Industrial Control Systems - PLC

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Industrial Control Systems - PLC

  1. 1. Industrial Control Behzad Samadi Department of Electrical Engineering Amirkabir University of Technology Winter 2011 Tehran, Iran Behzad Samadi (Amirkabir University) Industrial Control 1 / 1
  2. 2. Programmable Logic Controllers Outline: Introduction [Jack, 2008] Behzad Samadi (Amirkabir University) Industrial Control 2 / 1
  3. 3. Programmable Logic Controllers Outline: Introduction Hardware [Jack, 2008] Behzad Samadi (Amirkabir University) Industrial Control 2 / 1
  4. 4. Programmable Logic Controllers Outline: Introduction Hardware Programming [Jack, 2008] Behzad Samadi (Amirkabir University) Industrial Control 2 / 1
  5. 5. Programmable Logic Controllers Outline: Introduction Hardware Programming Ladder Diagrams [Jack, 2008] Behzad Samadi (Amirkabir University) Industrial Control 2 / 1
  6. 6. Programmable Logic Controllers Outline: Introduction Hardware Programming Ladder Diagrams Instruction List [Jack, 2008] Behzad Samadi (Amirkabir University) Industrial Control 2 / 1
  7. 7. Programmable Logic Controllers Outline: Introduction Hardware Programming Ladder Diagrams Instruction List Structured Text [Jack, 2008] Behzad Samadi (Amirkabir University) Industrial Control 2 / 1
  8. 8. Programmable Logic Controllers Outline: Introduction Hardware Programming Ladder Diagrams Instruction List Structured Text Sequential Function Chart [Jack, 2008] Behzad Samadi (Amirkabir University) Industrial Control 2 / 1
  9. 9. Programmable Logic Controllers Outline: Introduction Hardware Programming Ladder Diagrams Instruction List Structured Text Sequential Function Chart Function Block Diagram [Jack, 2008] Behzad Samadi (Amirkabir University) Industrial Control 2 / 1
  10. 10. Programmable Logic Controllers Definition: A digitally operating electronic system, designed for use in an industrial environment, which uses memory for the internal storage of user-oriented instructions for implementing specific functions such as logic, sequencing, timing, counting and arithmetic to control, through digital or analog inputs and outputs, various types of machines or processes. [Fes, 2002] Behzad Samadi (Amirkabir University) Industrial Control 3 / 1
  11. 11. Programmable Logic Controllers What is a PLC? A programmable logic controller (PLC) is a specialized computer to perform logic functions for machine control. PLCs are used to implement logic functions such as not allowing a drill press to start unless the operator has one hand on each of the two start switches. Such control functions used to be implemented using relays. PLCs revolutionized this by allowing the control logic to be implemented using software. [Fes, 2002] Behzad Samadi (Amirkabir University) Industrial Control 4 / 1
  12. 12. Programmable Logic Controllers PLC Origin: Developed to replace relays in the late 1960s Costs dropped and became popular by 1980s Now used in many industrial designs [Jack, 2008] Behzad Samadi (Amirkabir University) Industrial Control 5 / 1
  13. 13. Programmable Logic Controllers Advantages of using PLCs: Highly reliable [Fes, 2002] Behzad Samadi (Amirkabir University) Industrial Control 6 / 1
  14. 14. Programmable Logic Controllers Advantages of using PLCs: Highly reliable Highly versatile (universal applicability) [Fes, 2002] Behzad Samadi (Amirkabir University) Industrial Control 6 / 1
  15. 15. Programmable Logic Controllers Advantages of using PLCs: Highly reliable Highly versatile (universal applicability) Simple troubleshooting [Fes, 2002] Behzad Samadi (Amirkabir University) Industrial Control 6 / 1
  16. 16. Programmable Logic Controllers Advantages of using PLCs: Highly reliable Highly versatile (universal applicability) Simple troubleshooting Simple installation [Fes, 2002] Behzad Samadi (Amirkabir University) Industrial Control 6 / 1
  17. 17. Programmable Logic Controllers Advantages of using PLCs: Highly reliable Highly versatile (universal applicability) Simple troubleshooting Simple installation Quick modification of the program (highly flexible) [Fes, 2002] Behzad Samadi (Amirkabir University) Industrial Control 6 / 1
  18. 18. Programmable Logic Controllers Advantages of using PLCs: Highly reliable Highly versatile (universal applicability) Simple troubleshooting Simple installation Quick modification of the program (highly flexible) Capable of tasks not possible with relays before: [Fes, 2002] Behzad Samadi (Amirkabir University) Industrial Control 6 / 1
  19. 19. Programmable Logic Controllers Advantages of using PLCs: Highly reliable Highly versatile (universal applicability) Simple troubleshooting Simple installation Quick modification of the program (highly flexible) Capable of tasks not possible with relays before: calculation [Fes, 2002] Behzad Samadi (Amirkabir University) Industrial Control 6 / 1
  20. 20. Programmable Logic Controllers Advantages of using PLCs: Highly reliable Highly versatile (universal applicability) Simple troubleshooting Simple installation Quick modification of the program (highly flexible) Capable of tasks not possible with relays before: calculation information exchange [Fes, 2002] Behzad Samadi (Amirkabir University) Industrial Control 6 / 1
  21. 21. Programmable Logic Controllers Advantages of using PLCs: Highly reliable Highly versatile (universal applicability) Simple troubleshooting Simple installation Quick modification of the program (highly flexible) Capable of tasks not possible with relays before: calculation information exchange text and graphic display [Fes, 2002] Behzad Samadi (Amirkabir University) Industrial Control 6 / 1
  22. 22. Programmable Logic Controllers Advantages of using PLCs: Highly reliable Highly versatile (universal applicability) Simple troubleshooting Simple installation Quick modification of the program (highly flexible) Capable of tasks not possible with relays before: calculation information exchange text and graphic display data processing [Fes, 2002] Behzad Samadi (Amirkabir University) Industrial Control 6 / 1
  23. 23. Programmable Logic Controllers Advantages of using PLCs: Highly reliable Highly versatile (universal applicability) Simple troubleshooting Simple installation Quick modification of the program (highly flexible) Capable of tasks not possible with relays before: calculation information exchange text and graphic display data processing networking [Fes, 2002] Behzad Samadi (Amirkabir University) Industrial Control 6 / 1
  24. 24. Programmable Logic Controllers Advantages of using PLCs: Highly reliable Highly versatile (universal applicability) Simple troubleshooting Simple installation Quick modification of the program (highly flexible) Capable of tasks not possible with relays before: calculation information exchange text and graphic display data processing networking Low space requirement [Fes, 2002] Behzad Samadi (Amirkabir University) Industrial Control 6 / 1
  25. 25. Programmable Logic Controllers Advantages of using PLCs: Highly reliable Highly versatile (universal applicability) Simple troubleshooting Simple installation Quick modification of the program (highly flexible) Capable of tasks not possible with relays before: calculation information exchange text and graphic display data processing networking Low space requirement Low power consumption [Fes, 2002] Behzad Samadi (Amirkabir University) Industrial Control 6 / 1
  26. 26. Programmable Logic Controllers Advantages of using PLCs: Highly reliable Highly versatile (universal applicability) Simple troubleshooting Simple installation Quick modification of the program (highly flexible) Capable of tasks not possible with relays before: calculation information exchange text and graphic display data processing networking Low space requirement Low power consumption High processing speed [Fes, 2002] Behzad Samadi (Amirkabir University) Industrial Control 6 / 1
  27. 27. Programmable Logic Controllers Advantages of using PLCs: Highly reliable Highly versatile (universal applicability) Simple troubleshooting Simple installation Quick modification of the program (highly flexible) Capable of tasks not possible with relays before: calculation information exchange text and graphic display data processing networking Low space requirement Low power consumption High processing speed No moving parts, hence no wearing parts [Fes, 2002] Behzad Samadi (Amirkabir University) Industrial Control 6 / 1
  28. 28. Programmable Logic Controllers Disadvantages of using PLCs: High initial cost ( for a simple process ) [Fes, 2002] Behzad Samadi (Amirkabir University) Industrial Control 7 / 1
  29. 29. Programmable Logic Controllers Disadvantages of using PLCs: High initial cost ( for a simple process ) Sensitive to dust, high temperature and high humidity [Fes, 2002] Behzad Samadi (Amirkabir University) Industrial Control 7 / 1
  30. 30. Programmable Logic Controllers Disadvantages of using PLCs: High initial cost ( for a simple process ) Sensitive to dust, high temperature and high humidity Repair must be made by a qualified personnel [Fes, 2002] Behzad Samadi (Amirkabir University) Industrial Control 7 / 1
  31. 31. Programmable Logic Controllers Disadvantages of using PLCs: High initial cost ( for a simple process ) Sensitive to dust, high temperature and high humidity Repair must be made by a qualified personnel Not very widespread [Fes, 2002] Behzad Samadi (Amirkabir University) Industrial Control 7 / 1
  32. 32. Programmable Logic Controllers Disadvantages of using PLCs: High initial cost ( for a simple process ) Sensitive to dust, high temperature and high humidity Repair must be made by a qualified personnel Not very widespread No uniform programming language [Fes, 2002] Behzad Samadi (Amirkabir University) Industrial Control 7 / 1
  33. 33. Programmable Logic Controllers International Standard for PLC The IEC 1131 standards were developed to be a common and open framework for PLC architecture, agreed to by many standards groups and manufacturers. [Jack, 2008] Behzad Samadi (Amirkabir University) Industrial Control 8 / 1
  34. 34. Programmable Logic Controllers International Standard for PLC The IEC 1131 standards were developed to be a common and open framework for PLC architecture, agreed to by many standards groups and manufacturers. They were initially approved in 1992, and since then they have been reviewed as the IEC-61131 standards. [Jack, 2008] Behzad Samadi (Amirkabir University) Industrial Control 8 / 1
  35. 35. Programmable Logic Controllers International Standard for PLC The IEC 1131 standards were developed to be a common and open framework for PLC architecture, agreed to by many standards groups and manufacturers. They were initially approved in 1992, and since then they have been reviewed as the IEC-61131 standards. The main components of the standard are: [Jack, 2008] Behzad Samadi (Amirkabir University) Industrial Control 8 / 1
  36. 36. Programmable Logic Controllers International Standard for PLC The IEC 1131 standards were developed to be a common and open framework for PLC architecture, agreed to by many standards groups and manufacturers. They were initially approved in 1992, and since then they have been reviewed as the IEC-61131 standards. The main components of the standard are: IEC 61131-1 Overview [Jack, 2008] Behzad Samadi (Amirkabir University) Industrial Control 8 / 1
  37. 37. Programmable Logic Controllers International Standard for PLC The IEC 1131 standards were developed to be a common and open framework for PLC architecture, agreed to by many standards groups and manufacturers. They were initially approved in 1992, and since then they have been reviewed as the IEC-61131 standards. The main components of the standard are: IEC 61131-1 Overview IEC 61131-2 Requirements and Test Procedures [Jack, 2008] Behzad Samadi (Amirkabir University) Industrial Control 8 / 1
  38. 38. Programmable Logic Controllers International Standard for PLC The IEC 1131 standards were developed to be a common and open framework for PLC architecture, agreed to by many standards groups and manufacturers. They were initially approved in 1992, and since then they have been reviewed as the IEC-61131 standards. The main components of the standard are: IEC 61131-1 Overview IEC 61131-2 Requirements and Test Procedures IEC 61131-3 Data types and programming [Jack, 2008] Behzad Samadi (Amirkabir University) Industrial Control 8 / 1
  39. 39. Programmable Logic Controllers International Standard for PLC The IEC 1131 standards were developed to be a common and open framework for PLC architecture, agreed to by many standards groups and manufacturers. They were initially approved in 1992, and since then they have been reviewed as the IEC-61131 standards. The main components of the standard are: IEC 61131-1 Overview IEC 61131-2 Requirements and Test Procedures IEC 61131-3 Data types and programming IEC 61131-4 User Guidelines [Jack, 2008] Behzad Samadi (Amirkabir University) Industrial Control 8 / 1
  40. 40. Programmable Logic Controllers International Standard for PLC The IEC 1131 standards were developed to be a common and open framework for PLC architecture, agreed to by many standards groups and manufacturers. They were initially approved in 1992, and since then they have been reviewed as the IEC-61131 standards. The main components of the standard are: IEC 61131-1 Overview IEC 61131-2 Requirements and Test Procedures IEC 61131-3 Data types and programming IEC 61131-4 User Guidelines IEC 61131-5 Communications [Jack, 2008] Behzad Samadi (Amirkabir University) Industrial Control 8 / 1
  41. 41. Programmable Logic Controllers International Standard for PLC The IEC 1131 standards were developed to be a common and open framework for PLC architecture, agreed to by many standards groups and manufacturers. They were initially approved in 1992, and since then they have been reviewed as the IEC-61131 standards. The main components of the standard are: IEC 61131-1 Overview IEC 61131-2 Requirements and Test Procedures IEC 61131-3 Data types and programming IEC 61131-4 User Guidelines IEC 61131-5 Communications IEC 61131-6 Functional Safety [Jack, 2008] Behzad Samadi (Amirkabir University) Industrial Control 8 / 1
  42. 42. Programmable Logic Controllers International Standard for PLC The IEC 1131 standards were developed to be a common and open framework for PLC architecture, agreed to by many standards groups and manufacturers. They were initially approved in 1992, and since then they have been reviewed as the IEC-61131 standards. The main components of the standard are: IEC 61131-1 Overview IEC 61131-2 Requirements and Test Procedures IEC 61131-3 Data types and programming IEC 61131-4 User Guidelines IEC 61131-5 Communications IEC 61131-6 Functional Safety IEC 61131-7 Fuzzy control [Jack, 2008] Behzad Samadi (Amirkabir University) Industrial Control 8 / 1
  43. 43. Programmable Logic Controllers International Standard for PLC The IEC 1131 standards were developed to be a common and open framework for PLC architecture, agreed to by many standards groups and manufacturers. They were initially approved in 1992, and since then they have been reviewed as the IEC-61131 standards. The main components of the standard are: IEC 61131-1 Overview IEC 61131-2 Requirements and Test Procedures IEC 61131-3 Data types and programming IEC 61131-4 User Guidelines IEC 61131-5 Communications IEC 61131-6 Functional Safety IEC 61131-7 Fuzzy control IEC 61131-8 Guidelines for the application and implementation of programming languages [Jack, 2008] Behzad Samadi (Amirkabir University) Industrial Control 8 / 1
  44. 44. Programmable Logic Controllers Allen-Bradley Pico Controllers Rockwell Automation Behzad Samadi (Amirkabir University) Industrial Control 9 / 1
  45. 45. Programmable Logic Controllers Allen-Bradley Pico Controllers Rockwell Automation Behzad Samadi (Amirkabir University) Industrial Control 10 / 1
  46. 46. Programmable Logic Controllers Allen-Bradley Pico Controllers Rockwell Automation Behzad Samadi (Amirkabir University) Industrial Control 11 / 1
  47. 47. Programmable Logic Controllers Allen-Bradley Pico Controllers Rockwell Automation Behzad Samadi (Amirkabir University) Industrial Control 12 / 1
  48. 48. Programmable Logic Controllers Siemens LOGO! Siemens AG Behzad Samadi (Amirkabir University) Industrial Control 13 / 1
  49. 49. Programmable Logic Controllers LOGO! integrates: Control functions An operating and display unit Power supply An interface for program modules and a PC cable Ready-to-use basic functions that are often required in day-to-day operation, such as functions for on/off delays and current impulse relays Time switch Binary markers Inputs and outputs according to the device type Siemens AG Behzad Samadi (Amirkabir University) Industrial Control 14 / 1
  50. 50. Programmable Logic Controllers What device types are available? There are LOGO! models for 12 V DC, 24 V DC, 24 V AC and 230 V AC as: A standard variant with 6 inputs and 4 outputs with dimensions of 72 x 90 x 55 mm A variant without a display with 6 inputs and 4 outputs with dimensions of 72 x 90 x 55 mm A variant with 8 inputs and 4 outputs with dimensions of 72 x 90 x 55 mm A long variant with 12 inputs and 8 outputs with dimensions of 126 x 90 x 55 mm A bus variant with 12 inputs and 8 outputs, and additional AS interface bus connection, via which 4 further inputs and 4 further outputs are available in the bus system. All this is packed into dimensions of 126 x 90 x 55 mm. Siemens AG Behzad Samadi (Amirkabir University) Industrial Control 15 / 1
  51. 51. Programmable Logic Controllers How to recognize which LOGO! model you have: LOGO!s designation contains information on various characteristics: 12: 12 V DC variant 24: 24 V DC variant 230: 115/230 V AC variant R: Relay outputs (without R: Transistor output) C: Integrated seven-day time switch o: Variant without display L: Twice the number of outputs and inputs B11: slave with Actuator Sensor (AS) interface bus connection Siemens AG Behzad Samadi (Amirkabir University) Industrial Control 16 / 1
  52. 52. Programmable Logic Controllers Siemens LOGO! Siemens AG Behzad Samadi (Amirkabir University) Industrial Control 17 / 1
  53. 53. Programmable Logic Controllers Siemens LOGO! inputs and outputs Siemens AG Behzad Samadi (Amirkabir University) Industrial Control 18 / 1
  54. 54. Programmable Logic Controllers Siemens LOGO! inputs Siemens AG Behzad Samadi (Amirkabir University) Industrial Control 19 / 1
  55. 55. Programmable Logic Controllers Siemens LOGO! relay outputs Siemens AG Behzad Samadi (Amirkabir University) Industrial Control 20 / 1
  56. 56. Programmable Logic Controllers Siemens LOGO! transistor outputs Siemens AG Behzad Samadi (Amirkabir University) Industrial Control 21 / 1
  57. 57. Programmable Logic Controllers Siemens AG Behzad Samadi (Amirkabir University) Industrial Control 22 / 1
  58. 58. Programmable Logic Controllers Siemens S7-300 Siemens AG Behzad Samadi (Amirkabir University) Industrial Control 23 / 1
  59. 59. Programmable Logic Controllers Siemens S7-300 Siemens AG Behzad Samadi (Amirkabir University) Industrial Control 24 / 1
  60. 60. Programmable Logic Controllers Siemens S7-300 Signal Modules (SM) Siemens AG Behzad Samadi (Amirkabir University) Industrial Control 25 / 1
  61. 61. Programmable Logic Controllers Siemens S7-300 Signal Modules (SM) Digital input modules: 24V DC, 120/230V AC Siemens AG Behzad Samadi (Amirkabir University) Industrial Control 25 / 1
  62. 62. Programmable Logic Controllers Siemens S7-300 Signal Modules (SM) Digital input modules: 24V DC, 120/230V AC Digital output modules: 24V DC, Relay Siemens AG Behzad Samadi (Amirkabir University) Industrial Control 25 / 1
  63. 63. Programmable Logic Controllers Siemens S7-300 Signal Modules (SM) Digital input modules: 24V DC, 120/230V AC Digital output modules: 24V DC, Relay Analog input modules: Voltage, current, resistance, thermocouple Siemens AG Behzad Samadi (Amirkabir University) Industrial Control 25 / 1
  64. 64. Programmable Logic Controllers Siemens S7-300 Signal Modules (SM) Digital input modules: 24V DC, 120/230V AC Digital output modules: 24V DC, Relay Analog input modules: Voltage, current, resistance, thermocouple Analog output modules: Voltage, current Siemens AG Behzad Samadi (Amirkabir University) Industrial Control 25 / 1
  65. 65. Programmable Logic Controllers Siemens S7-300 Signal Modules (SM) Digital input modules: 24V DC, 120/230V AC Digital output modules: 24V DC, Relay Analog input modules: Voltage, current, resistance, thermocouple Analog output modules: Voltage, current Interface Modules (IM): The IM360/IM361 and IM365 make multi-tier configurations possible. Siemens AG Behzad Samadi (Amirkabir University) Industrial Control 25 / 1
  66. 66. Programmable Logic Controllers Siemens S7-300 Dummy Modules (DM): The DM 370 dummy module reserves a slot for a signal module whose parameters have not yet been assigned. It can also be used, for example, to reserve a slot for installation of an interface module at a later date. Siemens AG Behzad Samadi (Amirkabir University) Industrial Control 26 / 1
  67. 67. Programmable Logic Controllers Siemens S7-300 Dummy Modules (DM): The DM 370 dummy module reserves a slot for a signal module whose parameters have not yet been assigned. It can also be used, for example, to reserve a slot for installation of an interface module at a later date. Function Modules (FM): Perform special functions”: Siemens AG Behzad Samadi (Amirkabir University) Industrial Control 26 / 1
  68. 68. Programmable Logic Controllers Siemens S7-300 Dummy Modules (DM): The DM 370 dummy module reserves a slot for a signal module whose parameters have not yet been assigned. It can also be used, for example, to reserve a slot for installation of an interface module at a later date. Function Modules (FM): Perform special functions”: Counting Siemens AG Behzad Samadi (Amirkabir University) Industrial Control 26 / 1
  69. 69. Programmable Logic Controllers Siemens S7-300 Dummy Modules (DM): The DM 370 dummy module reserves a slot for a signal module whose parameters have not yet been assigned. It can also be used, for example, to reserve a slot for installation of an interface module at a later date. Function Modules (FM): Perform special functions”: Counting Positioning Siemens AG Behzad Samadi (Amirkabir University) Industrial Control 26 / 1
  70. 70. Programmable Logic Controllers Siemens S7-300 Dummy Modules (DM): The DM 370 dummy module reserves a slot for a signal module whose parameters have not yet been assigned. It can also be used, for example, to reserve a slot for installation of an interface module at a later date. Function Modules (FM): Perform special functions”: Counting Positioning Closed-loop control Siemens AG Behzad Samadi (Amirkabir University) Industrial Control 26 / 1
  71. 71. Programmable Logic Controllers Siemens S7-300 Dummy Modules (DM): The DM 370 dummy module reserves a slot for a signal module whose parameters have not yet been assigned. It can also be used, for example, to reserve a slot for installation of an interface module at a later date. Function Modules (FM): Perform special functions”: Counting Positioning Closed-loop control Communication Processors (CP): Provide the following networking facilities: Siemens AG Behzad Samadi (Amirkabir University) Industrial Control 26 / 1
  72. 72. Programmable Logic Controllers Siemens S7-300 Dummy Modules (DM): The DM 370 dummy module reserves a slot for a signal module whose parameters have not yet been assigned. It can also be used, for example, to reserve a slot for installation of an interface module at a later date. Function Modules (FM): Perform special functions”: Counting Positioning Closed-loop control Communication Processors (CP): Provide the following networking facilities: Point-to-Point connections Siemens AG Behzad Samadi (Amirkabir University) Industrial Control 26 / 1
  73. 73. Programmable Logic Controllers Siemens S7-300 Dummy Modules (DM): The DM 370 dummy module reserves a slot for a signal module whose parameters have not yet been assigned. It can also be used, for example, to reserve a slot for installation of an interface module at a later date. Function Modules (FM): Perform special functions”: Counting Positioning Closed-loop control Communication Processors (CP): Provide the following networking facilities: Point-to-Point connections PROFIBUS Siemens AG Behzad Samadi (Amirkabir University) Industrial Control 26 / 1
  74. 74. Programmable Logic Controllers Siemens S7-300 Dummy Modules (DM): The DM 370 dummy module reserves a slot for a signal module whose parameters have not yet been assigned. It can also be used, for example, to reserve a slot for installation of an interface module at a later date. Function Modules (FM): Perform special functions”: Counting Positioning Closed-loop control Communication Processors (CP): Provide the following networking facilities: Point-to-Point connections PROFIBUS Industrial Ethernet. Siemens AG Behzad Samadi (Amirkabir University) Industrial Control 26 / 1
  75. 75. Programmable Logic Controllers Siemens S7-300 Siemens AG Behzad Samadi (Amirkabir University) Industrial Control 27 / 1
  76. 76. Programmable Logic Controllers Siemens S7-300 Siemens AG Behzad Samadi (Amirkabir University) Industrial Control 28 / 1
  77. 77. Programmable Logic Controllers Siemens S7-300 Siemens AG Behzad Samadi (Amirkabir University) Industrial Control 29 / 1
  78. 78. Programmable Logic Controllers Siemens S7-300 Siemens AG Behzad Samadi (Amirkabir University) Industrial Control 30 / 1
  79. 79. Programmable Logic Controllers Multipoint Interface (MPI) Siemens AG Behzad Samadi (Amirkabir University) Industrial Control 31 / 1
  80. 80. Programmable Logic Controllers Siemens S7-300 Behzad Samadi (Amirkabir University) Industrial Control 32 / 1
  81. 81. Programmable Logic Controllers PLC manufacturers: ABB Allen-Bradley ALSTOM/Cegelec Beck Electronic/Festo Beckhoff Bosch Fisher & Paykel Fuji Electric GE-Fanuc Hitachi Honeywell LG Industrial Systems Matsushita (Europe)/Aromat Mitsubishi Omron Rockwell Automation Schneider Electric Siemens/Moore Products Toshiba Yamatake Yokogawa Behzad Samadi (Amirkabir University) Industrial Control 33 / 1
  82. 82. Programmable Logic Controllers Selecting a PLC: Number of I/Os Kind of signals : digital or analog Fieldbus system or standalone Modular or compact Operating voltage Positive or negative triggerred input Relay or transistor output Operating systems FESTO DIDACTIC Behzad Samadi (Amirkabir University) Industrial Control 34 / 1
  83. 83. Programmable Logic Controllers LS Industrial Systems (lsis.biz) Behzad Samadi (Amirkabir University) Industrial Control 35 / 1
  84. 84. Programmable Logic Controllers GLOFA - GM7: Global standard (IEC61131-3) language: IL, LD, SFC Various main module: 32 types 20(12in+8out)/30(18in+12out)/40(24in+16out)/60(36in+24out) points AC/DC power, DC input, Relay/Transistor output Various expansion module: 24 types Digital I/O 7 types, analog I/O 9 types, Communication I/F 6 types, option module 2 types Batteryless Backup Program backup: EEPROM Data backup: Supercapacitor LS Industrial Systems (lsis.biz)Behzad Samadi (Amirkabir University) Industrial Control 36 / 1
  85. 85. Programmable Logic Controllers LS Industrial Systems (lsis.biz) Behzad Samadi (Amirkabir University) Industrial Control 37 / 1
  86. 86. Programmable Logic Controllers GLOFA GM4: IEC standard programming: IL, LD, SFC Max. I/O points: GM4A/B (2,048), GM4C (3,584) Fast processing time with high-speed gate array Fit for small-and medium-sized manufacturing line In case of remote system configuration, large-scale control available Cnet, DeviceNet, Fast Ethernet, Fnet, Profibus-DP, Rnet support Downsizing and high performance/function Special function modules Analog I/O, PID, High-speed counter, Position control (APM), AT, TC, RTD, etc LS Industrial Systems (lsis.biz) Behzad Samadi (Amirkabir University) Industrial Control 38 / 1
  87. 87. Programmable Logic Controllers LS Industrial Systems (lsis.biz) Behzad Samadi (Amirkabir University) Industrial Control 39 / 1
  88. 88. Programmable Logic Controllers GMWIN: LS Industrial Systems (lsis.biz) Behzad Samadi (Amirkabir University) Industrial Control 40 / 1
  89. 89. Programmable Logic Controllers LS Industrial Systems (lsis.biz) Behzad Samadi (Amirkabir University) Industrial Control 41 / 1
  90. 90. Programmable Logic Controllers [Bolton, 2006] Behzad Samadi (Amirkabir University) Industrial Control 42 / 1
  91. 91. Programmable Logic Controllers Location and size prefix features for directly represented variables [IEC, 2003] Behzad Samadi (Amirkabir University) Industrial Control 43 / 1
  92. 92. Programmable Logic Controllers Input, Output, Memory Locations: %QX75 and %Q75 - Output bit 75 %IW215 - Input word location 215 %QB7 - Output byte location 7 %MD48 - Double word at memory location 48 %Q* - Output at a not yet specified location %IW2.5.7.1 - See explanation below Depending on the manufacturer specifications, the variable %IW2.5.7.1 may represent the first channel (word) of the seventh module in the fifth rack of the second I/O bus of a programmable controller system. [IEC, 2003] Behzad Samadi (Amirkabir University) Industrial Control 44 / 1
  93. 93. Programmable Logic Controllers Sequence Operation: LS Industrial Systems (lsis.biz) Behzad Samadi (Amirkabir University) Industrial Control 45 / 1
  94. 94. Programmable Logic Controllers Behzad Samadi (Amirkabir University) Industrial Control 46 / 1
  95. 95. Programmable Logic Controllers [IEC, 2003] Behzad Samadi (Amirkabir University) Industrial Control 46 / 1
  96. 96. Programmable Logic Controllers [IEC, 2003] Behzad Samadi (Amirkabir University) Industrial Control 47 / 1
  97. 97. Programmable Logic Controllers [IEC, 2003] Behzad Samadi (Amirkabir University) Industrial Control 48 / 1
  98. 98. Programmable Logic Controllers [IEC, 2003] Behzad Samadi (Amirkabir University) Industrial Control 49 / 1
  99. 99. Programmable Logic Controllers [IEC, 2003] Behzad Samadi (Amirkabir University) Industrial Control 50 / 1
  100. 100. Programmable Logic Controllers [IEC, 2003] Behzad Samadi (Amirkabir University) Industrial Control 51 / 1
  101. 101. Programmable Logic Controllers [Bolton, 2006] Behzad Samadi (Amirkabir University) Industrial Control 52 / 1
  102. 102. Programmable Logic Controllers [Bolton, 2006] Behzad Samadi (Amirkabir University) Industrial Control 53 / 1
  103. 103. Programmable Logic Controllers [Bolton, 2006] Behzad Samadi (Amirkabir University) Industrial Control 54 / 1
  104. 104. Programmable Logic Controllers [Bolton, 2006] Behzad Samadi (Amirkabir University) Industrial Control 55 / 1
  105. 105. Programmable Logic Controllers [Bolton, 2006] Behzad Samadi (Amirkabir University) Industrial Control 56 / 1
  106. 106. Programmable Logic Controllers [Bolton, 2006] Behzad Samadi (Amirkabir University) Industrial Control 57 / 1
  107. 107. Programmable Logic Controllers [Bolton, 2006] Behzad Samadi (Amirkabir University) Industrial Control 58 / 1
  108. 108. Programmable Logic Controllers [Bolton, 2006] Behzad Samadi (Amirkabir University) Industrial Control 59 / 1
  109. 109. Programmable Logic Controllers [Bolton, 2006] Behzad Samadi (Amirkabir University) Industrial Control 60 / 1
  110. 110. Programmable Logic Controllers Motor Start-Stop [Bolton, 2006] Behzad Samadi (Amirkabir University) Industrial Control 61 / 1
  111. 111. Programmable Logic Controllers [Bolton, 2006]Behzad Samadi (Amirkabir University) Industrial Control 62 / 1
  112. 112. Programmable Logic Controllers [Bolton, 2006] Behzad Samadi (Amirkabir University) Industrial Control 63 / 1
  113. 113. Programmable Logic Controllers [Bolton, 2006] Behzad Samadi (Amirkabir University) Industrial Control 64 / 1
  114. 114. Programmable Logic Controllers Example: A signal lamp is required to be switched on if a pump is running and the pressure is satisfactory, or if the lamp test switch is closed. Behzad Samadi (Amirkabir University) Industrial Control 65 / 1
  115. 115. Programmable Logic Controllers Example: A signal lamp is required to be switched on if a pump is running and the pressure is satisfactory, or if the lamp test switch is closed. [Bolton, 2006] Behzad Samadi (Amirkabir University) Industrial Control 65 / 1
  116. 116. Programmable Logic Controllers Example: Consider a valve which is to be operated to lift a load when a pump is running and either the lift switch is operated or a switch operated indicating that the load has not already been lifted and is at the bottom of its lift channel. Behzad Samadi (Amirkabir University) Industrial Control 66 / 1
  117. 117. Programmable Logic Controllers Example: Consider a valve which is to be operated to lift a load when a pump is running and either the lift switch is operated or a switch operated indicating that the load has not already been lifted and is at the bottom of its lift channel. [Bolton, 2006]Behzad Samadi (Amirkabir University) Industrial Control 66 / 1
  118. 118. Programmable Logic Controllers Example: Consider a system where there has to be no output when any one of four sensors gives an output, otherwise there is to be an output. Behzad Samadi (Amirkabir University) Industrial Control 67 / 1
  119. 119. Programmable Logic Controllers Example: Consider a system where there has to be no output when any one of four sensors gives an output, otherwise there is to be an output. [Bolton, 2006] Behzad Samadi (Amirkabir University) Industrial Control 67 / 1
  120. 120. Programmable Logic Controllers Stop switches: [Bolton, 2006] Behzad Samadi (Amirkabir University) Industrial Control 68 / 1
  121. 121. Programmable Logic Controllers Emergency stop switch: [Bolton, 2006] Behzad Samadi (Amirkabir University) Industrial Control 69 / 1
  122. 122. Programmable Logic Controllers Elementary Data Types: BOOL (Boolean): 0 or 1 - TRUE or FALSE [IEC, 2003] Behzad Samadi (Amirkabir University) Industrial Control 70 / 1
  123. 123. Programmable Logic Controllers Elementary Data Types: BOOL (Boolean): 0 or 1 - TRUE or FALSE SINT (Short integer): −27 to 27 − 1 [IEC, 2003] Behzad Samadi (Amirkabir University) Industrial Control 70 / 1
  124. 124. Programmable Logic Controllers Elementary Data Types: BOOL (Boolean): 0 or 1 - TRUE or FALSE SINT (Short integer): −27 to 27 − 1 INT (Integer): −215 to 215 − 1 [IEC, 2003] Behzad Samadi (Amirkabir University) Industrial Control 70 / 1
  125. 125. Programmable Logic Controllers Elementary Data Types: BOOL (Boolean): 0 or 1 - TRUE or FALSE SINT (Short integer): −27 to 27 − 1 INT (Integer): −215 to 215 − 1 DINT (Double integer): −231 to 231 − 1 [IEC, 2003] Behzad Samadi (Amirkabir University) Industrial Control 70 / 1
  126. 126. Programmable Logic Controllers Elementary Data Types: BOOL (Boolean): 0 or 1 - TRUE or FALSE SINT (Short integer): −27 to 27 − 1 INT (Integer): −215 to 215 − 1 DINT (Double integer): −231 to 231 − 1 LINT (Long integer): −263 to 263 − 1 [IEC, 2003] Behzad Samadi (Amirkabir University) Industrial Control 70 / 1
  127. 127. Programmable Logic Controllers Elementary Data Types: BOOL (Boolean): 0 or 1 - TRUE or FALSE SINT (Short integer): −27 to 27 − 1 INT (Integer): −215 to 215 − 1 DINT (Double integer): −231 to 231 − 1 LINT (Long integer): −263 to 263 − 1 USINT (Unsigned short integer): 0 to 28 − 1 [IEC, 2003] Behzad Samadi (Amirkabir University) Industrial Control 70 / 1
  128. 128. Programmable Logic Controllers Elementary Data Types: BOOL (Boolean): 0 or 1 - TRUE or FALSE SINT (Short integer): −27 to 27 − 1 INT (Integer): −215 to 215 − 1 DINT (Double integer): −231 to 231 − 1 LINT (Long integer): −263 to 263 − 1 USINT (Unsigned short integer): 0 to 28 − 1 UINT (Unsigned integer): 0 to 216 − 1 [IEC, 2003] Behzad Samadi (Amirkabir University) Industrial Control 70 / 1
  129. 129. Programmable Logic Controllers Elementary Data Types: BOOL (Boolean): 0 or 1 - TRUE or FALSE SINT (Short integer): −27 to 27 − 1 INT (Integer): −215 to 215 − 1 DINT (Double integer): −231 to 231 − 1 LINT (Long integer): −263 to 263 − 1 USINT (Unsigned short integer): 0 to 28 − 1 UINT (Unsigned integer): 0 to 216 − 1 UDINT (Unsigned double integer): 0 to 232 − 1 [IEC, 2003] Behzad Samadi (Amirkabir University) Industrial Control 70 / 1
  130. 130. Programmable Logic Controllers Elementary Data Types: BOOL (Boolean): 0 or 1 - TRUE or FALSE SINT (Short integer): −27 to 27 − 1 INT (Integer): −215 to 215 − 1 DINT (Double integer): −231 to 231 − 1 LINT (Long integer): −263 to 263 − 1 USINT (Unsigned short integer): 0 to 28 − 1 UINT (Unsigned integer): 0 to 216 − 1 UDINT (Unsigned double integer): 0 to 232 − 1 ULINT (Unsigned double integer): 0 to 264 − 1 [IEC, 2003] Behzad Samadi (Amirkabir University) Industrial Control 70 / 1
  131. 131. Programmable Logic Controllers Elementary Data Types: STRING: 8 bits per character [IEC, 2003] Behzad Samadi (Amirkabir University) Industrial Control 71 / 1
  132. 132. Programmable Logic Controllers Elementary Data Types: STRING: 8 bits per character BYTE: Bit string of length 8 [IEC, 2003] Behzad Samadi (Amirkabir University) Industrial Control 71 / 1
  133. 133. Programmable Logic Controllers Elementary Data Types: STRING: 8 bits per character BYTE: Bit string of length 8 WORD: Bit string of length 16 [IEC, 2003] Behzad Samadi (Amirkabir University) Industrial Control 71 / 1
  134. 134. Programmable Logic Controllers Elementary Data Types: STRING: 8 bits per character BYTE: Bit string of length 8 WORD: Bit string of length 16 DWORD: Bit string of length 32 [IEC, 2003] Behzad Samadi (Amirkabir University) Industrial Control 71 / 1
  135. 135. Programmable Logic Controllers Elementary Data Types: STRING: 8 bits per character BYTE: Bit string of length 8 WORD: Bit string of length 16 DWORD: Bit string of length 32 LWORD: Bit string of length 64 [IEC, 2003] Behzad Samadi (Amirkabir University) Industrial Control 71 / 1
  136. 136. Programmable Logic Controllers Elementary Data Types: STRING: 8 bits per character BYTE: Bit string of length 8 WORD: Bit string of length 16 DWORD: Bit string of length 32 LWORD: Bit string of length 64 WSTRING: Variable-length double-byte character string [IEC, 2003] Behzad Samadi (Amirkabir University) Industrial Control 71 / 1
  137. 137. Programmable Logic Controllers Timers: [IEC, 2003] Behzad Samadi (Amirkabir University) Industrial Control 72 / 1
  138. 138. Programmable Logic Controllers ON Delay Timers: [IEC, 2003] Behzad Samadi (Amirkabir University) Industrial Control 73 / 1
  139. 139. Programmable Logic Controllers ON Delay Timers: [IEC, 2003] Behzad Samadi (Amirkabir University) Industrial Control 74 / 1
  140. 140. Programmable Logic Controllers OFF Delay Timers: [IEC, 2003] Behzad Samadi (Amirkabir University) Industrial Control 75 / 1
  141. 141. Programmable Logic Controllers OFF Delay Timers: [IEC, 2003] Behzad Samadi (Amirkabir University) Industrial Control 76 / 1
  142. 142. Programmable Logic Controllers Pulse Timers: [IEC, 2003] Behzad Samadi (Amirkabir University) Industrial Control 77 / 1
  143. 143. Programmable Logic Controllers Pulse Timers: [IEC, 2003] Behzad Samadi (Amirkabir University) Industrial Control 78 / 1
  144. 144. Programmable Logic Controllers Example: Write a program such that: Lecture Notes by Nazarian Behzad Samadi (Amirkabir University) Industrial Control 79 / 1
  145. 145. Programmable Logic Controllers Solution: Lecture Notes by Nazarian Behzad Samadi (Amirkabir University) Industrial Control 80 / 1
  146. 146. Programmable Logic Controllers Example: Write a program such that: Lecture Notes by Nazarian Behzad Samadi (Amirkabir University) Industrial Control 81 / 1
  147. 147. Programmable Logic Controllers Solution: Lecture Notes by Nazarian Behzad Samadi (Amirkabir University) Industrial Control 82 / 1
  148. 148. Programmable Logic Controllers Up Counter: [IEC, 2003] Behzad Samadi (Amirkabir University) Industrial Control 83 / 1
  149. 149. Programmable Logic Controllers Down Counter: [IEC, 2003] Behzad Samadi (Amirkabir University) Industrial Control 84 / 1
  150. 150. Programmable Logic Controllers Up-down Counter: [IEC, 2003] Behzad Samadi (Amirkabir University) Industrial Control 85 / 1
  151. 151. Programmable Logic Controllers Example: A motor will be controlled by two switches. The Go switch will start the motor and the Stop switch will stop it. If the Stop switch was used to stop the motor, the Go switch must be thrown twice to start the motor. When the motor is active a light should be turned on. The Stop switch will be wired as normally closed. Behzad Samadi (Amirkabir University) Industrial Control 86 / 1
  152. 152. Programmable Logic Controllers Example: A motor will be controlled by two switches. The Go switch will start the motor and the Stop switch will stop it. If the Stop switch was used to stop the motor, the Go switch must be thrown twice to start the motor. When the motor is active a light should be turned on. The Stop switch will be wired as normally closed. [Jack, 2008] Behzad Samadi (Amirkabir University) Industrial Control 86 / 1
  153. 153. Programmable Logic Controllers Example: Consider the task of counting cars as they enter a multi-storage parking lot and as they leave it. An output is to be triggered if the number of cars entering is some number greater than the number leaving, i.e. the number in the parking lot has reached a saturation value. Behzad Samadi (Amirkabir University) Industrial Control 87 / 1
  154. 154. Programmable Logic Controllers Example: Consider the task of counting cars as they enter a multi-storage parking lot and as they leave it. An output is to be triggered if the number of cars entering is some number greater than the number leaving, i.e. the number in the parking lot has reached a saturation value. [Jack, 2008] Behzad Samadi (Amirkabir University) Industrial Control 87 / 1
  155. 155. Programmable Logic Controllers Timers with counters: Behzad Samadi (Amirkabir University) Industrial Control 88 / 1
  156. 156. Programmable Logic Controllers Question: [Jack, 2008] Behzad Samadi (Amirkabir University) Industrial Control 89 / 1
  157. 157. Programmable Logic Controllers Instruction list: [Jack, 2008] Behzad Samadi (Amirkabir University) Industrial Control 90 / 1
  158. 158. Programmable Logic Controllers Instruction list: [Jack, 2008]Behzad Samadi (Amirkabir University) Industrial Control 91 / 1
  159. 159. Programmable Logic Controllers Instruction list: [Jack, 2008] Behzad Samadi (Amirkabir University) Industrial Control 92 / 1
  160. 160. Programmable Logic Controllers Structured text is a programming language that strongly resembles the programming language PASCAL. [Jack, 2008] Behzad Samadi (Amirkabir University) Industrial Control 93 / 1
  161. 161. Programmable Logic Controllers Structured text: [Jack, 2008] Behzad Samadi (Amirkabir University) Industrial Control 94 / 1
  162. 162. Programmable Logic Controllers Structured text: [Jack, 2008] Behzad Samadi (Amirkabir University) Industrial Control 95 / 1
  163. 163. Programmable Logic Controllers Structured text: [Jack, 2008] Behzad Samadi (Amirkabir University) Industrial Control 96 / 1
  164. 164. Programmable Logic Controllers Sequential Function Chart (SFC): [Jack, 2008] Behzad Samadi (Amirkabir University) Industrial Control 97 / 1
  165. 165. Programmable Logic Controllers Sequential Function Chart (SFC): [Jack, 2008] Behzad Samadi (Amirkabir University) Industrial Control 98 / 1
  166. 166. Programmable Logic Controllers Sequential Function Chart (SFC): Behzad Samadi (Amirkabir University) Industrial Control 99 / 1
  167. 167. Programmable Logic Controllers Sequential Function Chart (SFC): Example: A two door security system. One door requires a two digit entry code, the second door requires a three digit entry code. [Jack, 2008] Behzad Samadi (Amirkabir University) Industrial Control 100 / 1
  168. 168. Programmable Logic Controllers Sequential Function Chart (SFC): Example: Controlling a stamping press [Jack, 2008] Behzad Samadi (Amirkabir University) Industrial Control 101 / 1
  169. 169. Programmable Logic Controllers Sequential Function Chart (SFC): [IEC, 2003] Behzad Samadi (Amirkabir University) Industrial Control 102 / 1
  170. 170. Programmable Logic Controllers Sequential Function Chart (SFC): Sequence evolution: [IEC, 2003] Behzad Samadi (Amirkabir University) Industrial Control 103 / 1
  171. 171. Programmable Logic Controllers Sequential Function Chart (SFC): Sequence evolution: [IEC, 2003] Behzad Samadi (Amirkabir University) Industrial Control 104 / 1
  172. 172. Programmable Logic Controllers Sequential Function Chart (SFC): Sequence evolution: [IEC, 2003] Behzad Samadi (Amirkabir University) Industrial Control 105 / 1
  173. 173. Programmable Logic Controllers Sequential Function Chart (SFC): Sequence evolution: [IEC, 2003] Behzad Samadi (Amirkabir University) Industrial Control 106 / 1
  174. 174. Programmable Logic Controllers Sequential Function Chart (SFC): Sequence evolution: [IEC, 2003] Behzad Samadi (Amirkabir University) Industrial Control 107 / 1
  175. 175. Programmable Logic Controllers Sequential Function Chart (SFC): Sequence evolution: [IEC, 2003] Behzad Samadi (Amirkabir University) Industrial Control 108 / 1
  176. 176. Programmable Logic Controllers Sequential Function Chart (SFC): Sequence evolution: [IEC, 2003] Behzad Samadi (Amirkabir University) Industrial Control 109 / 1
  177. 177. Programmable Logic Controllers Function Block Diagram (FBD): [Jack, 2008] Behzad Samadi (Amirkabir University) Industrial Control 110 / 1
  178. 178. Programmable Logic Controllers Function Block Diagram (FBD): Boolean NOT, AND, OR [Jack, 2008] Behzad Samadi (Amirkabir University) Industrial Control 111 / 1
  179. 179. (2002). Programmable Logic Controllers: Basic Level. FESTO. (2003). IEC 61131-3 programmable controllers - part 3: Programming languages. Bolton, W. (2006). Programmable Logic Controllers. Newnes, 4 edition. Jack, H. (2008). Automating Manufacturing Systems with PLCs. Grand Valley State University, MI, 5.2 edition. Behzad Samadi (Amirkabir University) Industrial Control 111 / 1

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