An Introduction toAn Introduction to Entivity SeminarEntivity Seminar

Presented by Presented by

Happy Chng Koa HengHappy Chng Koa Heng

Alstron (Singapore) Pte Alstron (Singapore) Pte LtdLtd

(Entivity – Asia)(Entivity – Asia)

An Introduction toAn Introduction to EntivityEntivitySeminar ContentsSeminar Contents1.1. Design – Starting from the TopDesign – Starting from the Top

a.a. What is Flowchart ProgrammingWhat is Flowchart Programmingb.b. Why Flowchart Programming Why Flowchart Programming c.c. Notes on Learning & Programming Think & DoNotes on Learning & Programming Think & Do

2.2. PC Based Control PC Based Control a.a. PC Based Control SystemPC Based Control Systemb.b. What is PC Based Control SystemWhat is PC Based Control Systemc. The Obstacle: Legacy PLC Systems d.d. Typical PC Control System Hardware ComponentsTypical PC Control System Hardware Componentse.e. Why PC based ControlWhy PC based Control

3.3. Entivity PC Based SolutionEntivity PC Based Solution4.4. Live OverviewLive Overview5.5. ConclusionConclusion

Topic 1Topic 1Design – Starting from the Design – Starting from the TopTop

1.1. What is Flowchart Programming What is Flowchart Programming ??

2.2. Why Flowchart Programming ?Why Flowchart Programming ?

3.3. Notes on Learning & Notes on Learning & Programming Think & DoProgramming Think & Do

What is Flowchart What is Flowchart Programming ?Programming ?

Flowchart ProgrammingFlowchart Programming A Machine Control Development A Machine Control Development

& Implementation Language& Implementation Language Instructions resemble original flowchart Instructions resemble original flowchart

symbolssymbols PC based graphical programming lang. PC based graphical programming lang.

ladder logic program in PLC ladder logic program in PLC

Begin Block

Decision Block

Control Block

Decision Block

Control Block

Return Block

Yes

Yes

No

No

Start Block

Decision Block

Control Block

Decision Block

Control Block

Return Block

Yes

Yes

No

No

What is Flowchart What is Flowchart Programming ?Programming ?

Flowchart ElementsFlowchart Elements Control (Processing)Control (Processing)

Represents Control CommandsRepresents Control Commands Defines actionsDefines actions

Decision Represents a Branching operation No work performed Set the path which defines work to be done

Start (Enable) Represents Beginning of Process Defined In Think & Do, Defines Conditions for execution

Connecting Lines Represents Process Flow graphically

Start Block

Decision Block

Control Block

Why Flowchart Programming ?‘The Advantage of the Flowchart Programming Environment’

Which is easier to determine the sequence’?

Which looks easier to debug?

Which provides ‘historical’ logic solve information?

Why Flowchart Why Flowchart Programming ?Programming ?

1)1) Process Flow DesignProcess Flow Designa)a) Illustrates seq. of operationIllustrates seq. of operationb)b) Break down complex process into simple stepsBreak down complex process into simple stepsc)c) Top-Down Design – Modular DesignTop-Down Design – Modular Design

2)2) Integral part of machine designIntegral part of machine designa)a) From process design to tool designFrom process design to tool designb)b) Make use of existing designs directly in developmentMake use of existing designs directly in development

3)3) Natural Process descript. Lang. Natural Process descript. Lang. )a)a no need to develop state and timing chartsno need to develop state and timing charts

(For Ladder) (For Ladder))b)b development timedevelopment time

c)c) Directly translate from design (½ step)Directly translate from design (½ step)

4)4) Easy to UnderstandEasy to Understanda)a) Widely Recognized – even by End userWidely Recognized – even by End userb)b) Able verify design changes easily (Even End User)Able verify design changes easily (Even End User)c)c) Ease Program Team CommunicationEase Program Team Communicationd)d) Easily understand other members’ programEasily understand other members’ program

Begin Block

Decision Block

Control Block

Decision Block

Control Block

Return Block

Yes

Yes

No

No

Why Flowchart Why Flowchart Programming ?Programming ?5)5) Easy to Program Easy to Program

)a)a Learning Curve Learning Curve )i)i Faster Development Faster Development

)ii)ii New Team member can be of help earlier New Team member can be of help earlier

6)6) GUI Programming InterfaceGUI Programming Interfacea)a) Clear Process FlowClear Process Flowb)b) Avoid command line base process visualization Avoid command line base process visualization

problem (Command line programming, C/C++)problem (Command line programming, C/C++)c)c) Allow EasyTrac Debugging Mode Allow EasyTrac Debugging Mode

)i)i Graphical Debugging (Graphical step through of the Graphical Debugging (Graphical step through of the process flow)process flow)

d)d) Ease Documentation just by Printing out Flowcharts Ease Documentation just by Printing out Flowcharts )i)i Avoid wasting time in Project DocumentationAvoid wasting time in Project Documentation

)ii)ii Ease Documenting changes Ease Documenting changes

Why Flowchart Why Flowchart Programming ?Programming ?7)7) Easy to DebugEasy to Debug

a)a) Can easily get a Technician to Service Can easily get a Technician to Service MaintenanceMaintenance

i.i. Free up Designer for other projectFree up Designer for other project

b)b) Clear Understanding of ProcessClear Understanding of Process

8)8) Modular by defaultModular by defaulta)a) Ease Project team project scope break Ease Project team project scope break

downdownb)b) Localized Troubleshooting area Localized Troubleshooting area Ease Ease

Maintenance Maintenance troubleshooting time troubleshooting time ( ( Downtime ) Downtime )

Notes on Learning Notes on Learning & Programming Think & Do& Programming Think & Do If experienced in Control SystemIf experienced in Control System

Would be quick to pick up (Short Learning Would be quick to pick up (Short Learning Curve)Curve)

A lot of Control People already think of A lot of Control People already think of state & sequence of the process & have to state & sequence of the process & have to translate this to ladder logic when design a translate this to ladder logic when design a control systemcontrol system

Flowchart programming Flowchart programming eliminates this translation process as it naturally eliminates this translation process as it naturally

represents the state & sequencerepresents the state & sequence Directly translate from Design flow chartsDirectly translate from Design flow charts

For experienced Ladder Logic programmerFor experienced Ladder Logic programmer May need just a bit unlearning to do May need just a bit unlearning to do

Topic 2 Topic 2 PC Based ControlPC Based Control

1.1. PC-Based ControlPC-Based Control

2.2. What is PC-Based ControlWhat is PC-Based Control

3.3. The Obstacle: Legacy PLC SystemsThe Obstacle: Legacy PLC Systems

4.4. Typical PC Control System Typical PC Control System Hardware ComponentsHardware Components

5.5. Why PC-based Control ?Why PC-based Control ?

PC-Based Control• What is PC-Based Control?

• Why do you need it?

. . . Differences from PLC control

. . . Components

. . . Architecture

. . . Just can’t do it with a PLC?

. . . Need to reduce implementation time/costs?

. . . Need to reduce launch cycle?

. . . Need to improve quality & reduce down time?

HMI PC

Programming PC

What is PC-Based Control?Let’s first look at PLC Architecture . . .

Data Collector PC

PLC w/ rack I/O

HMIProgramming\Debug

Control Data Collection

What is PC-Based Control?‘What if we combined the functionality of all this hardware into one box?’

‘The Single Box Solution’

What is PC-Based Control?

Choose the I/O brand that you want!Choose the I/O bus that you want!

Mix & match brands and buses!

‘Freedom from the confines of the PLC’

Distribute the I/O closer to actual devices

Legacy Automation SystemsLegacy Automation Systems Based on 30 year old PLC technology Programmed with “relay ladder logic”

emulates wired relay cabinets circa 1950s difficult to program, understand, maintain

Equipped with less memory – thus, applications like trending, sorting or data analysis requires a separate PC

Not Designed for Advanced AutomationNot Designed for Advanced Automation Product ID &Tracking Vision Inspection Systems Data Collection & SPC/SQC

( Statistical Process Ctrl / Statistical Quality Ctrl )

IT Connectivity

Mode:operate F10=Menu P2/0> \TD5\PLC5\TEST¦N010:005 I:021 O:020 I:020 O:017¦+--] [-----]/[---]/[---] [-------------------------------------------------( )-¦¦ 00 06 02 02 ¦ 02¦¦ ¦O:020¦¦ +-( )-¦¦ ¦ 00¦¦ ¦B003 ¦¦ +-(U)-¦¦ 28¦¦ B003 O:020 I:014 +- BTW ------------+ ¦+--]/[---] [---------] [------------------------------¦ BLOCK XFER WRITE +(EN)-¦¦¦ 245 01 ¦ 03 ¦ ¦ RACK: 00 ¦ ¦¦¦N007:064 C005:006¦ ¦ ¦ GROUP: 2 +(DN) ¦¦+--] [------] [---+ ¦ ¦ SLOT: 0 ¦ ¦¦¦ 01 DN ¦ ¦ CTRL: #N007:000 +(ER) ¦¦¦ I:017 N009:023 I:001 I:004 N024:018¦ ¦ DATA: #O:017 ¦ ¦¦+--] [------] [-----]/[-----]/[-----] [--+ ¦ LENGTH: 10 ¦ ¦¦ 04 05 01 00 07 ¦ CONTINUOUS: N ¦ ¦¦ +------------------+ ¦¦T004:003 +- EQU ------------+ O:017¦+--]/[----¦ A = B +---------------------------------------------(L)-¦¦ 01 ¦ A: N007:009 ¦ ¦ 02¦¦ ¦ B: N007:008 ¦ ¦O:010¦¦ +------------------+ +-( )-¦¦ 04¦

The Obstacle: Legacy PLC Systems

Typical PC Control System Typical PC Control System Hardware ComponentsHardware Components I/O Scanner CardI/O Scanner Card

Accessory Card equipped with processor Accessory Card equipped with processor Regularly schedules, polls & Updates I/O Status along Regularly schedules, polls & Updates I/O Status along

with I/O Sub-Systemwith I/O Sub-System I/O Network CardI/O Network Card

Intelligent I/O DevicesIntelligent I/O Devices Attached directly to network cablesAttached directly to network cables Include I/O Modules with built-in network adapters, I/O Include I/O Modules with built-in network adapters, I/O

processors in racks, smart sensors and actuators.processors in racks, smart sensors and actuators. Industrial PC (IPC)Industrial PC (IPC)

Equipped with better RFI & EMI shieldingEquipped with better RFI & EMI shielding More robust power supplyMore robust power supply More easily replaceable componentsMore easily replaceable components Usually LCD VGA IntegratedUsually LCD VGA Integrated

Why PC-Based Control ?Why PC-Based Control ?(Vs. Conventional PLC) (Vs. Conventional PLC) PC-based Control combines functions that

runs on several separate platforms in a PLC system into a single PC cost & space

Includes Advanced Control Functions Eg. Graphical operator interface, Data collection,

Alarming & storage (Previously done by SCADA) PC platforms typically utilizes more PC platforms typically utilizes more

advanced technologyadvanced technology Software platform supported by thousands Software platform supported by thousands

of vendorsof vendors

Why PC-Based Control ?Why PC-Based Control ? Off-the-shelf Hardware & Software

Cost effective solutions available with both hardware & software solutions to readily integrate with the system

Same technology used in office system = common comm. Platform

Using Windows NT, 2000, XP platform offers built-in comm. services (TCP/IP & low cost PC Ethernet cards)

-> Very cost effective enterprise-wide network connectivity

Open to cheaper commercial alternatives (eg. Open to cheaper commercial alternatives (eg. Scan Card -> Ethernet Card)Scan Card -> Ethernet Card) Typical PC comes with more memory Less cost of memory upgrade compared to PLC Hard disk getting cheaper & bigger

Why PC-Based Control ?Why PC-Based Control ? Open Hardware Architecture Open Hardware Architecture

Allow to mixing & matching of various bus systems & Allow to mixing & matching of various bus systems & modules of various brands modules of various brands

Hardware Manufacturer IndependenceHardware Manufacturer Independence Not held hostage by Single PLC ManufacturerNot held hostage by Single PLC Manufacturer

Ease partial Upgrading Ease partial Upgrading Allow scaling project upgrade Allow scaling project upgrade {instead of changing all hardware at same time}{instead of changing all hardware at same time}

No need for re-engineering the control program No need for re-engineering the control program Due to hardware product obsolescence or absence of vendor support Due to hardware product obsolescence or absence of vendor support

is eliminatedis eliminated Avoid Proprietary Interfaces & ease Network

Connectivity Unlike PLC that are difficult to extract info from

(proprietary interface, networks), PC offers ease Office Network Connectivity, cheap

commercial network solutions

Why PC-Based Control ?Why PC-Based Control ? Programming LanguageProgramming Language

Not limited to Not limited to RLL (Relay Ladder Logic) Allow Allow Other choice of programming lang. Other choice of programming lang. (Flowchart)(Flowchart)

Allow use & interaction with other software, utilities & programming language

Enterprise ConnectivityEnterprise Connectivity Ease Connectivity to Office PC, or even across Internet Ease Connectivity to Office PC, or even across Internet Ease Connectivity to MES, SAP, etc Ease Connectivity to MES, SAP, etc

Enable Data Connectivity Standard Windows Comm. Tools

Real-time data shared with other windows applications through DDE, OPC

Real-time Database Connectivity

Why PC-Based Control ?Why PC-Based Control ? Moving to a Data driven platform

Readily info on production, statistic, quality info, historical data to managers at their very desk

Online data access & control available to Maintenance Technicians

Operators can get online tutorial stored in a remote file server

Topic 3Topic 3

Entivity PC Based Entivity PC Based SolutionSolution

1.1. Entivity PC Based SolutionEntivity PC Based Solution

2.2. VLC Overview VLC Overview

3.3. Studio OverviewStudio Overview

Entivity PC Based SolutionEntivity PC Based Solution More than Emulating a PLC on a PC!More than Emulating a PLC on a PC!

Control Entire Automation System Clip on to Legacy Systems

Enabling Automation ProductivityEnabling Automation Productivity Faster Time to Market Lower Launch Times Increased Throughput Better Quality Tools for Continuous Improvement

Process Control Flow ChartsProcess Control Flow Charts Focus on the Process No need to “Program” the Technology

Entivity Products EasiestEasiest

FastestFastest

Most Most CompleteComplete

EasiestEasiest

FastestFastest

Most Most CompleteComplete

LIVE! – Easy to UseLive! is a full-function, simple PC-based control software product. Filled with easy to use features, a great solution for many applications.•Flowchart Logic

•Integrated HMI

•Integrated Motion Control

•Full Feature PID Loop Control

•Downtime & Cycle-time Analysis

•Instant I/O Configurator

•Application Debugger

•Windows CE runtimes

VLC - FastestVLC version 5.x Password protection on Flowcharts Support for Sub-Millisecond scan-rates Upgraded to IN-time 2.1 with latest TCP/IP stack Includes Latest drivers &Motion Development

System Flowchart & RLL Editor

                                                                              

                

VLC version 6.x Windows XP support PCI RetMem Cognex Vision block Latest HMI version SQL block

Studio - Complete•Flowchart Control Logic •Sophisticated HMI•Connectivity Center •Integrated Motion Control •Advanced PID Control•Downtime and Cycle Analysis Tools •Visual Debugging Tools •Project Management Tools •System Support Tools

Topic 6Topic 6Think & Do Live ! Think & Do Live ! OverviewOverview

1.1. Think & Do Live! OverviewThink & Do Live! Overview

2.2. Think & Do Live! FeaturesThink & Do Live! Features

Think & Do Live!Live !

A versatile control & visualization package

With wide range of I/O & motion drivers Basic HMI Runs under Windows NT, 2000, & XP Can also run under Windows CE for

distributed/embedded control in smaller footprint applications

Project Binder• Familiar Microsoft Outlook User Interfaces

To organize all automation project components, tools & documentation

• Common Tagname Database supports control logic, HMI, external programs and enterprise connectivity

Control Logic• Flowchart Programming

“Program” Control Logic with only user friendly Flow Charts. Double-click to Tag to Tagnames (I/O tag with variable names)

• Comprehensive Logic BlocksLogic Blocks provides comprehensive control functionality, including discrete logic, motion control, PID loop control, serial port communications, and external program interfaces

• Automatic CompilationFlowcharts automatically converted to an executable format that can be run on Windows 2000, NT, and Embedded NT & CE

I/O Connectivity• Auto I/O Discovery

Auto-discovery and configuration tools provide the easiest way to connect to many popular I/O networks

• COM/DCOM supportFull COM/DCOM interface support

• OPC Client & ServerClient and server capabilities supported with built-in OPC 2.0

HMI• Create HMI in Integrated Environment

Create HMI screens from within Live!, that is directly linked to the I/O Tagnames (Variables)

• Shapes from Symbol Factory Includes a library of automation specific shapes for a wide rangeof applications.

• Easy Access to Variable Easy Access to Tagnames with a double-click to tag Tagnames to Control Buttons, including creating directly Output Control Button without any Flowchart

Motion• Easy Interface to Motion Controllers

Integrated motion control parameters provide the easiest of use to interface with many popular motion controllers all from within the control logic

• Multiple concurrent motion ControllersSupports multiple motion controllers simultaneously

PID Loop Control• Full-featured PID loop control

built-in with the control logic

• Easy PID ProgrammingParameters are available for simple and sophisticated loop control along with support for up to 64 loops

Debugging

• Graphical Debugging with EasyTrac Modeallowing you to track easily the logic execution progress with colored path of the flowchart

• AppTracker

(Application Tracker) gives you extensive debugging

capabilities for use in project development.

Topic 6Topic 6

In ConclusionIn Conclusion

helping customers achieve … Shorter time to market through faster automation

development and fewer system integration problems, Tightly integrated control and information systems, Access to real-time data for dynamic scheduling and

customer visibility into the manufacturing process, Access to productivity data for asset utilization

management, Flexible solutions with an open architecture, Flexible, maintainable systems with open interfaces and

self-documenting logic, Rapid development through the use of the industry

standard Microsoft Visio user interface for logic and HMI development.

… BOTTOM LINE RESULTS!

Applications• Materials Handling• Sortation• Packaging• Machine Control• Process Control• Test Systems• Facilities Management• Web Processing• Water/Wastewater• Remote Monitoring• Productivity• E-Manufacturing• Continuous Processing

• Batch Processing• Extrusion• Refrigeration• Security• E-Fulfillment• Electronic Assembly• Semiconductor Processing• Intelligent Conveying• RTU• Bio-Remediation• E-Control• And many more ...

@ www.entivity.com/case_studies.asp

Sample Customers• Gateway Computers• Dell• General Motors• Hewlett-Packard• 3M• Caterpillar• QSC Audio• Delphi• Eskay• Honeywell• Lucent Technologies• Pete’s Coffee• NASA

• Motorola• Lens Crafters• Six Flags Great Adventure• Seagate• Viewtronix• US Department of Energy• University of Arizona• United Parcel Service• IBM• Xerox• Chevron USA• And more … adding

everyday

ConclusionConclusion1.1. Q & A Q & A

2.2. FeedbackFeedback