Automation Systems Discrete Event Control Systems and Networked Automation Systems
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1 Automation Systems Discrete Event Control Systems and Networked Automation Systems 4 th Lecture Realization of Logic Controllers: PLC
2 Introduction and Conception Standardization in Logic Control NEMA Programmable Controllers Committee formed (USA) GRAFCET (France) DIN 40719, Function Charts (Germany) NEMA ICS-3-304, Programmable Controllers (USA) IEC SC65A/WG6 formed DIN , Programmable Controller (Germany) IEC 65A(Sec)38, Programmable Controllers MIL-STD-1815 Ada (USA) IEC SC65A(Sec)49, PC Languages IEC SC65A(Sec)67 IEC 60848, Function Charts (Grafcet) IEC 64A(Sec)90 IEC IEC CD
3 IEC (DIN EN 61131) Part 1: General information Contains general definitions and typical functional features which distinguish a PLC from other systems. These include standard PLC properties, for example, the cyclic processing of the application program with stored image of the input and output values. CONCEPT Part 2: Equipment requirements and tests Defines the electrical, mechanical and functional demands on the devices as well as corresponding qualification tests. HARDWARE Part 3: Programming language Definition of basic software model. The PLC programming languages widely used throughout the world have been coordinated into a harmonised and future-oriented version. SOFTWARE Part 4: User guidelines A guide to help the PLC customers in all project phases of automation. Practiceoriented information is given on topics ranging from system analysis to maintenance. PROJECT HANDLING Part 5: Messaging service specification Communication between PLCs from different manufacturers with each other and with other devices. COMMUNICATION 125
4 Definition: PLC (according to DIN EN Part 1) A PLC is a digital electrical system used in manufacturing. It utilizes programmable memory to store practice-oriented control programs. Thus is suitable for implementation of specific functions such as combinatorial control, sequence control, time-, count- and arithmetic functions. Due to its special arrangement of digital or analog input/output, it is used for controlling various machines and processes.( ) 126
5 PLC-Scan Cycle 127
6 Process Image Memory for storing the signal values of inputs and outputs: Constant input signals during a program cycle. Output values are buffered, i.e. temporary changes during the cycle have no effects outwards. Maximum response time is about a double of cycle time Tc. i.e. there is a limitation of program length due to the given maximum response time. (typical value: 1000 instructions/ms ) Minimum time of a input signal (width of pulse) to be detected is about a cycle time Tc Due to program branches, the cycle time is not constant Monitoring of the cycle time Cycles are executed in regular time interval TI >Tc,max Special PLCs permit the direct access to the process signals (with out process image) Slowly 128
7 Minimum and Maximum Response Time 129
8 PLC-Hardware Hardwired Control PLC Programmable Logic Controller S1 S4 K1 K1 S1 S4 S2 S3 S2 PLC S3 K1 H1 H1 Function changing by: Re-wiring Re-programming 130
9 PLC in Automation Database Modem Process computer Visualization Fieldbus PLC PLC Actuators Sensors 131 Actuators Sensors
10 PLC-Structure Power supply CPU-Module Input-Module Output-Module Communication-Module Function-Module Operating unit optional 132
11 Power supply Supply of the operating voltage (normally 24V) Possibly additional transformer for Power-Module Battery for memory buffering 133
12 CPU-Module Processor Memory EPROM with Program (optional) Programming interface (optional) 134
13 Input-Module Digital inputs Analog inputs Specific inputs for: Temperature sensor, Resistor measuring etc. 135
14 Output-Module Digital outputs Analog outputs Relay outputs 136
15 Communication-Module Fieldbus (I, Profibus...) Industrial Ethernet GSM-Module Programming interface Serial interfaces (RS422, RS485...) 137
16 Function-Module Positioner Module Controller Module Image processing Module etc. 138
17 Operating Unit Operator Panels Touch Screens Text Displays Keyboard 139
18 Programmer Hand programmer: small project e.g. Changes local control only text based programming Display programmer: extensive functionality Debugging-possibility Clear representation graphic programming 140
19 Design Mini-PLC (e.g. Siemens Logo) Standard-PLC (e.g. Siemens S7-400) Slot or Software PLC 141
20 Summary of Lecture 4 Programmable Logic Controllers Hardware-Structure Execution Model Timing Behavior 142
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