Beruflich Dokumente
Kultur Dokumente
BASIC 1
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Genesis of Automation Industrial Revolution
• Operation sheets • High-volume production
– May date back to the 1830s • Interchangeable parts
• Listing of: • Transportation system
– All machining operations • Inexpensive energy (coal)
– The machine tools employed
• Frederick W. Taylor
– Tools, jigs, fixtures, and gauges
– Scientific management
• Organization and flow of work
• Henry Ford
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Automobile body line system
1. Introduction 3. System configuration
Forces Driving Automation - Front Longi welding line application in automobile line
1) Installation: 2001/12
2) Field: Automobile
Ethernet (10BASE5)
A 1 A A A A A A A to A A A B A A A A A A C
3) Type: GM1/GM2 (DI/DO, Enet) A2P MG UEE 82D Y4R 4YR R8T 82D Y4R Sl IDF A2P 82D R8T 82D 28D 82D Y4R 4YR Y4R RIF
공
Handler OP OP
Robot Sub operation Sub operation panel A A A A A A ty yt ty C A A A A to C
A2P Y4R 4YR Y4R 4YR Y4R pm pm pm RIF A2P 4YR Y4R 4YR Sl RIF
• Faster production (ABB) panel Storage
E E E 공
A A A A A B B B B C
A2P 82D 28D 82D 28D 8RT R8T 8RT R8T RIF
• Better quality control Part
Load
Slide
JIG
OP Welding Welding Welding
4. Main functions
gun gun gun
Main 1) Automobile type grading
operation - Manual input for grading data (automotive type,
panel steering wheel, domestic/foreign demand, etc)
Storage
- Shift table operation
2) Robot control and interlock
- Work complete detection and robot operation
- Welding condition detection
3) Main/sub operation panel control (total/each process)
- Line operation mode setup (manual/automatic)
Welding Welding Welding Welding
OP gun gun gun gun
- Utility status lamp (power, air, cooling water, etc)
- Error status display (robot, pneumatic, valve, etc)
Sub
OP OP
- Emergency stop
operation
panel
4) Line status/automobile type display (TR output)
Sub operation panel Sub operation panel - Production state display
(production/inferior goods number, cycle time)
- Present/next automobile type display
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Building air conditioning system
1. Introduction 3. Main functions
- Building air conditioning system application using 1) Inverter operation parameter control using RS-485
Course Contents
PMU-600 and iH communication of PMU-600
1) Installation: 2002/02 2) Building air conditioning by controlling inverter frequency
2) Field: Electric/electronic/semiconductor and its operation
(building airconditioning)
3) Type: PMU-600, iH
History of Programmable Controllers
2. System configuration
Relay Ladder Logic
Central Processing Unit
Applications
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8
Air in 4
-
S
R
Air out
PMU-600
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Historical Background Historical Background
The Hydramatic Division of the General Motors • The controller had to be designed in modular form, so that
Corporation specified the design criteria for the first sub-assemblies could be removed easily for replacement or
programmable controller in 1968 repair.
Their primary goal • The control system needed the capability to pass data
collection to a central system.
To eliminate the high costs associated with inflexible,
relay-controlled systems. • The system had to be reusable.
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Programmable Logic Controllers Leading Brands Of PLC
( Definition according to NEMA standard ICS3-1978)
AMERICAN 1. Allen Bradley
A digitally operating electronic apparatus which uses a 2. Gould Modicon
programming memory for the internal storage of instructions 3. Texas Instruments
for implementing specific functions such as logic, 4. General Electric
sequencing, timing, counting and arithmetic to control 5. Westinghouse
through digital or analog modules, various types of machines 6. Cutter Hammer
or process. 7. Square D
EUROPEAN 1. Siemens
2. Klockner & Mouller
3. Festo
4. Telemechanique
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Power
Mining
Petrochemical / Chemical
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PLC Size Tank Used to Mix Two Liquids
1. SMALL - it covers units with up to 128 I/O’s and
memories up to 2 Kbytes. MOTOR
- these PLC’s are capable of providing A
FS FLOAT SWITCH
simple to advance levels or machine
controls. SOLENOIDS B
2. MEDIUM - have up to 2048 I/O’s and memories up
to 32 Kbytes.
3. LARGE - the most sophisticated units of the PLC
family. They have up to 8192 I/O’s and
SOLENOID
memories up to 750 Kbytes. C
- can control individual production TIMER
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Tank Used to Mix Two Liquids Tank Used to Mix Two Liquids
A tank is used to mix two liquids. The control
4. When the tank is empty, the float switch de-
circuit operates as follows:
energizes solenoid C.
MOTOR
1. When the start button is pressed, solenoids A
5. A stop button can be used to stop the
A and B energize. This permits the two liquids to MOTOR
FS FLOAT SWITCH A
process at any point.
B
begin filling the tank. FS FLOAT SWITCH
SOLENOIDS
SOLENOIDS
B
6. If the motor becomes overloaded, the action
2. When the tank is filled, the float switch trips.
of the entire circuit will stop.
This de-energizes solenoids A and B and starts
SOLENOID
the motor used to mix the liquids together.
TIMER
C
C
SOLENOID
7. Once the circuit has been energized it will
TIMER
continue to operate until it is manually stopped.
1 -MINUTE 3. The motor is permitted to run for one minute. 1 -MINUTE
After one minute has elapsed, the motor turns off
and solenoid C energizes to drain the tank.
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Major Components of a Common PLC Major Components of a Common PLC
POWER POWER SUPPLY
SUPPLY
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Programming Device I/O Module
Types: • The I/O interface section of a PLC connects it to
external field devices.
Hand held unit with LED / LCD display
• The main purpose of the I/O interface is to condition the
various signals received from or sent to the external input
Desktop type with a CRT display
and output devices.
Compatible computer terminal
• Input modules converts signals from discrete or analog
input devices to logic levels acceptable to PLC’s processor.
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Dual opto-coupler IC in Basic DC input 37 3-Input circuit diagram 38
8 DIP IC
I/O Module
Input Connection
Block Isolation
Terminal Barrier
DC / AC OUTPUT MODULE
IS NEEDED TO: Input
• Prevent voltage
components 1
transients from
damaging the 2
processor.
•Helps reduce the 3
effects of electrical
L1 4
noise
5 P
Amplifier
L1 6 L
RELAY 7
FROM
PROCESSOR
TTL
Circuits
OPTO-
ISOLATOR TRIAC
X’SISTOR
TO
OUTPUT
DEVICE
8 C
9
10
L2 COM
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Output Connections
Isolation Terminal I/O Circuits
Barrier Block
Output DIFFERENT TYPES OF I/O CIRCUITS
components
OUT 1 L1
CR
OUT 1 L2 1. Pilot Duty Outputs
OUT 2 Outputs of this type typically are used to drive high-current
OUT 2
electromagnetic loads such as solenoids, relays, valves, and
motor starters.
P OUT 3 L1
OUT 3 L2
L OUT 4
These loads are highly inductive and exhibit a large inrush
current.
C OUT 4
OUT 5 Pilot duty outputs should be capable of withstanding an
OUT 5 inrush current of 10 times the rated load for a short period of
OUT 6 time without failure.
OUT 6
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I/O Circuits OUTPUTS
5. Special - Purpose I/O
INPUTS MOTOR
Circuits of this type are used to interface PLCs to very specific
types of circuits such as servomotors, stepping motors PID CONTACTOR
(proportional plus integral plus derivative) loops, high-speed LAMP
pulse counting, resolver and decoder inputs, multiplexed
displays, and keyboards. PUSHBUTTONS
PLC
This module allows for limited access to timer and counter
presets and other PLC variables without requiring a program
loader.
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CONTACTOR
L2 L1 N.O
Allen-Bradley 1746-1A16
L1 L2 I= Input MOTOR
Module L2
C •SOLENOID
L1
I:2 slot # in rack •VALVES
FIELD WIRING •LAMP
•BUZZER
P. B SWITCH 0 Module
Terminal # OUTPUT MODULE
Address I:2.0/0 WIRING
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Discrete Input
A discrete input also referred as digital input is an input that is
IN
either ON or OFF are connected to the PLC digital input. In the
OFF PLC
ON condition it is referred to as logic 1 or a logic high and in the Logic 0
OFF condition maybe referred to as logic o or logic low. Input
Module
24 V dc
Normally Open Pushbutton
OFF PLC
Normally Open switch Logic 1
Input
Normally Closed switch Module
24 V dc
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Analog Output Processor
An analog output is an output signal that has a continuous The processor module contains the PLC’s microprocessor,
signal. Typical outputs may vary from 0 to 20mA, 4 to 20mA its supporting circuitry, and its memory system.
or 0 to10V.
The main function of the microprocessor is to analyze data
Electric to pneumatic transducer
coming from field sensors through input modules, make
OUT
E
decisions based on the user’s defined control program and
Supply air
PLC 0 to 10V P
return signal back through output modules to the field
devices. Field sensors: switches, flow, level, pressure, temp.
Analog
Output transmitters, etc. Field output devices: motors, valves,
Module
Pneumatic control valve
solenoids, lamps, or audible devices.
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Memory Designs Memory Designs
Several Types of RAM Memory:
The words random access refer to the ability of any
1.MOS
location (address) in the memory to be accessed or used.
2.HMOS
Ram memory is used for both the user memory (ladder
3.CMOS
diagrams) and storage memory in many PLC’s.
The CMOS-RAM (Complimentary Metal Oxide
RAM memory must have battery backup to retain or protect
Semiconductor) is probably one of the most popular. CMOS-
the stored program.
RAM is popular because it has a very low current drain when
not being accessed (15microamps.), and the information
stored in memory can be retained by as little as 2Vdc.
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Memory Designs Memory Designs
EPROM, Erasable Programmable Read Only Memory
EEPROM, Electrically Erasable Programmable Read
Ideally suited when program storage is to be semi- Only Memory
permanent or additional security is needed to prevent
unauthorized program changes. Also referred to as E2PROM, is a chip that can be
programmed using a standard programming device and can
The EPROM chip has a quartz window over a silicon be erased by the proper signal being applied to the erase pin.
material that contains the electronic integrated circuits. This
window normally is covered by an opaque material, but EEPROM is used primarily as a non-volatile backup for the
when the opaque material is removed and the circuitry normal RAM memory. If the program in RAM is lost or erased,
exposed to ultra violet light, the memory content can be a copy of the program stored on an EEPROM chip can be
erased. down loaded into the RAM.
PLC Operation While the PLC is running, the scanning process includes the
following four phases, which are repeated continuously as
Basic Function of a Typical PLC individual cycles of operation:
Read all field input devices via the input interfaces, execute PHASE 1
Read Inputs
the user program stored in application memory, then, based
Scan
on whatever control scheme has been programmed by the
PHASE 2
user, turn the field output devices on or off, or perform Program
whatever control is necessary for the process application. Execution
PHASE 3
This process of sequentially reading the inputs, executing Diagnostics/
the program in memory, and updating the outputs is known Comm
as scanning. PHASE 4
Output
Scan
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PHASE 1 – Input Status scan PHASE 4 - Output Status Scan
•An output status scan is then performed, whereby the
• A PLC scan cycle begins with the CPU reading the status
stored output values are sent to actuators and other field
of its inputs.
output devices. The cycle ends by updating the outputs.
PHASE 2– Logic Solve/Program Execution
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PLC Communications
As soon as Phase 4 are completed, the entire cycle begins
again with Phase 1 input scan. Common Uses of PLC Communications Ports
The time it takes to implement a scan cycle is called SCAN Changing resident PLC programs - uploading/downloading
TIME. The scan time composed of the program scan time, from a supervisory controller (Laptop or desktop computer).
which is the time required for solving the control program, and
the I/O update time, or time required to read inputs and Forcing I/O points and memory elements from a remote
update outputs. The program scan time generally depends on terminal.
the amount of memory taken by the control program and type
of instructions used in the program. The time to make a single Linking a PLC into a control hierarchy containing several
scan can vary from 1 ms to 100 ms. sizes of PLC and computer.
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PLC Communications PLC Communications
Serial Communications Local Area Network (LAN)
PLC communications facilities normally provides serial Local Area Network provides a physical link between all
transmission of information. devices plus providing overall data exchange management or
protocol, ensuring that each device can “talk” to other
Common Standards machines and understand data received from them.
Used for longer-distance links, often between several PCs Dedicated Network System of Different Manufacturers
in a distributed system. RS 485 can have a maximum
distance of about 1000 meters. Manufacturer Network
Allen-Bradley Data Highway
Gould Modicon Modbus
General Electric GE Net Factory LAN
Mitsubishi Melsec-NET
Square D SY/NET
Texas Instruments TIWAY
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Selecting a PLC
Specifications
Several factors are used for evaluating the quality and
Criteria
performance of programmable controllers when selecting a
unit for a particular application. These are listed below.
• Number of logical inputs and outputs.
• Memory
NUMBER OF I /O PORTS
• Number of special I/O modules
• Scan Time
This specifies the number of I/O devices that can be
• Communications
connected to the controller. There should be sufficient I/O
• Software
ports to meet present requirements with enough spares to
provide for moderate future expansion.
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Specifications PLC Status Indicators
•Power On
MEMORY CAPACITY
•Run Mode
The amount of memory required for a particular application is
related to the length of the program and the complexity of the •Programming Mode
control system. Simple applications having just a few relays
do not require significant amount of memory. Program length
•Fault
tend to expand after the system have been used for a while. It
is advantageous to a acquire a controller that has more
memory than is presently needed.
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Examples of PLC Programming Software:
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