This document provides an overview of different Programmable Logic Controller (PLC) brands and their applications from the perspective of Optima Control Solutions, an automation company. It describes the basic components and functions of PLCs. It then compares Allen Bradley and Siemens PLCs, the two dominant brands, with Optima engineers Ian Brady and Nick Maclean offering differing views. Brady argues Allen Bradley PLCs are easier to program and troubleshoot, while Maclean believes Siemens is better suited for complex tasks. The document also discusses fixed versus modular PLC configurations and appropriate applications based on a PLC's capabilities.
The document discusses memory mapping using paging. It describes how paging divides the linear address space into fixed-size pages that can be mapped to physical memory frames or disk storage. The mapping is managed using a page directory and page tables. The page directory contains page table base addresses, and page tables contain the physical frame addresses of pages. Paging allows swapping pages between memory and disk, providing virtual memory that exceeds the available physical memory.
The document summarizes the multi-stage model of memory, including sensory memory, short-term/working memory, and long-term memory. It discusses the functions, capacities, and durations of each memory stage. Encoding and retrieval processes are described for transferring information between memory stores. Factors that influence memory, such as encoding specificity, interference, and forgetting, are also summarized.
There are three main methods for mapping memory addresses to cache addresses: direct mapping, associative mapping, and set-associative mapping. Direct mapping maps each block of main memory to a single block in cache in a one-to-one manner. Associative mapping allows any block of main memory to be mapped to any block in cache but requires tag bits to identify blocks. Set-associative mapping groups cache blocks into sets, with a main memory block mapped to a particular set and then flexibly to a block within that set, providing more flexibility than direct mapping but less complexity than full associative mapping.
This document provides an overview of a Siemens online course about programmable logic controllers (PLCs). The course covers basic PLC concepts, the S7-1200 line of PLCs from Siemens, programming S7-1200 PLCs, and additional information. It describes the topics that will be discussed in each chapter and the learning objectives. Siemens training options are also mentioned, including online self-paced learning courses.
This document provides an overview of a Siemens online course about programmable logic controllers (PLCs). The course covers basic PLC concepts, the S7-1200 line of PLCs from Siemens, programming S7-1200 PLCs, and additional information. It describes the topics that will be discussed in each chapter and the learning objectives. Siemens training options are also mentioned, including online self-paced learning courses.
Free PLC training PowerPoint from the 1 hour webinar we did for the Association for Facilities Engineering. Of course with 30 slides and instructor notes for each, because as those who use our training know, we give extra. Actually we went over by 45 min on this PLC training and we didn't even talk about the extra PLC training slides in this one. We start with what is a PLC put in the most simplest form possible, and then get you a little taste of our best practice PLC training and approach from our PLC training seminars and on-site PLc training.
پی ال سی دلتا مدل DVP14SS211R
دارای 8 ورودی دیجیتال شامل: 4 ورودی سرعت متوسط 20KHZ 4 ورودی سرعت متوسط 10KHZ دارای 6 خروجی دیجیتال شامل: 6 خروجی رله ای 1HZ ظرفیت برنامه نویسی 8KSTEP ورودی/خروجی قابل ارتقا
https://fcbuy.ir/plc/277-%D9%BE%DB%8C-%D8%A7%D9%84-%D8%B3%DB%8C-%D8%AF%D9%84%D8%AA%D8%A7-%D9%85%D8%AF%D9%84-dvp14ss211r.html
The document provides an introduction to programmable logic controllers (PLCs). It begins by stating the objectives of understanding PLC terminology, history, functions, advantages, and basic programming. It then explains what a PLC is and discusses its terminology, historical background, functions, advantages, basic components and instructions. Specific topics covered include the evolution of PLCs since 1968; their uses in various industries; how they can replace hard-wired relay systems; and how programming PLCs involves using ladder logic diagrams to represent circuits.
The document discusses memory mapping using paging. It describes how paging divides the linear address space into fixed-size pages that can be mapped to physical memory frames or disk storage. The mapping is managed using a page directory and page tables. The page directory contains page table base addresses, and page tables contain the physical frame addresses of pages. Paging allows swapping pages between memory and disk, providing virtual memory that exceeds the available physical memory.
The document summarizes the multi-stage model of memory, including sensory memory, short-term/working memory, and long-term memory. It discusses the functions, capacities, and durations of each memory stage. Encoding and retrieval processes are described for transferring information between memory stores. Factors that influence memory, such as encoding specificity, interference, and forgetting, are also summarized.
There are three main methods for mapping memory addresses to cache addresses: direct mapping, associative mapping, and set-associative mapping. Direct mapping maps each block of main memory to a single block in cache in a one-to-one manner. Associative mapping allows any block of main memory to be mapped to any block in cache but requires tag bits to identify blocks. Set-associative mapping groups cache blocks into sets, with a main memory block mapped to a particular set and then flexibly to a block within that set, providing more flexibility than direct mapping but less complexity than full associative mapping.
This document provides an overview of a Siemens online course about programmable logic controllers (PLCs). The course covers basic PLC concepts, the S7-1200 line of PLCs from Siemens, programming S7-1200 PLCs, and additional information. It describes the topics that will be discussed in each chapter and the learning objectives. Siemens training options are also mentioned, including online self-paced learning courses.
This document provides an overview of a Siemens online course about programmable logic controllers (PLCs). The course covers basic PLC concepts, the S7-1200 line of PLCs from Siemens, programming S7-1200 PLCs, and additional information. It describes the topics that will be discussed in each chapter and the learning objectives. Siemens training options are also mentioned, including online self-paced learning courses.
Free PLC training PowerPoint from the 1 hour webinar we did for the Association for Facilities Engineering. Of course with 30 slides and instructor notes for each, because as those who use our training know, we give extra. Actually we went over by 45 min on this PLC training and we didn't even talk about the extra PLC training slides in this one. We start with what is a PLC put in the most simplest form possible, and then get you a little taste of our best practice PLC training and approach from our PLC training seminars and on-site PLc training.
پی ال سی دلتا مدل DVP14SS211R
دارای 8 ورودی دیجیتال شامل: 4 ورودی سرعت متوسط 20KHZ 4 ورودی سرعت متوسط 10KHZ دارای 6 خروجی دیجیتال شامل: 6 خروجی رله ای 1HZ ظرفیت برنامه نویسی 8KSTEP ورودی/خروجی قابل ارتقا
https://fcbuy.ir/plc/277-%D9%BE%DB%8C-%D8%A7%D9%84-%D8%B3%DB%8C-%D8%AF%D9%84%D8%AA%D8%A7-%D9%85%D8%AF%D9%84-dvp14ss211r.html
The document provides an introduction to programmable logic controllers (PLCs). It begins by stating the objectives of understanding PLC terminology, history, functions, advantages, and basic programming. It then explains what a PLC is and discusses its terminology, historical background, functions, advantages, basic components and instructions. Specific topics covered include the evolution of PLCs since 1968; their uses in various industries; how they can replace hard-wired relay systems; and how programming PLCs involves using ladder logic diagrams to represent circuits.
This presentation provides an overview of programmable logic controllers (PLCs). It discusses what a PLC is, the history and major components of PLCs. The operational sequence and common programming languages like ladder logic are described. An example is given of using ladder logic to start and stop a motor. PLCs provide benefits like reliability, flexibility, cost-effectiveness and ease of maintenance. They are widely used in industrial automation applications such as robotics, materials handling, and process control. The presentation concludes by thanking the audience.
This document provides an overview of a Siemens manual on programmable logic controllers (PLCs) and related products. It introduces basic PLC components and concepts, number systems used in PLCs such as binary and hexadecimal, common PLC terminology, and Siemens S7 PLC families including the S7-200. The document aims to prepare distributors to sell and support Siemens PLC products.
Summer Internship Report For PLC Programming of Traffic light through Ladder ...Aman Gupta
For free download Subscribe to https://www.youtube.com/channel/UCTfiZ8qwZ_8_vTjxeCB037w and Follow https://www.instagram.com/fitrit_2405/ then please contact +91-9045839849 over WhatsApp.
An industrial PLCs system is used for the development of the controls of machinery. This paper describes the PLCs systems in terms of their architecture, their interface to the process hardware, the functionality and the application development facilities they provide. Some attention is also paid to the industrial standards to which they abide their planned evolution as well as the potential benefits of their use. Ladder Logic is a graphical programming language, initially programmed with simple contacts that simulates the opening and closing of relays. Ladder Logic programming has been expanded to include functions such as Counters, Timers, shift Registers and math operations. Ladder logic is a method of drawing electrical logic schematics. It is now a graphical language very popular for programming Programmable Logic Controllers (PLCs). It was originally invented to describe logic made from relays. The name is based on the observation that programs in this language resemble ladders, with two vertical "rails" and a series of horizontal "rungs" between them.
This document describes an automated car washing system that uses a programmable logic controller (PLC). It consists of multiple stations for cleaning, rinsing with water, applying soap, rinsing again, and drying. Sensors detect when a car reaches each station and the PLC controls motors and pumps to move the car between stations and operate the cleaning processes. The PLC allows the system to run automatically without human operators, saving time and labor costs compared to manual car washing. PLCs provide benefits like flexible input/output, small size, modularity, and ability to program automated sequences of operations for systems like this car wash.
Presentation for EEE Engineer on PLC By Dilip KumarDilip Kumar Ckt
This presentation provides an overview of programmable logic controllers (PLCs) for electrical and electronics engineers. It defines a PLC as an industrial computer that monitors input devices and controls output devices based on a custom program. The presentation discusses why PLCs are important for modern automation, common PLC types, brands, programming languages, components, operation, applications, job opportunities, and advantages/disadvantages. It emphasizes that as EEE engineers, understanding PLCs is important given their widespread use in industries like textiles, food processing, and power.
The document provides information about an industrial training project completed by Sudeep Giri at Insulators and Electricals Ltd. It includes an acknowledgement, preface, and table of contents. The content covers topics like the company background, software used, automation, PLC components, programming languages, and a motor start/stop example. It aims to describe PLC programming through ladder logic based on the training received.
Everything about PLC programming Practical lessons on PLC EMERSON EDUARDO RO...EMERSON EDUARDO RODRIGUES
This document provides an overview of PLC programming using Allen Bradley, Siemens, and Mitsubishi PLCs. It discusses the basics of PLCs, including processor memory organization and types of PLCs. It then covers Allen Bradley PLC series, wiring configuration, programming software, and communication protocols. Specific instructions for ladder logic programming are explained. The document also provides examples of PLC programming using different software for each manufacturer.
Everything about PLC programming Practical lessons on PLC EMERSON EDUARDO ROD...EMERSON EDUARDO RODRIGUES
This document provides an overview of PLC programming using Allen Bradley, Siemens, and Mitsubishi PLCs. It discusses the basics of PLCs including processor memory organization, types of PLCs and manufacturers. It then covers programming for specific PLC models from Allen Bradley, Siemens, and Mitsubishi including wiring, software, instructions, and examples. Case studies are also provided for different industrial applications.
Seminar Presentation on Programmeble Logic Controller , By an Engineering Student For doing Professional Presentation like Business Presentation, Industrial Use
Seminar Presentation on Programmeble Logic Controller , By an Engineering Student For doing Professional Presentation like Business Presentation, Industrial automation process,
This document describes an automatic mixing and filling bottle system that uses a Siemens S7-1200 PLC as the controller. The system uses submersible pumps to transfer water and flavoring from containers into a mixing container. A mixing motor mixes the contents and a solenoid valve fills bottles on a conveyor belt. The PLC programming is done using ladder logic in TIA Portal software. The project aims to design an appropriate model and program the PLC to control the system components for automatic mixing and filling of bottles.
training report. automation,plc , scada MdQutubuddin1
This document provides a training report on programmable logic controllers (PLCs), supervisory control and data acquisition (SCADA) systems, and automation. It introduces PLCs and their architecture, programming using ladder logic, applications of PLCs and SCADA systems, and common SCADA software. Examples of automation applications in various industries are also discussed. The report aims to explain the basic concepts and components of PLCs, SCADA, and automation through diagrams and a programming example.
This document provides an overview of a training report on programmable logic controllers (PLCs), supervisory control and data acquisition (SCADA) systems, and automation. It includes sections on the history and introduction of PLCs, the architecture of PLCs including the central processing unit and memory, programming PLCs using ladder logic, applications of PLCs and SCADA systems, the architecture of SCADA systems, and applications of automation in various industries. The training report was submitted to the Electrical Engineering department at the National Institute of Technology in Kurukshetra, India by a student as part of an internship on automation.
TRAINING REPORT ON INDUSTRIAL AUTOMATION- PLC SCADA, VARIABLE FREQUENCY DRIVEAKSHAY SACHAN
This document provides an overview of a training report on PLC, SCADA, and automation submitted by Akshay Sachan to the Electrical Engineering Department of the National Institute of Technology in Kurukshetra. The report includes an introduction to automation concepts, the history and introduction of programmable logic controllers, the architecture of PLCs including ladder diagrams, programming PLCs using ladder diagrams, applications of PLCs and SCADA systems, SCADA software and architecture, applications of SCADA, variable frequency drives, and a conclusion. Diagrams are provided to illustrate PLC internal architecture, simplified PLC structure, basic PLC sections, and ladder diagrams.
Basic PLC Programming program The Fundamental Knowledge of PLC.pdfLuisDavidCajavilcaCu1
This document provides an overview of basic PLC programming. It covers PLC introduction, design and operation, programming, common programming languages, and examples of Omron, Mitsubishi, Siemens, GE Fanuc, and Allen Bradley PLC programming. The key points covered include the basic components and functions of a PLC, common programming languages like ladder logic, function block diagrams and structured text, and examples of creating programs for specific PLC models from different manufacturers.
The document provides an overview of a PLC basics course. It begins with questions to start a discussion about PLC history and applications. It then covers the basic structure and components of a PLC system, including the central processor, memory, power supply, and input/output modules. The document discusses PLC programming and explains the operation of inputs, outputs, and the control logic. It also reviews the evolution of PLCs and some optional interfaces that can be used.
The document provides an overview of a PLC basics course. It begins with 20 questions about PLC history and applications. It then outlines that the course will familiarize students with PLC structure, operation, and interfaces. It will explain the central processing unit, user memories, and I/O and CPU scans. Students will learn about input/output interfaces, functional operation, and PLC components. The document discusses logic functions, control system options, and why PLCs were adopted. It defines PLCs, describes typical parts and applications. The history of PLC development from the 1960s to distributed control networks is reviewed.
The document discusses the hardware control capabilities and selection criteria of Siemens S7-1200 and S7-1500 programmable logic controllers (PLCs). The S7-1200 has a maximum of 256 digital inputs/outputs while the S7-1500 can support up to 960. Both PLCs support analog and communication modules. Key factors for PLC selection include the application requirements, required input/output capacity, memory needs, and communication requirements. The document also compares the two PLC models.
In business most questions must satisfy a commercial rationale. Any monetary investment
needs to have justification with a confidently predicted return on that investment. So what
improvements can be reasonably expected from the decision to migrate? In this report, we consider a few of the more frequently undertaken migration projects:
1) Analogue control equipment to digital control equipment.
2) Obsolete PLC to Current PLC
3) DC motor control technology to AC technology
4) Traditional copper cable machine wiring and distributed Fieldbus networks.
Control Systems Obsolescence – Support Strategies and Key ConsiderationsOptima Control Solutions
Naturally, robust steel frameworks of machines age much more slowly than their moving parts and also have an extremely long life span if well-maintained. However, with those same machines’ control systems the case is different. Modern technology advances so quickly that a system can be out of date in as little as 10-12 years.
In this article, Michael Hill, managing director of Optima Control Solutions, looks at three different manifestations of control system obsolescence and offers practical advice on how to deal with each case. The last part of the article contains a checklist of the key factors to consider before moving forward with any obsolescence support strategy.
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This presentation provides an overview of programmable logic controllers (PLCs). It discusses what a PLC is, the history and major components of PLCs. The operational sequence and common programming languages like ladder logic are described. An example is given of using ladder logic to start and stop a motor. PLCs provide benefits like reliability, flexibility, cost-effectiveness and ease of maintenance. They are widely used in industrial automation applications such as robotics, materials handling, and process control. The presentation concludes by thanking the audience.
This document provides an overview of a Siemens manual on programmable logic controllers (PLCs) and related products. It introduces basic PLC components and concepts, number systems used in PLCs such as binary and hexadecimal, common PLC terminology, and Siemens S7 PLC families including the S7-200. The document aims to prepare distributors to sell and support Siemens PLC products.
Summer Internship Report For PLC Programming of Traffic light through Ladder ...Aman Gupta
For free download Subscribe to https://www.youtube.com/channel/UCTfiZ8qwZ_8_vTjxeCB037w and Follow https://www.instagram.com/fitrit_2405/ then please contact +91-9045839849 over WhatsApp.
An industrial PLCs system is used for the development of the controls of machinery. This paper describes the PLCs systems in terms of their architecture, their interface to the process hardware, the functionality and the application development facilities they provide. Some attention is also paid to the industrial standards to which they abide their planned evolution as well as the potential benefits of their use. Ladder Logic is a graphical programming language, initially programmed with simple contacts that simulates the opening and closing of relays. Ladder Logic programming has been expanded to include functions such as Counters, Timers, shift Registers and math operations. Ladder logic is a method of drawing electrical logic schematics. It is now a graphical language very popular for programming Programmable Logic Controllers (PLCs). It was originally invented to describe logic made from relays. The name is based on the observation that programs in this language resemble ladders, with two vertical "rails" and a series of horizontal "rungs" between them.
This document describes an automated car washing system that uses a programmable logic controller (PLC). It consists of multiple stations for cleaning, rinsing with water, applying soap, rinsing again, and drying. Sensors detect when a car reaches each station and the PLC controls motors and pumps to move the car between stations and operate the cleaning processes. The PLC allows the system to run automatically without human operators, saving time and labor costs compared to manual car washing. PLCs provide benefits like flexible input/output, small size, modularity, and ability to program automated sequences of operations for systems like this car wash.
Presentation for EEE Engineer on PLC By Dilip KumarDilip Kumar Ckt
This presentation provides an overview of programmable logic controllers (PLCs) for electrical and electronics engineers. It defines a PLC as an industrial computer that monitors input devices and controls output devices based on a custom program. The presentation discusses why PLCs are important for modern automation, common PLC types, brands, programming languages, components, operation, applications, job opportunities, and advantages/disadvantages. It emphasizes that as EEE engineers, understanding PLCs is important given their widespread use in industries like textiles, food processing, and power.
The document provides information about an industrial training project completed by Sudeep Giri at Insulators and Electricals Ltd. It includes an acknowledgement, preface, and table of contents. The content covers topics like the company background, software used, automation, PLC components, programming languages, and a motor start/stop example. It aims to describe PLC programming through ladder logic based on the training received.
Everything about PLC programming Practical lessons on PLC EMERSON EDUARDO RO...EMERSON EDUARDO RODRIGUES
This document provides an overview of PLC programming using Allen Bradley, Siemens, and Mitsubishi PLCs. It discusses the basics of PLCs, including processor memory organization and types of PLCs. It then covers Allen Bradley PLC series, wiring configuration, programming software, and communication protocols. Specific instructions for ladder logic programming are explained. The document also provides examples of PLC programming using different software for each manufacturer.
Everything about PLC programming Practical lessons on PLC EMERSON EDUARDO ROD...EMERSON EDUARDO RODRIGUES
This document provides an overview of PLC programming using Allen Bradley, Siemens, and Mitsubishi PLCs. It discusses the basics of PLCs including processor memory organization, types of PLCs and manufacturers. It then covers programming for specific PLC models from Allen Bradley, Siemens, and Mitsubishi including wiring, software, instructions, and examples. Case studies are also provided for different industrial applications.
Seminar Presentation on Programmeble Logic Controller , By an Engineering Student For doing Professional Presentation like Business Presentation, Industrial Use
Seminar Presentation on Programmeble Logic Controller , By an Engineering Student For doing Professional Presentation like Business Presentation, Industrial automation process,
This document describes an automatic mixing and filling bottle system that uses a Siemens S7-1200 PLC as the controller. The system uses submersible pumps to transfer water and flavoring from containers into a mixing container. A mixing motor mixes the contents and a solenoid valve fills bottles on a conveyor belt. The PLC programming is done using ladder logic in TIA Portal software. The project aims to design an appropriate model and program the PLC to control the system components for automatic mixing and filling of bottles.
training report. automation,plc , scada MdQutubuddin1
This document provides a training report on programmable logic controllers (PLCs), supervisory control and data acquisition (SCADA) systems, and automation. It introduces PLCs and their architecture, programming using ladder logic, applications of PLCs and SCADA systems, and common SCADA software. Examples of automation applications in various industries are also discussed. The report aims to explain the basic concepts and components of PLCs, SCADA, and automation through diagrams and a programming example.
This document provides an overview of a training report on programmable logic controllers (PLCs), supervisory control and data acquisition (SCADA) systems, and automation. It includes sections on the history and introduction of PLCs, the architecture of PLCs including the central processing unit and memory, programming PLCs using ladder logic, applications of PLCs and SCADA systems, the architecture of SCADA systems, and applications of automation in various industries. The training report was submitted to the Electrical Engineering department at the National Institute of Technology in Kurukshetra, India by a student as part of an internship on automation.
TRAINING REPORT ON INDUSTRIAL AUTOMATION- PLC SCADA, VARIABLE FREQUENCY DRIVEAKSHAY SACHAN
This document provides an overview of a training report on PLC, SCADA, and automation submitted by Akshay Sachan to the Electrical Engineering Department of the National Institute of Technology in Kurukshetra. The report includes an introduction to automation concepts, the history and introduction of programmable logic controllers, the architecture of PLCs including ladder diagrams, programming PLCs using ladder diagrams, applications of PLCs and SCADA systems, SCADA software and architecture, applications of SCADA, variable frequency drives, and a conclusion. Diagrams are provided to illustrate PLC internal architecture, simplified PLC structure, basic PLC sections, and ladder diagrams.
Basic PLC Programming program The Fundamental Knowledge of PLC.pdfLuisDavidCajavilcaCu1
This document provides an overview of basic PLC programming. It covers PLC introduction, design and operation, programming, common programming languages, and examples of Omron, Mitsubishi, Siemens, GE Fanuc, and Allen Bradley PLC programming. The key points covered include the basic components and functions of a PLC, common programming languages like ladder logic, function block diagrams and structured text, and examples of creating programs for specific PLC models from different manufacturers.
The document provides an overview of a PLC basics course. It begins with questions to start a discussion about PLC history and applications. It then covers the basic structure and components of a PLC system, including the central processor, memory, power supply, and input/output modules. The document discusses PLC programming and explains the operation of inputs, outputs, and the control logic. It also reviews the evolution of PLCs and some optional interfaces that can be used.
The document provides an overview of a PLC basics course. It begins with 20 questions about PLC history and applications. It then outlines that the course will familiarize students with PLC structure, operation, and interfaces. It will explain the central processing unit, user memories, and I/O and CPU scans. Students will learn about input/output interfaces, functional operation, and PLC components. The document discusses logic functions, control system options, and why PLCs were adopted. It defines PLCs, describes typical parts and applications. The history of PLC development from the 1960s to distributed control networks is reviewed.
The document discusses the hardware control capabilities and selection criteria of Siemens S7-1200 and S7-1500 programmable logic controllers (PLCs). The S7-1200 has a maximum of 256 digital inputs/outputs while the S7-1500 can support up to 960. Both PLCs support analog and communication modules. Key factors for PLC selection include the application requirements, required input/output capacity, memory needs, and communication requirements. The document also compares the two PLC models.
In business most questions must satisfy a commercial rationale. Any monetary investment
needs to have justification with a confidently predicted return on that investment. So what
improvements can be reasonably expected from the decision to migrate? In this report, we consider a few of the more frequently undertaken migration projects:
1) Analogue control equipment to digital control equipment.
2) Obsolete PLC to Current PLC
3) DC motor control technology to AC technology
4) Traditional copper cable machine wiring and distributed Fieldbus networks.
Control Systems Obsolescence – Support Strategies and Key ConsiderationsOptima Control Solutions
Naturally, robust steel frameworks of machines age much more slowly than their moving parts and also have an extremely long life span if well-maintained. However, with those same machines’ control systems the case is different. Modern technology advances so quickly that a system can be out of date in as little as 10-12 years.
In this article, Michael Hill, managing director of Optima Control Solutions, looks at three different manifestations of control system obsolescence and offers practical advice on how to deal with each case. The last part of the article contains a checklist of the key factors to consider before moving forward with any obsolescence support strategy.
This document discusses key considerations for machine vision systems. It explains that vision systems are unique to each application and require custom engineering. It then discusses important elements like lighting, lenses, camera sensors, and integration with control systems. Proper lighting and component selection are essential for system success. The document also outlines common vision system types and imaging options like 2D and 3D.
OptimaoIn control has extensive experience with machine safety systems from major PLC, SCADA, and drive manufacturers like Siemens, Allen Bradley, GE Fanuc, Schneider, and Parker. Pegler Yorkshire, a manufacturer of plumbing products, upgraded the drive system controlling a cold forging press with a new AC motor and AC drives from Parker Hannifin. This resulted in a 25% increase in production availability through reduced downtime. Maintenance time was also cut from 2 hours per week to just 10 minutes per month, and annual maintenance costs decreased by £1500.
This report describes the development of a power conversion system for a floating tidal stream generator called the Evopod. A prototype Evopod will generate 25kW and test the effects of the marine environment. Optima Control Solutions designed power conversion equipment including a regenerative power converter, transformers, cables, and control systems to maximize power generation at different tidal flows and minimize transmission losses. Extensive simulation and dynamometer testing validated the design's performance before sea trials.
Variable speed drives control motor speed and torque by converting AC electricity from mains supply. Drives require a speed demand signal and feedback from motor sensors to run control algorithms. Drives are tuned to match the motor and load conditions for optimal speed maintenance. Variable speed drives can be programmed either using the drive's internal function blocks or programming blocks in a PLC. Using internal blocks is often quicker but requires learning proprietary software, while PLC programming is more flexible but more complex and resource-intensive. The best approach depends on the application and expertise of the engineering team.
In this presentation Mark Lane focuses on a project Optima has completed for a large paper-making company. The problem that the customer faced on the machine was a mixture of obsolescence and unreliability.
Optima improved the machine’s performance by at least 20% by completely re-designing four areas of its control system:
Drives and PLC control
Safety system
Pneumatics
Web tension control
UPGRADE BY OPTIMA CONTROL SOLUTIONS IS FUELLING DUNLOP’S PRODUCTIVITY DRIVEOptima Control Solutions
Optima Control Solutions completed a control and safety system upgrade for Dunlop, a world leading producer of rubber products, to improve productivity. Optima was chosen for its sector expertise and reputation for enhancing plant efficiency. The upgrade involved refurbishing a machine to meet stricter safety standards while allowing flexibility, using a Pilz safety relay and Siemens drive. The successful project established a collaborative relationship between the companies that is expected to lead to further projects.
API, a manufacturer of foil and laminate products, wanted to improve the performance and reduce costs of its laminating line. The original system used a complex arrangement of mechanical drives and gearboxes that was unreliable, difficult to maintain, and expensive. Optima replaced this with a solution using 13 individual AC vector motors controlled by variable speed drives. This significantly improved energy efficiency and machine functionality, reducing setup times and making operation easier. It allowed the laminating line to be in almost constant use.
(1) The document discusses web tension control systems, comparing open-loop and closed-loop systems. It focuses on the two main types of closed-loop systems: dancer mechanisms and load cell transducers.
(2) Dancer mechanisms provide easier setup and ability to accumulate web material, but do not directly measure tension and require more complex mechanical design. Load cell transducers directly measure tension but are harder to commission and debug.
(3) The selection of dancer mechanisms vs load cell transducers depends on the specific application factors like material type, machine type, and required dynamic response. Dancer mechanisms are generally better for applications requiring web accumulation like flying splice winders.
Industrial robots are increasingly being used for manufacturing due to their ability to improve productivity. Robots are automatically controlled machines that can be programmed to move in multiple axes to perform tasks. They are used widely in automotive, electronics, and other industries. Robots are programmed using software provided by the manufacturer and can be programmed online by teaching them motions or offline using simulation. Integrating a robot's control system with a production plant requires considering how the robot will interface with other machines and sensors.
The document discusses upgrading an Optima S5 PLC system to a Simatic S7 system. It describes how the Optima S57 processor can run S5 and S7 programs simultaneously, allowing the conversion to be done in stages. This minimizes risks by reducing engineering needs at each stage. The upgrade route offers flexibility in hardware upgrades and shutdown timelines.
The document describes a solution for automated production and downtime reporting. It provides accurate, reliable, and cost-effective reporting of a company's production performance across any number of machines and locations. The solution includes installation, commissioning, training and ongoing support services. It aims to help businesses improve productivity through comprehensive reporting and analysis tools accessible anywhere through a secure web-based system.
Using the AC Drive Motor as a Transducer for detecting electrical and electro...Optima Control Solutions
Original citation:
Lane, Mark (2011) Using the AC Drive Motor as a Transducer for Detecting
Electrical and Electromechanical Faults. Masters thesis, University of
Huddersfield.
Full report available at: http://eprints.hud.ac.uk/10167/
This report aims to familiarize the reader with basic but important information about
two specific types of controllers – DC drives and AC drives. The first part provides
descriptions of the general working principles of variable speed drive (VSD)
technology. It discusses their main advantages and disadvantages between AC and
DC drive solutions. The second part explains some problems that could possibly be
encountered when employing AC or DC drive systems and offers practical
recommendations about how to approach these problems.
Dr Adrian West, Optima’s technical director, has spent more than 30 years working
with, programming and troubleshooting drive systems. This report is based on his
extensive practical knowledge and experience. It is, therefore, a very accurate and independent source of information.
Threats to mobile devices are more prevalent and increasing in scope and complexity. Users of mobile devices desire to take full advantage of the features
available on those devices, but many of the features provide convenience and capability but sacrifice security. This best practices guide outlines steps the users can take to better protect personal devices and information.
Securing your Kubernetes cluster_ a step-by-step guide to success !KatiaHIMEUR1
Today, after several years of existence, an extremely active community and an ultra-dynamic ecosystem, Kubernetes has established itself as the de facto standard in container orchestration. Thanks to a wide range of managed services, it has never been so easy to set up a ready-to-use Kubernetes cluster.
However, this ease of use means that the subject of security in Kubernetes is often left for later, or even neglected. This exposes companies to significant risks.
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2. Automated control systems are the backbone of modern production. It is hard to imagine
engineering a manufacturing process without the help of a specialized computing system.
This is where Programmable Logic Controllers (or PLCs) are significant. The choice of a PLC
brand, therefore, is not a simple decision to make because that can affect the productivity of
a whole process line.
Optima Control Solutions is an expert independent automation company and has over 16
years of experience with a wide range of PLC equipment. This report briefly compares the
physical characteristics and the functional benefits of three PLC products and gives unbiased
perspectives regarding the appropriate applications of each.
The first part of this report describes the basic principles and architecture of a programmable
logic controller. The second part provides short comparisons of 3 PLC brands. The final part
is a debate between Optima’s senior engineers about the various benefits of each PLC brand
(focusing particularly on Siemens and Allen Bradley). Ian Brady and Nick Maclean offer two
different views on the pros and cons of the products of the two main PLC manufacturers.
3. Why PLC?
Since their inception in the 1960s in the US automotive industry, Programmable Logic
Controllers have become part of virtually every mass manufacturing process across all
industries and geographies. For manufacturers understanding the logic of a PLC is not a
necessity. Appreciating the way it makes a difference to the production process, however, is.
These are some of the benefits of employing the latest PLC technology:
oooo Efficiency – recent PLC models have greater memory capabilities and less space
requirements. Depending on the machine’s specifications, the PLC size will vary from nano
to large.
oooo Flexibility – A single PLC may run several machines at a time.
oooo Cost efficiency – Most PLC manufacturers offer controllers with varying capabilities. Some
machines can be successfully controlled by lower range PLCs, thus eliminating the need for
costly investments in high-end models.
oooo Safety – Safety PLCs can reduce the risk of industrial accidents significantly.
4. Logic inside the box
As with most computers, a PLC is often seen as a black box that receives, processes and
sends out signals. Looking inside the box is important when trying to make the most cost
effective and at the same time most benefitial for a production line decision.
The three main components of a PLC are the input/output modules, the central processing
unit(CPU) and memory.
Input and output modules are converters with the function of receiving and sending analog
or digital signals from and to parts of a machine. I/O modules now have remote capabilities,
meaning that a single PLC can control parts of a machine at significant distance, without the
need of extra wiring.
The CPU executes the program written for the particular PLC by using input signals and
translating them into appropriate outputs. It is interesting that a PLC is able to receive analog
signals and send out digital ones – this flexibility makes the controller applicable to almost
any production line irrespective of industry and proces..
As any other type of computer the PLC needs memory to store the latest input and output
data and make the appropriate translations, calculations or comparisons. The memory
capabilities of a PLC, however, are highly restrained – less than 100 Mbytes memory sounds
like a thing of the past for a personal computer, but it is an impressive value for a PLC.
A simple representation of what is inside ‘the box’
5. PLC ranges
The functionality of every PLC model is usually deciphered behind complex numerical
values that may not be easily understood by everyone. Optima Control Solutions offers a
simple comparison tool to help decision makers find the most effective solution for their
production line problems.
The following PLC models are classified according to the complexity of tasks they are able to
complete. This list is not exhaustive and certain models can be seen as niches of their own.
Other PLC brands such as Omron, Schneider Electric and GE Fanuc are not listed below but
tend to offer a similar range of functions. Optima is extensively using Siemens, Allen Bradley
and Mitsubishi PLCs and is able to compare their functional benefits.
oooo Low cost solutions for easy repetitive control tasks – fixed configurations, expandable
6. oooo Low cost solutions for open-ended control tasks – modular configurations
* Allen Bradley Temperature I/O modules cost approx. £300
7. oooo Mid to high performance ranges - high flexibility and high speed controllers
* Mitsubishi Special Function Modules cost up to £700.
oooo High-end solutions for very demanding tasks (high fail-safe requirements, high restart
costs, expensive downtimes, little supervision)
8. In the previous section a small sample of the large range of PLCs available are reported. The PLC
market is dominated by two giants – Siemens and Rockwell. Optima works with other PLC brands
but is most experienced with these two and is, therefore, able to provide a detailed expert
opinion about both Siemens and Allen Bradley controllers.
Two contrasting opinions prevail among Optima’s engineers. Some say Allen Bradley PLCs are
simple, hassle-free and that these benefits save both time and money to the customer. Others
believe that Siemens PLCs are very advanced in many aspects and that this improves production
processes. We asked Ian Brady and Nick Maclean, Optima’s senior engineers, to give their own
arguments on the topic.
9. By Ian Brady
I shall start like this - you cannot say that an
Allen Bradley (AB) PLC is faster or better than
a Siemens one. In certain categories they are
very similar. Now, why would you choose
one over the other? Simple question: first,
what does the company already use – if they
have Siemens equipment they will carry on
using it! It is usually the biggest criteria, not
whether one is better than the other. Also,
their maintenance people have got some
experience with it so rather than learning
about a new piece, they will carry on using
the old one.
So if your question is “why Allen Bradley is
better than Siemens in certain categories?”
my answer is – it is not. I have an opinion,
however, that if you are to give two
maintenance men who have not seen or not
used these things before a problem on a
machine at 2 a.m. and they have not seen it
for 6 months, they will find the fault quicker
on an Allen Bradley, Toshiba or Mitsubishi
PLC than they would do on Siemens. I think
it is easier to understand how it works and fix
it! At the end of the day it is not whether one
is better than the other, it is just that the
customer might find it easier to use.
Also, when I am commissioning, I find
debugging a lot quicker and a lot easier with
Allen Bradley than with Siemens. That may
be just down to the fact that I am more used
to AB than Siemens, it does not mean that
one is better than the other. AB is easy to
fault find, easier to modify, easier to
understand. That, for me, is a big plus
especially for the customer who would find
it easier to work with this piece of kit than
with Siemens.
[H: Do you think that certain PLCs are more
appropriate for, say, extruders, than other
PLC brands?]
Absolutely not! It depends again – if you
have a customer who says ‘I want to use only
Siemens’ you cannot put an AB PLC.
Sometimes we have choice; we say ‘Hold on,
we have a choice here so let’s design the
best mix!’ We have had both cases. We have
used Parker drives with AB and with
Siemens. One machine I am doing in
Scotland has Siemens PLCs and an SSD drive.
The easiest mix for every machine is
different.
Why would I use an AB PLC? Sometimes,
because of its functionality! If you want to
do servo opposition control, a very accurate
system, it may be better to use AB PLCs
because their function blocks are more
appropriate for that particular application.
[H: Can you explain what a function block is
in more detail?]
Here is one example. When you start a
machine, you start at 0 meters/minute but
after one minute you want it to run at, say,
500 meters/min. To get from 0 to 500, we
call that a ramp and what we do is ramping
the reference value. That ramp we can put in
a block, so what we have in a block is just
input and output. What goes on in the block
really does not matter. All you need to know
about input is: there is a start (or stop), there
is a maximum value and a minimum value
and there is rate – for example, ramp time
per minute. Finally, there is output also
known as reference. This is called a function.
In Siemens terms that would be called a FC
(function call) – once it is written, it can be
used as many times as needed. But it will not
do anything else – everything it will do is to
produce a ramp output every single time. In
AB words, these function blocks would be
called subroutines.
Next thing, software can be written in many
different ways – ladder diagrams (1), SFC –
sequential function charts (2) or in language
terms known as statement lists (3). Now, (3)
10. is where it all gets complicated and harder!
Siemens writes a lot of the PLC programs like
(3). When you are trying to figure out how
things work, when you look at the machine
and ask “show me what is happening?” the
charts change colours, for example. If the
inputs are on, the chart will go green so that
one can see how the line works. In (3) you
will have a couple of columns and there will
be numbers all over the place. If the code is
written in this way, it is really hard for the
maintenance engineer to understand what
all of these column values mean – it means
nothing to him. Siemens was written for
programmers, AB and all the rest of them
were written for electricians and
maintenance people. (1) and (2) are easy to
understand, (3) is not. It is sometimes
frightening – the problem is if the processor
you’ve got is not too powerful. What it does
is to turn a statement list into a ladder
diagram in its own little brain. If the ladder is
too complex and gets translated into a code,
the processor may never translate it back
so, all you see on the screen is code! This
might be completely staggering for
maintenance people!
That is the difference when using a simple
PLC or simple and understandable way of
writing. The problem with machines is that
nobody looks at them when they are
working. When they are not working, people
lose money! The maintenance guy goes to
the machine when it is not working. He will
try to find out what is wrong with it and the
quicker he does that, the sooner it gets back
into production. So if you use a simple PLC
such as AB, you may find the problem faster
and make less loss.
11. [H: Can you explain me the difference
between fixed and modular configuration?]
The fixed configuration has a certain number
of inputs and outputs, it is totally fixed, and
you cannot add bits to it! Basically, you get
what you get. Some can be extended but
rarely. These are used for fairly simple
control tasks. Here (4) is one example –
Siemens Logo. I can show you four different
makes and they all look identical. There are a
few models with some additions but more or
less their functionality is the same. When
you go up the range, PLCs are also pretty
much fixed. Top of range PLCs are modular,
where you can add many more modules with
many more inputs and outputs. Quite
obviously, the prices reflect how advanced a
PLC is – and prices will not vary too much
across brands as much as they will vary
across the individual product ranges of
every PLC manufacturer! If you buy an
expensive PLC you will be sure that its
control capabilities are better. But again
unless you own a nuclear power plant and
must have the most advanced control
systems, you do not need to spend over
£5000 for a single PLC from the high end of
the line.
[H: What about scan time?]
If you look at (2), the system works from top
to bottom before it repeats the process and
starts over.
In programming there is something called
parallel processing or let us call it another
way – multitasking. A PLC tends not to do
that – it tends to do one thing at a time. It
runs one thing and then goes on to the next
task. So a scan is the time it takes a PLC to
do a job from top to bottom. It depends on
how big the program is, how fast the
processor is and so on. Well, it all depends
on how much you are going to spend, really.
Sometimes you can find that smaller PLCs
such as the Siemens 300 series are faster
than bigger ones (400 series). The 400 are
higher in price but the 300 will be able to do
total a lot more. The big AB Contrologix
PLCs, for example, can take up to 10000
inputs and outputs; the smaller ones are
more limited so they perform faster. It is a
matter of what you need – big PLCs have the
option to add more than one processor in a
rack so if one fails the other takes over –
these are perfect for safety critical tasks.
12. By Nick Maclean
I do not have enough experience with Allen
Bradley (AB) and I have always been a
Siemens programmer. It suits the style of
programming for very complex tasks, very
mathematical, analytical tasks. In my view,
Siemens supports these tasks better than an
AB. This might be because I do not know the
Rockwell stuff very well.
[H: What about ease of use and
programming?]
If you are a trained programmer, you will
find the Siemens one more intuitive. If you
are not a programmer by nature then you
want to do everything with ladder logic. And
you can go only so far with ladder logic, to go
beyond that you need to use a low language
that obviously gives more flexibility and
more efficiency of programming.
[H: Do you think Siemens is more
appropriate for particular production
processes then?]
I think for most of the work we do, you could
realistically use either. In terms of speed of
development, I would say Siemens is a
better one once you get used to it. It is
easier to make reusable components and
transfer them between projects. It has a
very integrated environment. For example,
with HMI screens –reading the text directly
out of the project. Probably the AB does the
same??
[H: What are the PLC components that you
consider being superior in a Siemens piece?]
The programming language as an
integration is more superior. There are
some shortcomings in using statement lists,
so an AB PLC would be easier to program.
But for complex tasks I must say Siemens is
the better one. At the bottom level they
are very similar. When you get to the more
in-depth features is where they differ.
There is a number of languages available
for Siemens PLCs. Some of them we use,
some – we do not; some languages will
become more important in the future. For
example, they have a language called SCL. It
is very similar to Pascal and compiles to a
low level language with native code in the
newer processors. Older ones use
interpretative code. So the new versions of
SCL compile native code that will allow
processors to execute much more
efficiently and will allow people to use
programmers from the industrial
marketplace – those who are experienced
Pascal programmers, they will not need to
be assembly code co-programmers.
There are different levels of people’s
understanding of PLCs. Those who prefer
ladder logic or sequential charts will tend
to use AB PLCs. Siemens has an advantage
in statement lists programming. For very
heavily mathematical stuff and highly
complex tasks I would choose Siemens.
Array handling is one of its weaknesses but
then the SCL code makes that a lot more
possible.
[H: Would you recommend a certain PLC
brand for, say, coating lines control? Or
this decision should be project specific?]
13. It really depends on what the customer’s
support network is for any given product. If
they ask us for a recommendation we will look
at their machine and design the best mix. In
certain industries it is more common to find
certain PLC brands. For example, in the steel
industry Bosch Rexroth or Modicon are very
popular. A mixture of either brands(Siemens
and AB) is typical, too.
[H: What about function blocks? Can you compare
AB and Siemens in terms of function blocks?]
Function block programming in a Rockwell is easier
for some engineers. With an AB you can produce
reusable blocks but I know people who have tried
using them more than once and it did not work
very well. I suspect that is a limitation in their
knowledge rather than the function blocks
themselves. [laughs] Function blocks are very easy
to use with Siemens and reuse them from one
project to the next one. It is a question of how
they are written – it is a matter of experience of
using the tool, really.
[H: Can you tell me more about the types of PLC
configurations and how do they differ?]
Fixed configurations tend to be the very small
PLCs, we do not use small ones – they are very
standardised and easy. We work with more
modular configurations, as our projects are bigger.
For a machine with the size of a table, you can get
away with a simple fixed configuration. We are
normally dealing with much larger pieces of
equipment; they have specific requirements that
outstrip what a fixed PLC piece offers as a
capability. All PLC manufacturers fall in both
categories – not only Siemens or AB. We have
worked with Mitsubishi and GE Fanuc, for example
– all of them have a wide range – from basic to
high-end.
I think both Siemens and AB are more specialized
in modular configurations. They do fulfil the fixed
configuration criteria just to compete in this niche
and create brand presence. To be honest, other
manufacturers such as Mitsubishi and Omron
dominate the fixed PLCs market.
[H: Scan time. What can you say about it for
both Siemens and AB?]
AB processors, the high-end ones, are very very
fast. This is because they are slightly different –
they have the acyclic I/O update which is…a bit
difficult to understand. The way most PLCs work
is cyclically: they run to the end of their program
and start over again (see 5).
(5) I/O update cycle
At the start of every program execution, they
read the input values into what is called
‘process image’ (or PII). Then the program
executes and at the end of the program there
is a bit called PIO – process image output. At
the end of the process the PIOs are
transferred into actual outputs. That is a cyclic
operation or a cyclic I/O update. With an AB
processor, it is actually not executed cyclically.
In a Siemens program, for example, you know
that if an input is true in point A (beginning of
the program), it will also be true in point B
(end of the program). If that input is updated
14. halfway through, it may not be true at the end of the program execution – that can influence how
you design the software. With an Allen Bradley processor there are complexities that are not
necessarily obvious to people who only understand ladder logic. So, it is an acyclic I/O update that
you most often need on Allen Bradley. I do not see it as an advantage; I see it as a disadvantage. In
terms of cycle time, the AB processor is much quicker but it is a question of being quick and being
quick enough against a certain cost. In terms of price, they tend to be quite competitive with each
other based on performance. Total cost of ownership is another thing people consider and it
comes down to what resources are available in-house.
[H: Does memory size matter?]
One good argument is ‘why would you want to put massive amounts of memory in a PLC?’ That
would imply that a program is very inefficient. If you could get the same program running in a
smaller amount of memory then it is a lot more efficient. There is some disadvantage to that as
well – you cannot download the source code into the PLC. In some of the newer ones, you can –
they are all moving in that direction.
15. Disclaimer: All data provided in this report is for informational purposes only. Opinions expressed
in this report are those of the relevant contributors. These do not reflect recommendations of
one brand over another.
Images sourced from:
1. Optima® gallery – all copyrights reserved.
2. Siemens® logo – www.siemens.com
3. Allen Bradley® logo – www.rockwellautomation.com
Design :
www.picnic.com
Written by:
Hristina Stefanova
Revised by:
Michael Hill