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PLC AUTOMATION
Submitted by:
Harpriya singh
101306066
2017
IC ULN2803is used in the circuit to form Darlington pair to invert the input
supply voltage.
PLC Hardware
Many PLC configurations are available, even from a single vendor. But, in each
of these there are common components and concepts. The most essential
components are:
Power Supply - This can be built into the PLC or be an external unit. Common
voltage levels required by the PLC (with and without the power supply) are
Indicator lights - These indicate the status of the PLC including power on,
program running, and a fault. These are essential when diagnosing problems.
The configuration of the PLC refers to the packaging of the components. Typical
configurations are listed below from largest to smallest as shown in Figure 3.1.
Rack - A rack is often large (up to 18” by 30” by 10”) and can hold multiple
cards.
When necessary, multiple racks can be connected together. These tend to be the
highest cost, but also the most flexible and easy to maintain.
Mini - These are similar in function to PLC racks, but about half the size.
Shoebox - A compact, all-in-one unit (about the size of a shoebox) that has
limited expansion capabilities. Lower cost and compactness make these ideal for
small applications.
Micro - These units can be as small as a deck of cards. They tend to have fixed
quantities of I/O and limited abilities, but costs will be the lowest.
Software - A software based PLC requires a computer with an interface card, but
allows the PLC to be connected to sensors and other PLCs across a network.
Advantages of PLC
2.3 CODESYS
CODESYS (an acronym for controller development system, previously
stylised CoDeSys) is a development environment for programming controller
applications according to the international industrial standard IEC 61131-3. it is
a complete development environment for a PLC. CoDeSys puts a simple
approach to the powerful IEC language at the disposal of the PLC programmer.
Use of the editors and debugging functions is based upon the proven development
program environments of advanced programming languages such as Visual C++.
All five programming languages for application programming defined in the IEC
61131-3 are available in the CODESYS development environment.
CFC (Continuous Function Chart) is a sort of freehand FBD editor. Other than
in the network-oriented FBD editor where the connections between inputs,
operators and outputs are set automatically they have to be drawn by the
programmer. All boxes can be placed freely which makes it possible to
program feedback loops without interim variables.
Integrated compilers transform the application code created by CODESYS into
native machine code (binary code) which is then downloaded onto the controller.
Visualization
CoDeSys provides visualizations so that you can display your project variables.
You can plot geometric elements off-line with the help of the visualization. In
Online mode, these can then change their form/colour/text output in response to
specified variable values. Visualization can be used as a pure operating interface
for a PLC with CoDeSys HMI or as a Web-Visualization or Target-Visualization
running via Internet resp. directly on the PLC. Supported Languages: CoDeSys
supports all languages described by the standard IEC-61131. PROJECT
EXAMPLES: Lighting 3 bulbs using 2 switches, Using button 1 bulb 1 &2 lights
up, Using button 2 bulb 2 lights up, Using button 1 & 2 bulb 3 lights up.
Ladder Logic
Ladder logic is the main programming method used for PLCs. As mentioned
before, ladder logic has been developed to mimic relay logic. The decision to use
the relay logic diagrams was a strategic one. By selecting ladder logic as the main
programming method, the amount of retraining needed for engineers and trades
people was greatly reduced.
Modern control systems still include relays, but these are rarely used for logic. A
relay is a simple device that uses a magnetic field to control a switch. When a
voltage is applied to the input coil, the resulting current creates a magnetic field.
The magnetic field pulls a metal switch (or reed) towards it and the contacts
touch, closing the switch. The contact that closes when the coil is energized is
called normally open. The normally closed contacts touch when the input coil is
not energized. Relays are normally drawn in schematic form using a circle to
represent the input coil. The output contacts are shown with two parallel lines.
Normally open contacts are shown as two lines, and will be open (non-
conducting) when the input is not energized. Normally closed contacts are shown
with two lines with a diagonal line through them. When the input coil is not
energized the normally closed contacts will be closed (conducting).
2.3.1 Examples of Codesys
2.3.1.1 2 inputs 3 output3
2.4 RS MicroLogix
The MicroLogix 1000 programmable controller is a packaged controller
containing a power supply, input circuits, output circuits, and a processor. The
controller is available in 10 I/O, 16 I/O and 32 I/O configurations, as well as an
analog version with 20 discrete I/O and 5 analog I/O. The MicroLogix power
supply does not require or need a high inrush current. However, if the power
source can supply a high inrush current, the MicroLogix power supply will accept
it. There is a high level of inrush current when a large capacitor on the input of
the MicroLogix is charged up quickly.
The RSLogix family of IEC-1131-compliant ladder logic programming packages
helps you maximize performance, save project development time, and improve
productivity. This family of products has been developed to operate on Microsoft
Windows operating systems. Supporting the Allen-Bradley SLC 500 and
MicroLogix families of processors, RSLogix 500 was the first PLC programming
software to offer unbeatable productivity with an industry-leading user
interface. When you connect a MicroLogix 1000 controller to a network, it
automatically finds which protocol is active (DF1 or DH-485), and establishes
communication accordingly. Therefore, no special configuration is required to
connect to either network.
2.6 SCADA
Supervisory control and data acquisition (SCADA) is a control
system architecture that uses computers, networked data communications
and graphical user interfaces for high-level process supervisory management, but
uses other peripheral devices such as programmable logic controllers and
discrete PID controllers to interface to the process plant or machinery. The
operator interfaces which enable monitoring and the issuing of process
commands, such as controller set point changes, are handled through the SCADA
supervisory computer system. However, the real-time control logic or controller
calculations are performed by networked modules which connect to the field
sensors and actuators. PLCs are connected to sensors and actuators in the process,
and are networked to the supervisor14.
Facility processes occur both in public facilities and private ones, including
buildings, airports, ships, and space stations. They monitor and control
HVAC, access, and energy consumption.
DAQ Factory
DAQ Factory is measurement and automation software from AzeoTech. DAQ
Factory Express, supports the T7/U3/U6/UE9/U12. To get DAQ Factory Express,
download the normal DAQ Factory Pro Trial from AzeoTech, and the Express
version is included.
DAQ Factory allows non-programmers to make custom applications. It is easy
to collect input data, convert to engineering units, display it, and log it to file,
without any programming (see the quick tutorial below). Scripting is also
supported so you can do advanced applications with control and automatic setting
of outputs.
2.7 HMI
Typical basic SCADA animations
A human machine interface or HMI is the apparatus which presents process data
to a human operator, and through which the human operator controls the process.
An HMI is usually linked to the SCADA system's databases and software
programs, to provide trending, diagnostic data, and management information
such as scheduled maintenance procedures, logistic information, detailed
schematics for a particular sensor or machine, and expert-system troubleshooting
guides.
The HMI system usually presents the information to the operating personnel
graphically, in the form of a mimic diagram. This means that the operator can see
a schematic representation of the plant being controlled. For example, a picture
of a pump connected to a pipe can show the operator that the pump is running and
how much fluid it is pumping through the pipe at the moment. The operator can
then switch the pump off. The HMI software will show the flow rate of the fluid
in the pipe decrease in real time. Mimic diagrams may consist of line graphics
and schematic symbols to represent process elements, or may consist of digital
photographs of the process equipment overlain with animated symbols.
The HMI package for the SCADA system typically includes a drawing program
that the operators or system maintenance personnel use to change the way these
points are represented in the interface. These representations can be as simple as
an on-screen traffic light, which represents the state of an actual traffic light in
the field, or as complex as a multi-projector display representing the position of
all of the elevators in a skyscraper or all of the trains on a railway.
An important part of most SCADA implementations is alarm handling. The
system monitors whether certain alarm conditions are satisfied, to determine
when an alarm event has occurred. Once an alarm event has been detected, one
or more actions are taken (such as the activation of one or more alarm indicators,
and perhaps the generation of email or text messages so that management or
remote SCADA operators are informed). In many cases, a SCADA operator may
have to acknowledge the alarm event; this may deactivate some alarm indicators,
whereas other indicators remain active until the alarm conditions are cleared.
Alarm conditions can be explicit—for example, an alarm point is a digital status
point that has either the value NORMAL or ALARM that is calculated by a
formula based on the values in other analogue and digital points—or implicit: the
SCADA system might automatically monitor whether the value in an analogue
point lies outside high and low limit values associated with that point. Examples
of alarm indicators include a siren, a pop-up box on a screen, or a coloured or
flashing area on a screen (that might act in a similar way to the "fuel tank empty"
light in a car); in each case, the role of the alarm indicator is to draw the operator's
attention to the part of the system 'in alarm' so that appropriate action can be
taken. In designing SCADA systems, care is needed in coping with a cascade of
alarm events occurring in a short time, otherwise the underlying cause (which
might not be the earliest event detected) may get lost in the noise. Unfortunately,
when used as a noun, the word 'alarm' is used rather loosely in the industry; thus,
depending on context it might mean an alarm point, an alarm indicator, or an
alarm event.