiding via Function Blocks MC_MoveAbsolute AXIS_REF Axis Axis BOOL Execute Done BOOL ContinuousUpdate Busy REAL Position Active REAL Velocity CommandAborted REAL Acceleration Error REAL Deceleration ErrorID REAL Jerk MC_DIRECTION Direction MC_BUFFER_MODE BufferMode AXIS_REF BOOL BOOL BOOL BOOL BOOL WORD Page 8 printed at 9/14/2011

9 Axis_Ref with 1 FB Axis1 FB Task Manager Time or event driven Axis_Ref Structure Conversion I/F Drive Page 9 printed at 9/14/2011

10 Axis_Ref with 2 FBs Axis1 FB1 FB2 Task Manager Time or event driven Axis_Ref Structure Conversion I/F Drive Page 10 printed at 9/14/2011

11 HW Independence via Function Blocks Software View Hardware View Encapsulation / Information Hiding Inputs Name Outputs I/F Sercos Drive Motor E PWM I/F Drive Motor E Page 11 printed at 9/14/2011

12 Encapsulation: Webcutting Synchronization of web feeding & rotating cutter Page 12 printed at 9/14/2011

13 Mechatronic solutions Mechanical solution. Control solution Page 13 printed at 9/14/2011

14 Decomposition and Reuse Automation application INPUT OUTPUT IN_OUT EXTERNAL FUNCTION_BLOCK Type Local PROGRAM Type Local GLOBAL INPUT FUNCTION Type Local Page 14 printed at 9/14/2011

15 Sequential Function Chart, SFC S1 N Initialisation Step 1 N FILL S2 N Filling Transition 1 Step 2 S Empty S3 N Heating Transition 2 S4 N Fermenting Step 3 S5 N Harvesting S6 N Cleaning Page 15 printed at 9/14/2011

16 Time-to-Market via flexibility in equipment and process Asset utilization minimal finished good inventory Flexibility in Manufacturing process followed by packaging to provide end product Overall Equipment Effectiveness, OEE Page 16 printed at 9/14/2011

17 Mapping OMAC State Diagram to SFC Page 17 printed at 9/14/2011

18 PLCopen How? Page 18 printed at 9/14/2011

19 2011 Page 19 printed at 9/14/2011

20 PLCopen as a World-wide association Main Office in Europe Office in North America Office in China Office in Japan Page 20 printed at 9/14/2011

21 PLCopen Standardization in Industrial Control programming Organization General Meeting, BOM, MD TC1 TC2 TC3 TC4 TC5 TC6 PC1 PC2 PC3 PC4 PC5 TECHNICAL COMMITTEES PROMOTIONAL Page 21 printed at 9/14/2011

22 TC1 Standards: the basis IEC Harmonizing the way people look to control Page 22 printed at 9/14/2011

23 IEC Parts Project Title Valid till , Ed 2.0 General information, , Ed 3.0 Equipment requirements and tests, , Ed 3.0 Programming languages (Currently CDV - Committee Draft for Voting) , Ed 2.0 User guidelines (TR), , Ed 1.0 Communications, , Ed 1.0 Functional safety for PLC (Currently CDV - Committee Draft for Voting) , Ed 1.0 Fuzzy control programming, , Ed 2.0 Guidelines applic. & implem. progr. languages (TR), , Ed 1.0 Single-drop digital communication interface for small sensors and actuators (SDCI) aka IO-Link (Currently CD - Committee Draft) Page 23 printed at 9/14/2011

24 Why include Object Orientation in the 3 rd edition? Main reason: To link better to the scared resources of engineers in the future We d better adapt to them then vice versa Page 24 printed at 9/14/2011

25 IEC Harmonizing the way people look to control and PLCopen extends this basis Page 25 printed at 9/14/2011

26 TC2 Functions and Function Blocks - Harmonization of libraries of reusable components - Example: Motion Control Page 26 printed at 9/14/2011

27 PLCopen Motion Control : The merge of Logic and Motion Logic Motion Control PLCopen IEC Page 27 printed at 9/14/2011

28 Status PLCopen Motion Control Part 1 Function Blocks for Motion Control Part 2 Extensions Part 3 User Guidelines Part 4 Coordinated Motion Part 5 Homing procedures Part 6 Fluid Power Over 27 companies certified with over 36 products (check website for full list) Page 28 printed at 9/14/2011

29 Current PLCopen Motion Control Releases Merge of Part 1 and Part 2 Motion Control 2.0 Release of Part 5 Homing Update of Part 3 User Guidelines Part 6 Extension for Fluid Power Page 29 printed at 9/14/2011

30 The next step: Adding Safety (TC5) (at machine level) Logic Safety PLCopen Motion Control IEC Page 30 printed at 9/14/2011

31 Reasons to merge a changing environment Too many dialects, too many standards, including IEC and IEC 62061; Additional governmental requirements increasing the liability issues; No independent training material Trend to software solutions Too much done by machine builder themself Growing market expected Page 31 printed at 9/14/2011

32 Reasons to merge a changing environment The tendency to move from one motor (master axis) to multiple axes, driven by mechatronic solutions; The availability and acceptance of digital networks with safety functionality built-in; The inherent move from hardwired safety functionalities to software solutions; The increasing importance of safety related issues regarding personnel and machines. Page 32 printed at 9/14/2011

33 TC5 - Safety : New initiative Focused to material presses used for metal forming Extensions for Presses will be published as Part 5 MC_PathGearInMaster for press application Robot1 Robot2 Page 33 printed at 9/14/2011 Axis Press Motion (Single Axis Motion) MC_MoveAbsolute Axis MasterAxis Robot Motion (Axis Group Motion) MC_PathGearInMaster MasterAxis

34 PLCopen Combining Logic, Motion and Safety Providing Structuring, Decomposition, Reuse and less training Page 34 printed at 9/14/2011

35 TC3 - Benchmarking A benchmark is a reproducible, portable test to measure the performance of a given system in comparison to other systems Page 35 printed at 9/14/2011

36 TC3 - Benchmarking There are two main objectives to use a benchmark: 1. To estimate the performance of the PLC in your own application 2. To compare the performance of the PLC with other PLCs and find out the specific strength and weakness of a given system Page 36 printed at 9/14/2011

37 Benchmarking (TC3) Two different sets of benchmarks defined: 1. 5 different types of applications, which are typical for the usage of a PLC. 2. Measures each language feature of the IEC separately Page 37 printed at 9/14/2011

38 Communication (TC4) Page 38 printed at 9/14/2011

39 TC4 Communication OPC UA specifies HOW PLCopen specifies WHAT Page 39 printed at 9/14/2011

40 BaseVariableType OPC UA Part 5 BaseObject Type OPC UA Part 5 OPC-UA OPC-UA DI Configurable ObjectType TopologyElement Type BlockType DeviceType IEC OPC-UA CtrlTaskType CtrlConfigurationType CtrlResourceType CtrlProgramOrganizationUnitType Priority ConfigurableComponentsType: Resources CtrlProgramType CtrlFunctionBlockType Examples PLC_Z345 CPU_A100 Main FB_MotorControler ConfigurableComponentsType: Resources CPU_A100: CPU1 CPU_A100: CPU2 blocalmain FB_MotorControler: MotorControler1 FB_MotorControler: MotorControler2 ninput foutput blocal Page 40 printed at 9/14/2011

41 TC6 XML Opening up the development environments by specifying XML formats for IEC Page 41 printed at 9/14/2011

42 XML (TC6) Producer of graphical and logical information XML Other Development tool XML Development tool XML Other Development tool XML Consumer of graphical and logical information Page 42 printed at 9/14/2011

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45 The link to other simulation tools MatLab / Simulink Calculate / simulate complex behaviors like a 80 synchronized motors in one packaging machine or like the control of windmills Page 45 printed at 9/14/2011

46 PC2 - Training Important to create sufficient human resources capable to create and innovate Page 46 printed at 9/14/2011

47 Overview Page 47 printed at 9/14/2011

48 More Information... and to download the specifications (f.o.c) Free-of-Charge electronic Newsletter PLCopening (in English) Page 48 printed at 9/14/2011

49 Thanks! Help us helping you think about joining Page 49 printed at 9/14/2011