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softplc_intro.ppt

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Transcript

  • 1.  
  • 2. Company Overview
  • 3. SoftPLC Corp. - A Brief History
    • 1983: Tele-Denken Resources Founded
      • By former A-B employees
    • 1984: TOPDOC PLC programming/documentation software
      • For PLC-2, then PLC-3 and PLC-5
    • 1985: SoftWIRES PLC emulation/simulation & process modeling
      • To run A-B Logic in a computer
    • 1988: SoftPLC Open architecture control software
      • A combination of existing proven technologies & new ideas, based on PLC-5 SoftWIRES
    • 1993: SoftPLC Processor Systems
      • PC & I/O hardware catches up to software technology
      • Combination of industrial computers and embedded SoftPLC software
    • 1996: Company renamed to SoftPLC Corporation
    • 1997: SoftPLC In Tealware
      • Traditional PLC hardware form factor, industrial I/O with SoftPLC software features
    • 2000: Released Linux Version
    • 2009: Release of Smart ™Controllers
      • Including SoftPLC brand of A-B RIO protocol interface
  • 4. SoftPLC–Innovators & Visionaries
    • Many industry first software inventions
    • Embrace open technologies
    • Apply technologies developed for fast moving software/computer industries to controls industry
      • Reliability and deterministic performance always comes first
  • 5. SoftPLC–Customer Partnerships
    • Privately held, small business
      • Treasure customer feedback
      • Focused, experts in our chosen area
    • Excellent customer service & support
      • "I can't remember a time in the last 20 years that a vendor went to the lengths that SoftPLC Corp. did to ensure our projects were a success.” (US Army Corps of Engineers)
      • Worldwide network of distributors and system integrators
      • No “case numbers”, responsive phone/email support from field experienced application engineers/ programmers
  • 6. Products
  • 7. SoftPLC Corp. Products
    • SoftPLC ® Controllers
      • SoftPLC is the runtime control software (“firmware”) included in each controller
      • Stand-Alone Controllers - use w/ remote I/O or PC-bus I/O
        • SoftPLC Hardbooks & Processors
      • DIN/Rack-Mounted Controllers - traditional PLC form factor
        • Smart SoftPLC
        • SoftPLC In Tealware
    • TOPDOC ®
      • The configuration/application development/troubleshooting software for SoftPLC based systems
  • 8. SoftPLC Products
    • Industrial I/O
      • Tealware – modular rack mounted system for local systems or remote I/O
      • A-Series – low cost serial/ethernet/wireless I/O
      • Drivers and interface cards to industrial networks
        • Profibus, DeviceNet, CANopen, SERCOS, A-B RIO, etc.
    • Auxiliary Equipment
      • Power protection
      • Ethernet switches, fiber converters, etc.
    • Gatecraft Industrial Firewalls
      • Network Protection, Modem Gateway, Wireless Access Point
  • 9. SoftPLC CPU Options Smart ™ SoftPLC SoftPLC In Tealware TM SoftPLC Hardbook Processors TM
  • 10. Smart SoftPLC
    • DIN rail mount CPU w/ 4 serial ports, 2 ethernet interfaces (fiber option), modem or RS-485 port option
    • Selectable daughter board interfaces
      • 3 local Tealware Modules
      • Tealware LocalPorts Board
      • PC/104 board
      • A-B RIO interface (mid-2009 release)
    • Built-in ethernet switch
  • 11. SoftPLC In Tealware
    • Compact backplane mount CPU’s & wide range of I/O modules
      • Traditional PLC packaging
      • Can use Tealware I/O w/ industrial PC’s
        • Local, Remote or Ethernet configurations
      • Hot Standby Option
  • 12. Tealware CPU Modules
    • CPU resides in single slot on base
    • 32MB RAM, 32MB Flash
    • (2) serial ports, 10MB ethernet port
    • 128 Kwords battery-backed RAM retentive memory area
    • SoftPIPE TM Remote I/O interface port (optional)
  • 13. Hardbook SoftPLC Processors
    • Compact Stand-Alone CPU’s
      • Dual Ethernet ports
        • Ideal for Ethernet I/O
      • Some models have PCI slot(s)
        • Profibus, DeviceNet….
        • Add’l Serial Ports
        • Motion Control Cards
        • A-B RIO Interface Cards
      • USB, Serial
      • Fanless, diskless
  • 14. Tiny Hardbook Processor
    • Small, low cost industrial CPU
      • 1 Ethernet, 2 serial, 3 USB ports
      • 802.11GB Wireless option
      • Fanless, diskless
  • 15. SoftPLC Processors
    • Node-box Industrial CPU’s
      • 486, Pentium & Celeron class CPU’s
      • 2, 4, 6, 8 slot enclosures or 19” rack mount
      • ISA and/or PCI bus
      • Good when multiple add-in interface cards are required
  • 16. I/O Tealware TM Remote Bus A Series
  • 17. I/O Options
      • Tealware - Local & Remote
      • Modbus TCP
      • A-B RIO -1771, SLC-500 (1746), Flex, Block & compatible devices
      • Profibus, DeviceNet, CANOpen, Interbus, etc.
      • Variety of PC I/O (eg: PCI, PC/104 bus)
      • Serial/USB & Wireless I/O
  • 18. Tealware I/O Modules
    • Wide variety of digital, analog, & specialty modules
    • Detachable terminal block for easy module replacement w/o re-wiring
    • Diagnostic LED’s
    • Wide angle swing connector - easy installation
    • Digital modules hot swappable under power
    • IEEE C37.90.1 Surge Withstand
  • 19. Local Systems
    • Up to 3 expansion bases per local interface
      • 6 or 8 I/O module Local Expansion bases
    • Max. 30 feet from first base to last base
    • Smart CPU w/ Localports Daughter Board
      • Up to 12 expansion racks per Smart CPU
    • Tealware CPU in Base
      • 4, 6, or 8 modules in CPU Base plus up to 3 expansion bases
  • 20. Remote I/O
    • Up to 15 remote drops in addition to local drop
      • Up to 1024 I/O per drop (x 16 = 16K I/O capacity)
    • Two Options: (Fiber options available for both network types)
      • Ethernet ModbusTCP
      • SoftPIPE TM (Hot Standby applications)
    • Smart CPU can be Ethernet Adapter
      • 3 modules/Smart with 3 module daughter board
      • 12 racks/Smart with local ports daughter board
    • Hardbook CPU to Tealware Ethernet I/O
      • Remote Base (4, 6, or 8 slots) with Adapter (EIOA11) plus up to 3 expansion bases
      • Up to 64 Adapters per Hardbook
  • 21. Example Configurations
  • 22. Example Configurations
    • Hardbook/Processor with Bus I/O
    BASE0x (Backplane) + Profibus ASI DeviceNet Interbus CANOpen SERCOS etc. Hilscher Interface Card
  • 23. Example Configurations
    • Hardbook/Processor with A-B Remote I/O
    BASE0x (Backplane) + 1785-PKTX/PKTXD* 1771-ASB or other A-B RIO Adapter * A SoftPLC interface board for the Smart CPU to be developed in 2009 as an alternative to this solution
  • 24. Example Configurations
    • Hardbook/Processor with Tealware I/O
      • or other ethernet I/O on ModbusTCP
    BASE0x (Backplane) PWSxx (Power Supply) EIOA11 I/O Adapter I/O Modules Ethernet ModbusTCP
  • 25. Example Configurations
    • Smart SoftPLC w/ 3 module daughter board
    BASE0x (Backplane) I/O Modules
  • 26. Example Configurations
    • SoftPLC In Tealware System
    BASE0x (Backplane) PWSxx (Power Supply) SPLC-2A-y (CPU) I/O Modules
  • 27. Open Architecture Control Software
  • 28. SoftPLC Architecture
  • 29. What is SoftPLC?
    • SoftPLC control software turns an industrial computer into an open architecture automation controller
      • Embedded software, runs on dedicated system
      • “ Headless” system (eg: no monitor, keyboard…)
    • Features of proprietary PLC’s (I/O control, PID) PLUS features of computers (flexibility, networking, speed)
  • 30. Operation
    • SoftPLC turns PC into PLC, it is not PC-based control
      • Deterministic scan (“hard” realtime)
      • Online run-mode program changes
      • Troubleshooting tools like PLC (Runtime Fault detection/correction, I/O Forcing)
      • Runs on embedded Linux, no Windows
  • 31. Data Table
    • PLC-5/SLC-500 Data Table Addressing
        • Binary, integer, floating point, timers, counters, PID, strings and others
    • 10,000 Data Table Files of 10,000 elements each *
      • Status File for fault analysis, system time/date, etc.
      • Output/input file size determined by “size” of runtime purchased (LT, 1K, 2K or 8K)
    * except for O, I, S files
  • 32. User Logic
    • PLC-5/SLC-500 ladder logic programming
      • Up to 10,000 subroutines of 10,000 rungs each
      • Instruction set combines PLC-5, SLC-500, and unique SoftPLC functions
    • Logic documentation stored in SoftPLC
  • 33. TOPDOC Loadable Modules (TLM’s)
    • Loadable functions can be instructions or drivers
      • Created using SoftPLC Programmer’s Toolkit
      • Written in C++/Java
    • Example SoftPLC provided TLM’s
      • .001 TIMERS - Very fast/high resolution timing
      • COMGENIUS – ASCII/Serial Communications
      • LOG DATA - Selected data to file
  • 34. Other Example TLM’s
    • Computations
      • Fourier transforms, load balancing, . . .
    • Special “non-PLC” functions
      • DCS process blocks, SENDMAIL
    • Device interfaces
      • Modbus, Motion Controller Interfaces, PC I/O boards, Intelligent UPS
    • Proprietary logic embedded in functions
  • 35. Remote File Access
    • SoftPLC can be a file access client to a server (eg: Microsoft Windows File Sharing, Samba, NFS, Novell Netware)
    • This means SoftPLC can easily read or write production data to a remote disk
      • Databases (eg: SQL, Oracle)
      • Data Files/Reports/XML
  • 36. “Properties” Memory Area
    • Internal relational database
    • Ladder instructions to read and/or process data
    • Ideal for warehousing, sorting, recipe, RFID applications
  • 37. I/O Support
    • Total digital I/O maximum 16K
    • Analog I/O above and beyond digital total
    • Up to 16 I/O drivers can be loaded at once
    • Available Drivers:
      • Tealware local & remote
      • Modbus TCP
      • A-B RIO -1771, SLC-500 (1746), Flex, Block & compatible devices
      • Profibus, DeviceNet, Interbus, etc.
      • Variety of PC I/O (ISA, PCI, PC/104 bus)
      • Serial & Wireless I/O (ICO-7000 Series)
      • Third party drivers also available
  • 38. Communications
    • Networks for HMI/SCADA, program monitoring, PLC peer-to-peer, etc.
    • SoftPLC appears as PLC-5
      • Virtually all HMI/SCADA and many other 3rd party devices supported
    • Up to 32 networks per system
      • Ethernet
      • Serial (DF1)
      • Data Highway Plus or Data Highway
  • 39. FTP/SSH Servers
    • Used for TCP/IP exchanges of files, system maintenance
    • Use with any FTP/SSH client (many are free)
    • Example uses:
      • Update/backup SoftPLC configurations & files
      • View/retrieve SoftPLC files, documentation
      • Run command line programs
  • 40. Syslog
    • A complete log record for user messages
      • User Messages include operating mode, startup status or faults, runtime faults
    • Syslog messages can be directed to any output (eg: ram fifo, local file/disk/ramdisk, remote file on a windows PC)
    • Helps users comply with FDA 21CFR11
  • 41. Web Server Module
    • Add-on software module for SoftPLC
    • Allows browsers to access SoftPLC data
      • Applets (run in browser, but reside in SoftPLC)
      • Servlets (run in SoftPLC, good for remote applications, secure)
  • 42. Gatecraft™ Firewall Technology
    • Feature-rich industrial firewall
      • Stateful inspection, NAT/IP masquerading, blacklisting
      • Multiple VPN tunnels
      • Ethernet-to-Ethernet, Modem, Wireless options
    • Runs embedded in SoftPLC
  • 43. SoftPLC Architecture
  • 44. A-B Conversions
  • 45. A-B Conversions
    • Most convert 90-100%
      • SL i C k Convert - $195 web based utility to convert SLC-500 applications to SoftPLC
      • PLC-2, PLC-5 conversion services from SoftPLC
      • SoftLogix, PLC-5/250 & PLC-3 conversion services quoted per application
  • 46. A-B Conversions
    • PLC-5
      • Send TEXT version of logic and documentation to SoftPLC for conversion ($150 minimum fee)
      • Use a Hardbook-PCI or a SoftPLC Processor with 1785-PKTX card
      • Replace PLC-5 CPU w/ 1771-ASB Remote I/O Adapter
  • 47. A-B Conversions
    • PLC-2/30, -2/20
      • Replace CPU with Hardbook-PCI or SoftPLC Processor with 1785-PKTX card
      • Send program and documentation to SoftPLC
        • Upload logic with TOPDOC PLC-2
        • Text version of documentation files if available
        • $750 fee includes loan of TOPDOC PLC-2 package and conversion services
  • 48. A-B Conversions
    • PLC-2 with Remote I/O
      • Existing I/O can remain
    • PLC-2 with Local I/O
      • Change 1771-AL Adapters to 1771-ASB/ASC Adapters
      • Racks & Power Supplies must be Series B
  • 49. A-B Conversions
    • Mini-PLC-2
      • Cost of 1785-PKTX and Remote I/O Adapter makes upgrade often not cost justifiable
      • May be opportunity to replace entire system instead
      • Especially if older 8 point I/O modules were used
  • 50. A-B Conversions
    • SLC-500
      • Customer uses SliCk Convert Utility on SoftPLC Website to convert logic & documentation
      • Conversion provides equivalent Tealware I/O modules
    • If customer wants to re-use SLC I/O:
      • Use Hardbook-PCI or SoftPLC Processor with 1785-PKTX interface card
      • Replace CPU w/ 1747-ASB Remote I/O Adapter
  • 51. A-B Conversions
    • Any system using Flex or block I/O, same principle applies
      • 1794-ASB Remote I/O Adapter
  • 52.