Industrial Control Systems - PLC

Industrial Control

Behzad Samadi

Department of Electrical EngineeringAmirkabir University of Technology

Winter 2011Tehran, Iran

Behzad Samadi (Amirkabir University) Industrial Control 1 / 1

Programmable Logic Controllers

Outline:

Introduction

Hardware

Programming

Ladder DiagramsInstruction ListStructured TextSequential Function ChartFunction Block Diagram

[Jack, 2008]

Outline:

Introduction

Hardware

Programming

[Jack, 2008]

Outline:

Introduction

Hardware

Programming

[Jack, 2008]

Outline:

Introduction

Hardware

Programming

Ladder Diagrams

Instruction ListStructured TextSequential Function ChartFunction Block Diagram

[Jack, 2008]

Outline:

Introduction

Hardware

Programming

Ladder DiagramsInstruction List

Structured TextSequential Function ChartFunction Block Diagram

[Jack, 2008]

Outline:

Introduction

Hardware

Programming

Ladder DiagramsInstruction ListStructured Text

Sequential Function ChartFunction Block Diagram

[Jack, 2008]

Outline:

Introduction

Hardware

Programming

Ladder DiagramsInstruction ListStructured TextSequential Function Chart

Function Block Diagram

[Jack, 2008]

Outline:

Introduction

Hardware

Programming

[Jack, 2008]

Definition:

A digitally operating electronic system, designed for use in anindustrial environment, which uses memory for the internal storage ofuser-oriented instructions for implementing specific functions such aslogic, sequencing, timing, counting and arithmetic to control, throughdigital or analog inputs and outputs, various types of machines orprocesses.

[Fes, 2002]

What is a PLC?

A programmable logic controller (PLC) is a specialized computer toperform logic functions for machine control.

PLCs are used to implement logic functions such as not allowing adrill press to start unless the operator has one hand on each of thetwo start switches.

Such control functions used to be implemented using relays. PLCsrevolutionized this by allowing the control logic to be implementedusing software.

[Fes, 2002]

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]

Advantages of using PLCs:

Highly reliable

Highly versatile (universal applicability)Simple troubleshootingSimple installationQuick modification of the program (highly flexible)Capable of tasks not possible with relays before:

calculationinformation exchangetext and graphic displaydata processingnetworking

Low space requirementLow power consumptionHigh processing speedNo moving parts, hence no wearing parts

[Fes, 2002]

Highly reliableHighly versatile (universal applicability)

Simple troubleshootingSimple installationQuick modification of the program (highly flexible)Capable of tasks not possible with relays before:

[Fes, 2002]

Highly reliableHighly versatile (universal applicability)Simple troubleshooting

Simple installationQuick modification of the program (highly flexible)Capable of tasks not possible with relays before:

[Fes, 2002]

Highly reliableHighly versatile (universal applicability)Simple troubleshootingSimple installation

Quick modification of the program (highly flexible)Capable of tasks not possible with relays before:

[Fes, 2002]

Highly reliableHighly versatile (universal applicability)Simple troubleshootingSimple installationQuick modification of the program (highly flexible)

Capable of tasks not possible with relays before:

[Fes, 2002]

Highly reliableHighly versatile (universal applicability)Simple troubleshootingSimple installationQuick modification of the program (highly flexible)Capable of tasks not possible with relays before:

[Fes, 2002]

calculation

information exchangetext and graphic displaydata processingnetworking

[Fes, 2002]

calculationinformation exchange

text and graphic displaydata processingnetworking

[Fes, 2002]

calculationinformation exchangetext and graphic display

data processingnetworking

[Fes, 2002]

calculationinformation exchangetext and graphic displaydata processing

networking

[Fes, 2002]

Low space requirement

Low power consumptionHigh processing speedNo moving parts, hence no wearing parts

[Fes, 2002]

Low space requirementLow power consumption

High processing speedNo moving parts, hence no wearing parts

[Fes, 2002]

Low space requirementLow power consumptionHigh processing speed

No moving parts, hence no wearing parts

[Fes, 2002]

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]

Not very widespread

[Fes, 2002]

Not very widespread

[Fes, 2002]

Not very widespread

[Fes, 2002]

Not very widespread

[Fes, 2002]

International Standard for PLC

The IEC 1131 standards were developed to be a common and openframework for PLC architecture, agreed to by many standards groupsand manufacturers.

They were initially approved in 1992, and since then they have beenreviewed as the IEC-61131 standards.The main components of the standard are:

IEC 61131-1 OverviewIEC 61131-2 Requirements and Test ProceduresIEC 61131-3 Data types and programmingIEC 61131-4 User GuidelinesIEC 61131-5 CommunicationsIEC 61131-6 Functional SafetyIEC 61131-7 Fuzzy controlIEC 61131-8 Guidelines for the application and implementation ofprogramming languages

[Jack, 2008]

They were initially approved in 1992, and since then they have beenreviewed as the IEC-61131 standards.

The main components of the standard are:

[Jack, 2008]

IEC 61131-1 Overview

IEC 61131-2 Requirements and Test ProceduresIEC 61131-3 Data types and programmingIEC 61131-4 User GuidelinesIEC 61131-5 CommunicationsIEC 61131-6 Functional SafetyIEC 61131-7 Fuzzy controlIEC 61131-8 Guidelines for the application and implementation ofprogramming languages

[Jack, 2008]

IEC 61131-1 OverviewIEC 61131-2 Requirements and Test Procedures

IEC 61131-3 Data types and programmingIEC 61131-4 User GuidelinesIEC 61131-5 CommunicationsIEC 61131-6 Functional SafetyIEC 61131-7 Fuzzy controlIEC 61131-8 Guidelines for the application and implementation ofprogramming languages

[Jack, 2008]

IEC 61131-1 OverviewIEC 61131-2 Requirements and Test ProceduresIEC 61131-3 Data types and programming

IEC 61131-4 User GuidelinesIEC 61131-5 CommunicationsIEC 61131-6 Functional SafetyIEC 61131-7 Fuzzy controlIEC 61131-8 Guidelines for the application and implementation ofprogramming languages

[Jack, 2008]

IEC 61131-1 OverviewIEC 61131-2 Requirements and Test ProceduresIEC 61131-3 Data types and programmingIEC 61131-4 User Guidelines

IEC 61131-5 CommunicationsIEC 61131-6 Functional SafetyIEC 61131-7 Fuzzy controlIEC 61131-8 Guidelines for the application and implementation ofprogramming languages

[Jack, 2008]

IEC 61131-1 OverviewIEC 61131-2 Requirements and Test ProceduresIEC 61131-3 Data types and programmingIEC 61131-4 User GuidelinesIEC 61131-5 Communications

IEC 61131-6 Functional SafetyIEC 61131-7 Fuzzy controlIEC 61131-8 Guidelines for the application and implementation ofprogramming languages

[Jack, 2008]

IEC 61131-1 OverviewIEC 61131-2 Requirements and Test ProceduresIEC 61131-3 Data types and programmingIEC 61131-4 User GuidelinesIEC 61131-5 CommunicationsIEC 61131-6 Functional Safety

IEC 61131-7 Fuzzy controlIEC 61131-8 Guidelines for the application and implementation ofprogramming languages

[Jack, 2008]

IEC 61131-1 OverviewIEC 61131-2 Requirements and Test ProceduresIEC 61131-3 Data types and programmingIEC 61131-4 User GuidelinesIEC 61131-5 CommunicationsIEC 61131-6 Functional SafetyIEC 61131-7 Fuzzy control

IEC 61131-8 Guidelines for the application and implementation ofprogramming languages

[Jack, 2008]

Allen-Bradley Pico Controllers

Rockwell Automation

Siemens LOGO!

Siemens AG

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-dayoperation, such as functions for on/off delays and current impulserelays

Time switch

Binary markers

Inputs and outputs according to the device type

Siemens AG

What device types are available?There are LOGO! models for 12 V DC, 24 V DC, 24 V AC and 230 V ACas:

A standard variant with 6 inputs and 4 outputs with dimensions of 72x 90 x 55 mm

A variant without a display with 6 inputs and 4 outputs withdimensions of 72 x 90 x 55 mm

A variant with 8 inputs and 4 outputs with dimensions of 72 x 90 x55 mm

A long variant with 12 inputs and 8 outputs with dimensions of 126 x90 x 55 mm

A bus variant with 12 inputs and 8 outputs, and additional ASinterface bus connection, via which 4 further inputs and 4 furtheroutputs are available in the bus system. All this is packed intodimensions of 126 x 90 x 55 mm.

Siemens AG

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

Siemens LOGO!

Siemens AG

Siemens LOGO! inputs and outputs

Siemens AG

Siemens LOGO! inputs

Siemens AG

Siemens LOGO! relay outputs

Siemens AG

Siemens LOGO! transistor outputs

Siemens AG

Siemens S7-300

Siemens AG

Siemens S7-300

Siemens AGBehzad Samadi (Amirkabir University) Industrial Control 24 / 1

Siemens S7-300

Signal Modules (SM)

Digital input modules: 24V DC, 120/230V ACDigital output modules: 24V DC, RelayAnalog input modules: Voltage, current, resistance, thermocoupleAnalog output modules: Voltage, current

Interface Modules (IM): The IM360/IM361 and IM365 makemulti-tier configurations possible.

Siemens AG

Siemens S7-300

Signal Modules (SM)Digital input modules: 24V DC, 120/230V AC

Digital output modules: 24V DC, RelayAnalog input modules: Voltage, current, resistance, thermocoupleAnalog output modules: Voltage, current

Siemens AG

Siemens S7-300

Signal Modules (SM)Digital input modules: 24V DC, 120/230V ACDigital output modules: 24V DC, Relay

Analog input modules: Voltage, current, resistance, thermocoupleAnalog output modules: Voltage, current

Siemens AG

Siemens S7-300

Signal Modules (SM)Digital input modules: 24V DC, 120/230V ACDigital output modules: 24V DC, RelayAnalog input modules: Voltage, current, resistance, thermocouple

Analog output modules: Voltage, current

Siemens AG

Siemens S7-300

Signal Modules (SM)Digital input modules: 24V DC, 120/230V ACDigital output modules: 24V DC, RelayAnalog input modules: Voltage, current, resistance, thermocoupleAnalog output modules: Voltage, current

Siemens AG

Siemens S7-300

Signal Modules (SM)Digital input modules: 24V DC, 120/230V ACDigital output modules: 24V DC, RelayAnalog input modules: Voltage, current, resistance, thermocoupleAnalog output modules: Voltage, current

Siemens AG

Siemens S7-300

Dummy Modules (DM): The DM 370 dummy module reserves a slotfor a signal module whose parameters have not yet been assigned. Itcan also be used, for example, to reserve a slot for installation of aninterface module at a later date.

Function Modules (FM): Perform special functions”:

CountingPositioningClosed-loop control

Communication Processors (CP): Provide the following networkingfacilities:

Point-to-Point connectionsPROFIBUSIndustrial Ethernet.

Siemens AG

Siemens S7-300

Siemens AG

Siemens S7-300

Counting

PositioningClosed-loop control

Siemens AG

Siemens S7-300

CountingPositioning

Closed-loop control

Siemens AG

Siemens S7-300

Siemens AG

Siemens S7-300

Siemens AG

Siemens S7-300

Point-to-Point connections

PROFIBUSIndustrial Ethernet.

Siemens AG

Siemens S7-300

Point-to-Point connectionsPROFIBUS

Industrial Ethernet.

Siemens AG

Siemens S7-300

Siemens AG

Siemens S7-300

Siemens AG

Siemens S7-300

Siemens AG

Siemens S7-300

Siemens AG

Siemens S7-300

Siemens AG

Multipoint Interface (MPI)

Siemens AG

Siemens S7-300

Siemens AGBehzad Samadi (Amirkabir University) Industrial Control 32 / 1

PLC manufacturers:

Allen-Bradley

ALSTOM/Cegelec

Beck Electronic/Festo

Beckhoff

Fisher & Paykel

Fuji Electric

GE-Fanuc

Hitachi

Honeywell

LG Industrial Systems

Matsushita (Europe)/Aromat

Mitsubishi

Rockwell Automation

Schneider Electric

Siemens/Moore Products

Toshiba

Yamatake

Yokogawa

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

LS Industrial Systems (lsis.biz)

GLOFA - GM7:

Global standard (IEC61131-3) language: IL, LD, SFCVarious main module: 32 types

20(12in+8out)/30(18in+12out)/40(24in+16out)/60(36in+24out)pointsAC/DC power, DC input, Relay/Transistor output

Various expansion module: 24 typesDigital I/O 7 types, analog I/O 9 types, Communication I/F 6 types,option module 2 types

Batteryless BackupProgram backup: EEPROMData backup: Supercapacitor

LS Industrial Systems (lsis.biz)Behzad Samadi (Amirkabir University) Industrial Control 36 / 1

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

GMWIN:

[Bolton, 2006]

Location and size prefix features for directly represented variables

[IEC, 2003]

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 %IW2.5.7.1may represent the first channel (word) of the seventh module in the fifthrack of the second I/O bus of a programmable controller system.[IEC, 2003]

Sequence Operation:

[IEC, 2003]

[Bolton, 2006]

Motor Start-Stop

[Bolton, 2006]

[Bolton, 2006]Behzad Samadi (Amirkabir University) Industrial Control 62 / 1

[Bolton, 2006]

Example: A signal lamp is required to be switched on if a pump is runningand the pressure is satisfactory, or if the lamp test switch is closed.

[Bolton, 2006]

Example: A signal lamp is required to be switched on if a pump is runningand the pressure is satisfactory, or if the lamp test switch is closed.

[Bolton, 2006]

Example: Consider a valve which is to be operated to lift a load when apump is running and either the lift switch is operated or a switch operatedindicating that the load has not already been lifted and is at the bottom ofits lift channel.

[Bolton, 2006]

Example: Consider a valve which is to be operated to lift a load when apump is running and either the lift switch is operated or a switch operatedindicating that the load has not already been lifted and is at the bottom ofits lift channel.

[Bolton, 2006]Behzad Samadi (Amirkabir University) Industrial Control 66 / 1

Example: Consider a system where there has to be no output when anyone of four sensors gives an output, otherwise there is to be an output.

[Bolton, 2006]

Example: Consider a system where there has to be no output when anyone of four sensors gives an output, otherwise there is to be an output.

[Bolton, 2006]

Stop switches:

[Bolton, 2006]

Emergency stop switch:

[Bolton, 2006]

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]

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]

Timers:

[IEC, 2003]

ON Delay Timers:

[IEC, 2003]

ON Delay Timers:

[IEC, 2003]

OFF Delay Timers:

[IEC, 2003]

OFF Delay Timers:

[IEC, 2003]

Pulse Timers:

[IEC, 2003]

Pulse Timers:

[IEC, 2003]

Example: Write a program such that:

Lecture Notes by Nazarian

Solution:

Example: Write a program such that:

Solution:

Up Counter:

[IEC, 2003]

Down Counter:

[IEC, 2003]

Up-down Counter:

[IEC, 2003]

Example: A motor will be controlled by two switches. The Go switch willstart the motor and the Stop switch will stop it. If the Stop switch wasused to stop the motor, the Go switch must be thrown twice to start themotor. When the motor is active a light should be turned on. The Stopswitch will be wired as normally closed.

[Jack, 2008]

Example: A motor will be controlled by two switches. The Go switch willstart the motor and the Stop switch will stop it. If the Stop switch wasused to stop the motor, the Go switch must be thrown twice to start themotor. When the motor is active a light should be turned on. The Stopswitch will be wired as normally closed.

[Jack, 2008]

Example: Consider the task of counting cars as they enter a multi-storageparking lot and as they leave it. An output is to be triggered if the numberof cars entering is some number greater than the number leaving, i.e. thenumber in the parking lot has reached a saturation value.

[Jack, 2008]

Example: Consider the task of counting cars as they enter a multi-storageparking lot and as they leave it. An output is to be triggered if the numberof cars entering is some number greater than the number leaving, i.e. thenumber in the parking lot has reached a saturation value.

[Jack, 2008]

Timers with counters:

[Jack, 2008]

Question:

[Jack, 2008]

Instruction list:

[Jack, 2008]

Instruction list:

[Jack, 2008]Behzad Samadi (Amirkabir University) Industrial Control 91 / 1

Instruction list:

[Jack, 2008]

Structured text is a programming language that strongly resembles theprogramming language PASCAL.

[Jack, 2008]

Structured text:

[Jack, 2008]

Structured text:

[Jack, 2008]

Structured text:

[Jack, 2008]

Sequential Function Chart (SFC):

[Jack, 2008]

Sequential Function Chart (SFC):Example: A two door security system. One door requires a two digit entrycode, the second door requires a three digit entry code.

[Jack, 2008]

Sequential Function Chart (SFC):Example: Controlling a stamping press

[Jack, 2008]

[IEC, 2003]

Sequential Function Chart (SFC):Sequence evolution:

[IEC, 2003]

Function Block Diagram (FBD):

[Jack, 2008]

Function Block Diagram (FBD):

Boolean NOT, AND, OR [Jack, 2008]

(2002).Programmable Logic Controllers: Basic Level.FESTO.

(2003).IEC 61131-3 programmable controllers - part 3: Programminglanguages.

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.

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