Automating manufacturing systems with plc

page ix 25.2 25.3 25.4 25.5 25.6 25.7 25.8 26. INTRODUCTION COMMERCIAL CONTROLLERS REFERENCES SUMMARY PRACTICE PROBLEMS PRACTICE PROBLEM SOLUTIONS ASSIGNMENT PROBLEMS 26.1 26.7 26.7 26.7 26.8 26.8 26.8 SERIAL COMMUNICATION . . . . . . . . . . . . . . . . . . . . . . . . . . 27.1 27.1 27.2 27.3 27.4 27.5 27.6 27.7 27.8 28. 25.4 25.5 25.5 25.6 25.8 25.12 25.14 25.14 25.17 25.20 25.20 25.21 25.26 FUZZY LOGIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.1 26.1 26.2 26.3 26.4 26.5 26.6 26.7 27. CONTROL OF LOGICAL ACTUATOR SYSTEMS CONTROL OF CONTINUOUS ACTUATOR SYSTEMS 25.3.1 Block Diagrams 25.3.2 Feedback Control Systems 25.3.3 Proportional Controllers 25.3.4 PID Control Systems DESIGN CASES 25.4.1 Oven Temperature Control 25.4.2 Water Tank Level Control SUMMARY PRACTICE PROBLEMS PRACTICE PROBLEM SOLUTIONS ASSIGNMENT PROBLEMS INTRODUCTION SERIAL COMMUNICATIONS 27.2.1 RS-232 ASCII Functions PARALLEL COMMUNICATIONS DESIGN CASES 27.4.1 PLC Interface To a Robot SUMMARY PRACTICE PROBLEMS PRACTICE PROBLEM SOLUTIONS ASSIGNMENT PROBLEMS 27.1 27.2 27.5 27.9 27.13 27.14 27.14 27.15 27.15 27.16 27.18 NETWORKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28.1 28.1 28.2 INTRODUCTION 28.1.1 Topology 28.1.2 OSI Network Model 28.1.3 Networking Hardware 28.1.4 Control Network Issues NETWORK STANDARDS 28.2.1 Devicenet 28.1 28.2 28.3 28.5 28.7 28.8 28.8 page x 28.3 28.4 28.5 28.6 28.7 28.8 28.9 29. 28.12 28.13 28.14 28.15 28.15 28.16 28.16 28.20 28.22 28.22 28.23 28.23 28.24 28.28 INTERNET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.1 29.1 29.2 29.3 29.4 29.5 29.6 30. 28.2.2 CANbus 28.2.3 Controlnet 28.2.4 Ethernet 28.2.5 Profibus 28.2.6 Sercos PROPRIETARY NETWORKS 28.3.1 Data Highway NETWORK COMPARISONS DESIGN CASES 28.5.1 Devicenet SUMMARY PRACTICE PROBLEMS PRACTICE PROBLEM SOLUTIONS ASSIGNMENT PROBLEMS INTRODUCTION 29.1.1 Computer Addresses IPV6 29.1.2 Phone Lines 29.1.3 Mail Transfer Protocols 29.1.4 FTP - File Transfer Protocol 29.1.5 HTTP - Hypertext Transfer Protocol 29.1.6 Novell 29.1.7 Security Firewall IP Masquerading 29.1.8 HTML - Hyper Text Markup Language 29.1.9 URLs 29.1.10 Encryption 29.1.11 Compression 29.1.12 Clients and Servers 29.1.13 Java 29.1.14 Javascript 29.1.15 CGI 29.1.16 ActiveX 29.1.17 Graphics DESIGN CASES 29.2.1 Remote Monitoring System SUMMARY PRACTICE PROBLEMS PRACTICE PROBLEM SOLUTIONS ASSIGNMENT PROBLEMS 29.1 29.2 29.3 29.3 29.3 29.4 29.4 29.4 29.5 29.5 29.5 29.5 29.6 29.6 29.7 29.7 29.9 29.9 29.9 29.9 29.10 29.10 29.10 29.11 29.11 29.11 29.11 HUMAN MACHINE INTERFACES (HMI) . . . . . . . . . . . . . . . 30.1 page xi 30.1 30.2 30.3 30.4 30.5 30.6 30.7 31. 31.3 31.4 31.5 31.6 31.7 31.8 31.9 INTRODUCTION ELECTRICAL WIRING DIAGRAMS 31.2.1 Selecting Voltages 31.2.2 Grounding 31.2.3 Wiring 31.2.4 Suppressors 31.2.5 PLC Enclosures 31.2.6 Wire and Cable Grouping FAIL-SAFE DESIGN SAFETY RULES SUMMARY REFERENCES SUMMARY PRACTICE PROBLEMS PRACTICE PROBLEM SOLUTIONS ASSIGNMENT PROBLEMS 31.1 31.1 31.8 31.9 31.12 31.13 31.14 31.16 31.17 31.18 31.20 31.20 31.20 31.20 31.20 SOFTWARE ENGINEERING . . . . . . . . . . . . . . . . . . . . . . . . . . 32.1 32.1 32.2 32.3 32.4 32.5 32.6 32.7 32.8 32.9 32.10 32.11 33. 30.1 30.2 30.3 30.3 30.4 30.4 30.4 ELECTRICAL DESIGN AND CONSTRUCTION . . . . . . . . . . 31.1 31.1 31.2 32. INTRODUCTION HMI/MMI DESIGN DESIGN CASES SUMMARY PRACTICE PROBLEMS PRACTICE PROBLEM SOLUTIONS ASSIGNMENT PROBLEMS INTRODUCTION 32.1.1 Fail Safe Design DEBUGGING 32.2.1 Troubleshooting 32.2.2 Forcing PROCESS MODELLING PROGRAMMING FOR LARGE SYSTEMS 32.4.1 Developing a Program Structure 32.4.2 Program Verification and Simulation DOCUMENTATION COMMISIONING REFERENCES SUMMARY PRACTICE PROBLEMS PRACTICE PROBLEM SOLUTIONS ASSIGNMENT PROBLEMS 32.1 32.1 32.2 32.3 32.3 32.3 32.8 32.8 32.11 32.12 32.20 32.20 32.21 32.21 32.21 32.21 SELECTING A PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1 page xii 33.1 33.2 33.3 33.4 33.5 33.6 34. 33.1 33.6 33.9 33.10 33.10 33.10 FUNCTION REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.1 34.1 34.2 35. INTRODUCTION SPECIAL I/O MODULES SUMMARY PRACTICE PROBLEMS PRACTICE PROBLEM SOLUTIONS ASSIGNMENT PROBLEMS FUNCTION DESCRIPTIONS 34.1.1 General Functions 34.1.2 Program Control 34.1.3 Timers and Counters 34.1.4 Compare 34.1.5 Calculation and Conversion 34.1.6 Logical 34.1.7 Move 34.1.8 File 34.1.9 List 34.1.10 Program Control 34.1.11 Advanced Input/Output 34.1.12 String DATA TYPES 34.1 34.1 34.3 34.5 34.10 34.14 34.20 34.21 34.22 34.27 34.30 34.34 34.37 34.42 COMBINED GLOSSARY OF TERMS . . . . . . . . . . . . . . . . . . . 35.1 35.1 35.2 35.3 35.4 35.5 35.6 35.7 35.8 35.9 35.10 35.11 35.12 35.13 35.14 35.15 35.16 35.17 35.18 35.19 35.20 A B C D E F G H I J K L M N O P Q R S T 35.1 35.2 35.5 35.9 35.11 35.12 35.13 35.14 35.14 35.16 35.16 35.16 35.17 35.19 35.20 35.21 35.23 35.23 35.25 35.27 page xiii 35.21 35.22 35.23 35.24 35.25 35.26 36. 35.28 35.29 35.29 35.30 35.30 35.30 PLC REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36.1 36.1 36.2 36.3 37. U V W X Y Z SUPPLIERS PROFESSIONAL INTEREST GROUPS PLC/DISCRETE CONTROL REFERENCES 36.1 36.2 36.2 GNU Free Documentation License . . . . . . . . . . . . . . . . . . . . . . . 37.1 37.1 37.2 37.3 37.4 37.5 37.6 37.7 37.8 37.9 37.10 37.11 37.12 PREAMBLE APPLICABILITY AND DEFINITIONS VERBATIM COPYING COPYING IN QUANTITY MODIFICATIONS COMBINING DOCUMENTS COLLECTIONS OF DOCUMENTS AGGREGATION WITH INDEPENDENT WORKS TRANSLATION TERMINATION FUTURE REVISIONS OF THIS LICENSE How to use this License for your documents 37.1 37.1 37.2 37.3 37.3 37.5 37.5 37.6 37.6 37.6 37.6 37.7 plc wiring - 1.1 PREFACE Some sections are still in point form. The last major task of this book will be to write the preface to reflect the book contents and all of the features. Control systems apply artificial means to change the behavior of a system. The type of control problem often determines the type of control system that can be used. Each controller will be designed to meet a specific objective. The major types of control are shown in Figure 1.1. CONTROL CONTINUOUS LINEAR DISCRETE NON_LINEAR CONDITIONAL e.g. MRAC e.g. PID BOOLEAN SEQUENTIAL EVENT BASED TEMPORAL e.g. COUNTERS EXPERT SYSTEMS e.g. TIMERS e.g. FUZZY LOGIC Figure 1.1 Control Dichotomy • Continuous - The values to be controlled change smoothly. e.g. the speed of a car. • Logical - The value to be controlled are easily described as on-off. e.g. the car motor is on-off. NOTE: all systems are continuous but they can be treated as logical for simplicity. e.g. “When I do this, that always happens!” For example, when the power is turned on, the press closes! • Linear - Can be described with a simple differential equation. This is the preferred starting point for simplicity, and a common approximation for real world problems. e.g. A car can be driving around a track and can pass same the same spot at a constant velocity. But, the longer the car runs, the mass decreases, and it travels faster, but requires less gas, etc. Basically, the math gets