Arquitetura control logix


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  • ControlLogix is the new control architecture from Allen Bradley. It is a state of the art control platform designed as a multi-control discipline platform: sequential, motion, process, and coordinated drives systems. Only once every few years do we introduce a major new control platform. Never have we introduced as encompassing a system that changes the entire control model as ControlLogix does! Note that ControlLogix is the system name and Logix 5000 is the generic name for Logix based controllers. Logix 55xx designates controllers in the ControlLogix chassis (i.e. PLC 5). Logix5550 is the first one of those controllers (i.e. PLC 5/40).
  • Each ControlLogix I/O module is configured using a graphical dialog screen, eliminating the need to set switches or send block transfers to modules The dialogs expose the highly functional modules in an easy to use format Module diagnostics are provided along with keying information Changes to the configuration are loaded with your program onto the Logix5000 controller, here the controller monitors the state of the module in the system and when it determines that a module is missing its configuration it automatically downloads the settings to the module This means you only have to do the configuration once You do not have to load anything into a replaced module the Logix5000 does all the work for you After you complete a modules configuration, a set of I/O tags are automatically created in the controllers memory This data area is created specific to the modules needs Eliminates to need to do block transfers
  • Note that the PLC5 and SLC500 were also preemptive multitasking controllers. The continuous task is interrupted by a higher priority task when needed. Both the PLC5 and SLC500 provided Periodic tasks called Selectable Timed Interrupt (STI). Additionally, these controllers provided Peripheral Input Interrupt (PII) which is an event task. The difference with the Logix5000 is that multiple periodic task can exist on the processor and each task can have multiple isolated programs that run in sequence. What used to be called program files, now follow the IEC1131-3 name of “Routine”. The programs assigned to each task, provide a local data area for the routines within the program so that routines in other programs cannot modify the value. This local data area allows you to create a program and make copies of it without having to re-address the logic. In addition to the local data areas, there is a controller scoped data area that any program’s routines can access. Also all I/O information is available at the controller scope so any routine can view / change I/O values. The overhead in the Logix5550 is used to process RS232 and backplane messages. You can set this to be a % of the controllers continuous task’s scan time. Example: if set to 10%, every 10ms of scan of the continuous scan, 1ms will be given to the CPU to perform communications housekeeping. Turning this value up increases the communications throughput but slows the scan, turning the value down decreases the communications throughput but speeds up the scan. You can choose which you prefer based on the application, the default setting is 10%.
  • The majority of the PLC/SLC instruction set has been brought forward in order to preserve the installed base of programs running on these controllers by providing a future migration path. In fact, a PLC/SLC translation tool is built into RSLogix 5000 to bring logic from these controllers forward. You can also cut/copy/paste logic between RSLogix5 and 500. Additionally, the instruction set is now optimized to work with 32bit data, giving you the ability to do 32bit math natively vs 16bit in previous products. Instruction parameter overloading eliminates the need to perform data type conversion before exe In addition to the PLC/SLC instructions a suite of Motion Control ladder diagram instructions have been added to the Logix5550 so you can write one program for both PLC and Motion control applications. Symbolic addressing helps to make the code more readable because you use real names to create the data instead of physical memory address. Other changes or Enhancements: New NOP instruction acts as a placeholder for outputs FOR instruction now repetitively calls a subroutine rather execute in-line code BTW / BTR are now part of the MSG instruction Series outputs are supported and input instructions can appear between output instructions (still scans left to right, logic flow not current flow): |-----| |----------------( )----| |-----( )-----| This is valid!
  • In a traditional control system development, a system layout defines where all of the I/O devices will reside and then an electrical design defines which I/O Points these devices will be wired to. Normally, you cannot begin program development until the I/O addresses are assigned because you need to address to write the code. This approach is depicted in the block diagram on the left of this slide. In the Logix5550 you can actually begin writing code in parallel with the Electrical design because you can develop code that uses internal tags and then at a latter date change the tag to point or alias to an I/O value. The advantage is that you can do this as a simple assignment and not have to re-write the code. This approach is depicted in the block diagram in the center of this slide. This concurrent engineering approach helps to reduce the length time it takes to get a system completed because tasks that were once done in series are now done simultaneously in the Logix5550 This can also support the re-use of code across multiple jobs by creating a program that uses internal tags and then depending on the system, assign the tag to different I/O. You no longer need to search and replace all of the address references in the logic. The right side of the slide give a step by step description of how to utilize the tag aliasing feature in RSLogix5000 to utilize a concurrent engineering approach.
  • Over the years applications running on PLCs have needed the ability to link multiple fields together so that when something moves all of the fields move together. We have had this ability in the PLC/SLC for many years with the Timer, Counter, Control and String structures. Now with the Logix5550 you have the ability to create a custom user defined structure. The screen-shot on the left of the slide shows a structure containing fields that represent all of the ingredients of a cookie recipe. The middle screen-shot shows this recipe structure used to create a table of information where each position in the table contains all of the ingredients listed in the structure. The logic screen-shot then shows what the code that might reference this structure would look like. Looking at the code in this slide you can see that the symbolic addressing provides self documenting logic. It is much easier to read “Weight_Scale is less than Cookies[Chocolate_Chip].Flour” and understand what it is doing than to read “Address 00030 is less than 40005” (Modicon address). Note that the reference “Cookies[Chocolate_Chip]” is using the tag “Chocolate_Chip” to indirectly reference an element in the “Cookies” array. This is how you would do dynamic data indirection at run time. The reference could have also been a complete expression that equates to an element number, such “A+(B*C)”. This is something you could never do in any PLC in the past. This just shows the power that the Logix5550 provides.
  • Five networks are available.
  • Today’s networks, which are source/destination based, cannot offer the required functionality and accommodate increased traffic, thus restricting system capabilities and productivity improvements. In Source/Destination, all data packets have a unique source (“sender”) and destination (“receiver”). But what if the user wanted to communicate the same data to multiple devices, or nodes? In source/destination, that will require multiple packets, even though the only thing that is different is the destination !! The new model is producer/consumer. With producer/consumer networks, messages are identified by content. If a node needs data (maybe based on how they are developed, how they are configured, or how they are programmed), it will “accept” that identifier and consume it. Multicast. Because data is identified by its content; if a node needs that data, multiple nodes can consume the same data at the same time from a single producer. Nodes may be synchronized more precisely while achieving more efficient bandwidth usage. The source of data has to produce the information only once. Additional EOI and MMI can be added without increasing network traffic, since they can consume these same messages.
  • A control example. [Devices can be substituted to meet audiences application(s).] Again, the efficiency advantage increases as we add (1) devices and/or (2) number of data exchanges between devices and/or (3) complexity or size of data exchanged The source/destination model used for the past two decades can no longer meet today’s network needs. The only model available today that can meet these demanding requirements and allows for future migration is the producer/consumer network model. Here’s why: Diagnostics Networks provide a convenient way to retrieve diagnostics from devices. Device-specific information, such as detection of a photoelectric sensor’s low margin due to a dirty lens can be communicated over the network to the control system during run time. The network delivers the diagnostic to the system operator interface, alerting plant personnel to the problem. The lens can be cleaned at a convenient time before there is a glitch in the process. Trouble-shooting a device, reading its fault codes, updating data logs -- all while not impacting the remote I/O control data exchange among other nodes -- is a must.
  • Producer - Consumer is not only a more efficient way to due communication but it also yields greater system performance because: 1. The controller(s) is freed up to due control by not service multiple network ports. 2. Each network module has its own processor so cpu intensive communication servicing is spread out between multiple modules. 3. Messages with multiple designations (i.e. multiple consumers) now receive them at the same time, reducing system latencies.
  • 2 2 3 3 3 3 3 At the Automation and Control layer the key drivers are data integrity and tight coupling between PLC’s and I/O devices: I/O racks, drives, dedicated MMI, and third parties. Speed (minimum response time), cost, and connectivity are important. An unmet industry need is deterministic (the ability to know when data will be sent) and repeatable (the ability to be able to reproduce; even with the addition and subtraction of devices) data delivery. Here performance is the key. A customer must be assured that data can be sent real-time between the control devices. Data must be sent deterministically and repeatably: sent at the same time every time. Here the desire for integrity supersedes the need for openness and unlimited multi-vendor connectivity. The loss of data, say between an I/O rack and a PLC, can be a safety issue. Speed is obviously important but primarily as a determinant of response time - a user must be able to send and receive I/O data in a timely fashion (msec range) or his process may not work. Also users typically want their control vendor accountable for system integrity and performance. If an Ethernet network does not work a user may have to turn to several vendors to determine accountability. This lack of system ownership is not acceptable at the control layer. A valid control network must be in the Mega Baud range and support: peer to peer messaging, program upload and download, deterministic transfer of: PLC to PLC interlocking and I/O updates. It must provide for expansion into the future such as multiplicity of inputs.
  • 3 3 4 4 4 4 4 ControlNet was developed because there was not one single network, ours or anybody else's, that met all the requirements above. The throughput and features that ControlNet offers are the aggregate of our customers requirements.
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  • Arquitetura control logix

    1. 1. Arquitetura ControlLogix AUTOMAÇÃO COM QUALIDADE. PERTO DE VOCÊ. RLAM
    2. 2. • Pontos fortes da arquitetura: – Controlador de alto desempenho – Configuração adequada às suas necessidades – Proteção do seu investimento em Hardware – Programação mais voltada para o processo O ControlLogix
    3. 3. • Capaz de manusear os requisitos sequenciais mais exigentes – Varreduras mais rápidas do que em produtos anteriores • Ciclos de maquina reduzidos aumentam a produtividade – Utilização mais eficiente dos recursos da CPU Controle de alto desempenho
    4. 4. • Maior eficiência e interação mais fácil com a estratégia de controle – Execução de pequenas parcelas de lógica sintonizada pelo usuário – Troca de mensagens em alta velocidade através do sistema sem deteriorar o desempenho dos controladores • Menos fatores de complexidade – Ausência de conexões de rede no controlador – Melhor desempenho com menos variações. Controle com alto desempenho
    5. 5. • Proporciona a informação necessária à manutenção da operação do sistema com diagnóstico individual para cada módulo. – Indicação de falha do módulo – Acesso por software à identificação do módulo – Função de “time-stamping” associada ao registro de dados e falhas. – Deteção de fio partido – Deteção de perda da carga – Presença de alimentação p/ saídas – Fusível eletrônico p/ cada ponto – Pulso de teste p/ saídas – “Time-stamping” p/ diagnóstico – Indicação de falhas ao nível de canais individuais – Memorização de dados intermitentes Controle de alto desempenho
    6. 6. • Manutenção sem interromper a operação – Remoção e inserção à quente viabiliza a alteração de alguns sub- sistemas de maneira independente dos demais • Construa um sistema que atenda exatamente aos seus requisitos – Expanda ou reconfigure de acordo com sua necessidade – Módulos podem ter o firmware atualizado por “Flash” EPROM • Menor espaço p/ montagem, – Área de montagem reduzida – Fiação para I/O com tampa removível e remoção à quente facilita instalação e/ou substituição Formato adequado às necessidades
    7. 7. • Aquisição apenas dos componentes necessários quando necessários – Expansível em todas as dimensões: processadores, memória, comunicação, I/O – Comunicação modular com funções de gateway independentes do processador • Acrescente Ethernet, ControlNet, DeviceNet, DH+ e RIO – Memória modular - desde o 5/03 até o dobro do PLC 5/80 • Possibilidade de acrescentar memória ao processador • Processadores podem ser acrescentados quando necessário • Vários processadores no mesmo chassi • Podemos ter chassis sem processadores • Não há privilégios para quaisquer “slots” Configuração que atende sua necessidade
    8. 8. • Reutilize o investimento realizado em seu sistema de controle – I/O: Reutilização dos produtos 1771, 1746, Flex e outros através da RIO – Software inclui ferramenta para conversão de programas do PLC5 e SLC 500 – Dados: Importação de bases de dados ASCII e lógica de outras fontes – Dispositivos: Comunicação com PanelView, RSView32, Inversores, etc... – Treinamento: ambiente de programação como RSLogix 5 & 500 A Arquitetura Logix
    9. 9. • Programas mais fáceis de ler, auto documentados – Endereçamento simbólico baseado em “tags” – Endereçamento de I/O - chassi.slot.dado.bit – I/O em ponto flutuante, linearização e alarme no módulo reduzem a programação e facilitam a configuração • Construção de uma tabela de dados orientada a objetos que reflete seu processo • Ambiente multi-tarefa oferece ao usuário modularidade e organização Programação acompanhando seu raciocínio
    10. 10. Assistentes para configuração dos módulos • Assistentes extremamente amigáveis guiam o usuário ao longo do processo para configuração – Todas as informações são apresentadas como formulários de fácil compreensão reduzindo o tempo de aprendizagem – Não há instruções especiais para transferência de dados aos módulos inteligentes – Criação automática das variáveis ( “tags” ) relacionados ao I/O.
    11. 11. System Task Motion Task Fault Task User Task Password Configuration Status User Task Password Configuration Status User Task Watchdog Configuration Status Program Program Program Program I/O Data array[x] float int struct struct array[x] Global Data struct array[x] array[x,y,z] Program Program Fault Routine if A=12 then B subroutine --| |------( )-- subroutine --| |------( )--subroutine --| |------( )-- subroutine --| |------( )-- Local Data Main Routine Logix5000 Controller Sistema operacional multitarefa preemptivo • Sistema multitarefa em conformidade com IEC 1131-3 • Suporte para até 32 tarefas permite segmentar aplicação e executar cada parte à taxa mais adequada. • 15 níveis de prioridade permitem configurar o controlador para garantir o atendimento às tarefas mais importantes • 32 programas por tarefa proporcionam subdivisões adicionais e áreas de dados isoladas • Overhead do sistema programado como percentual do tempo livre da CPU
    12. 12. Conjunto de Instruções do Logix5000 • Conjunto de instruções ladder altamente funcional baseado no PLC-5 / SLC-500 – Mesmo ambiente de utilização dos produtos atuais – Curva de apredizagem reduzida – Poderosas instruções p/ diagnóstico e arquivo – PID e outras instruções para Controle de Processo • Programação em blocos funcionais • Instruções básicas compatíveis com IEC1131-3 • Endereçamento simbólico facilita a compreensão do aplicativo e o código torna-se auto documentado.
    13. 13. System Layout Design Electrical Design Program Development Machine Startup Typical Control System Approach Electrical Device function and placement I / O Addresses of all Devices System Layout Design Electrical Design Program Development Machine Startup Logix5000 Approach Electrical Device function and placement I / O Addresses of all Devices 1. Create your tags based on system device needs 2. Write your program or create generic code blocks 3. At a later date map the Device tags to the I/O in the system 4. NO CODE CHANGES REQUIRED! Desenvolvimento simultâneo com “alias” • O recurso de atribuição de apelidos do Logix5000 pode reduzir tempo e custos para desenvolvimento de aplicações – Programas podem ser desenvolvidos sem o projeto eletrico final – Criação de uma biblioteca de programas reutilizáveis em múltiplos projetos – Múltiplos identificadores para a mesma variável aprimora a documentação
    14. 14. Estruturas definidas pelo usuário • Tipos de dados definidos p/ usuário compatíveis com IEC1131-3 • Adiciona flexibilidade ao projeto do sistema de controle. • Viabiliza o agrupamento lógico de dados de controle. • Permite combinar diferentes tipos de dados em uma mesma estrutura. • Resulta em um código auto-documentado.
    15. 15. DeviceNet ControlNet Ethernet RIO, DH+ ControlNet Comunicações via barramento e redes • Comunicação modular – Ethernet, ControlNet, DeviceNet, DF1 (porta serial do controlador), DH+ e RIO – Acréscimo de tantas interfaces quanto necessárias • Flexibilidade p/ comunicação – Roteamento e “bridging” entre redes sem envolvimento do controlador – Suporte à I/O (determinismo), mensagens peer-to-peer, a tráfego de mensagens não- programadas. • Compartilhamento de I/O • Configurável p/ SW
    16. 16. Paradigma do Controle Distribuído 1990’s Flex I/O Drive PB Panel 2000 Multi-disciplined Controller Drive w/PIDAxis Controller PB Panel Prox Flex I/O O.I. Packaged Controller 1980’s
    17. 17. Origem/Destino srcsrc dstdst datadata crccrc identifier data crc Produtor/ConsumidorProdutor/Consumidor (dados são identificados)(dados são identificados) Modelos de Redes
    18. 18. Drive1Drive1 Drive3Drive3Drive2Drive2 CTLR1CTLR1 IHMIHM SensorSensor CTLR2CTLR2 Produtor-Consumidor #1 #2
    19. 19. Arquitetura de comunicação Informação Dispositivos Automação & Controle 24vdc 509 -BOD 24vdc 509 -BOD Relatórios, Programas de Produção Controle, I/O, Intertrvamento, Configuração I/O, Controle, Configuração
    20. 20. Modelo Produtor/Consumidor • Interface do tipo ControlNet para todos os módulos: • Compartilhamento de I/O proporciona maior flexibilidade ao sistema • Aplicações produzem melhor resposta
    21. 21. • Dados de I/O em tempo real – Determinístico c/ alta repetibilidade • Intertravamento entre controladores • Mensagens entre controladores • Programação – “ Upload” e “download” Requisitos das redes de Controle Automation and Control 24 vdc 509 -BOD T
    22. 22. • Rede para I/O e Controladores - Alta velocidade (5Mbps) • Projetada para Processos contínuos e discretos • Rede única para programação, mensagens “peer to peer”, intertravamento em tempo real e aquisição de I/O • Baseada no modelo Produtor/Consumidor – “Entradas” podem ser compartilhadas por diferentes consumidores • Permite múltiplos controladores na mesma rede • Flexibilidade para o meio físico – Topologias barramento, árvore e estrela combinadas – Opção de redundância para o meio físico – Pleno acesso a rede a partir de qualquer dispositivo ControlNet TM
    23. 23. Hub em fibra ótica RPA RPFS Seg. Coaxial RPA RPFS Seg. Coaxial RPA RPFM Seg. Coaxial Segmento em Fibra Ótica (Ponto a ponto) Segmento em Fibra Ótica (Ponto a ponto) Produtos ControlNet Produtos ControlNet Produtos ControlNet RPFS RPFMRPA RPA - Bloco inicial do Hub (conexão coaxial) RPFS - Módulo Ótico de curta distância (até 300m) RPFM - Módulo Ótico de longa distância (até 3 Km)) RPFM Inversor 1336 Seg. Coaxial
    24. 24. 11 Método de acesso ao meio Intervalo de atualização da rede (NUT) Serviço Programado Serviços da Camada de Enlace Serviço Não- programado Serviço de Manutenção da rede Tempo
    25. 25. • Membros do comitê diretor (Board Members) – Cutler Hammer, Ford, Honeywell, Omron, Rockwell Automation • Membros do comitê técnico – Honeywell, Rockwell Automation, S&S Technologies • Participantes (Fonte: Allen-Bradley Cutler-Hammer Products Horner Electric Lutze, Inc. PDL Electronics Ltd Synergetic Micro Systems Beckhoff Industrie Elektronik DATA-LINC Group IDC Corporation McNaughton-McKay Eletric Company Phoenix Digital Corporation Toshiba International Corp. Belden Wire & Cable D.I.P. Inc. Industrial Technology Institute Mid-Island Electrical Sales Prosoft Technology TRW Nelson Stud Welding Division British Federal Ltd Event Technologies, Inc. Interlink BT LLC Nachi Robotic Systems Inc. Pyramid Solutions, Inc. Unico, Inc. CommScope, Inc. Ford Motor Company Kawasaki Robotics (USA), Inc. National Instruments Relcom Inc. Weltronic/Technitron Corporation Contemporary Controls HMS Fieldbus Systems AB Kendall Electric Inc. Nordson Corporation RBB Systems, Inc. Western Reserve Controls, Inc. Control Technology Inc. Honeywell, Inc. Lindener & Control Associates Omron Corporation S-S Technologies, Inc. Yokogawa Electric Corporation
    26. 26. AUTOMAÇÃO COM QUALIDADE. PERTO DE VOCÊ. RLAM Arquitetura ControlLogix