intro automation

8/2/2019 Intro Automation

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Introduction to Industrial Automation January 2005TOLED

Introduction to Industrial Automation

A

B

C

D

Duration : 32 min. Expert, Pedagogy : Philippe WARINRealization : EFISA

PLC's software architecture

PLC's hardware architecture

Operating principles and implementation

to bring the basic knowledge ofindustrial automation systemsrequired before moving on toimplementing specializedmodules for functions such as

communications

Application development phases


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OPERATING PRINCIPLESAND IMPLEMENTATION

A

B

C

D Application development phases





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- Operating principles

Command PartOperative Part

Commands

Actuators

Reports

Sensors

one or more processorscontrolled by

man-machine interfaces

acts on

physical values

solid, liquid or gaseous products

machines or processes


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- The various parts

Command Part

Operative Part

Control

Processing

ProcessSensors Actuators

Actuators

Pre-actuators


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- The implementation steps (1/2)

PLC configuration

Data declaration %I100 : niveau maxi

Programming

Analysis of the specifications

Specifications


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- The implementation steps (2/2)

Transfert of theapplication to the PLC

Application

running

Settings

applicationdocumentation and

archives

- - - - - - - -


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In an automated system: The Command Part is made up of one or more processing units controlled by a man-

machine interface,

The Operative Part is made up of one or more processing units controlled by a Man-Machine Interface,

The Operative Part acts on physical values.

Send Clear


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A sensor changes the status of the Operative Part depending on the orders generated by the

Command Part,

informs the Command Part of the status of the Operative Part, acts on physical values.

Send Clear


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A pre-actuator informs the Command Part of the status of the Operative Part

acts directly on the process: motor, jack...

acts on a power actuator

Send Clear


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An actuator measures a physical value: pressure, temperature, motion,

generates an electrical signal used to act on the Operative Part,

acts directly on the process: motor, jack...

Send Clear


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{questions} out of {total-questions} were

correct

Your total is {percent}%

Quiz Results


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PLCS HARDWARE ARCHITECTURE

A

B

C






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hardened to resist

mechanical constraints

electro-magnetic interference

heat constraints

- The PLC role

Command Part

Operative Part

ProcessSensors Actuators

Processing

Supervision PCs, PLCs,printers, modems etc

Communication

Control


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Introduction to Industrial Automation

January 2005TOLED

- PLC architecture

Main rack

1 or more racksfor the interfaces.

Analog input

interfaces

Analog output interfaces

Communication

interfaces

Processor Digital input

interfaces

Digital output

interfaces

Power supply

PLC's internal bus

Specialized interfaces


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Introduction to Industrial Automation January 2005

TOLED

- The power supply unit

Provides the electric power for all of themodules

One power supply module per rack

Indicators : OK, RUN, BAT

RESET push button

Fuse

Backup battery to save datas/application

Relay output ( Watchdog output)

PSU = Power Supply Unit


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TOLED

- The processor module

Programprocessing

Externaldatas

Inputinterfaces

InternalBus

Output

InterfacesOutputstate

InternalBus

OK

RUN

FAULT

Indicators

programming

terminal (a PC),


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TOLED

- The digital input interfaces

Insulation

Limit switches, proximity

detectors

3 7 1 9

Encoder wheels, digitalsensors

Adapatation

5 V

24 V

InternalBus

I0I1

I2

FAULT

Input statusdisplay


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TOLED

- The digital output interfaces

Actuators

Pre-actuators

InsulationInternal

Bus

Adaptation

Amplification

5 V24 V

Q0

Q1

Q2

FAULT

Output statusdisplay


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TOLED

- The analog input interfaces

Insulation

400Internal

Bus

400Analog /digital

Conversion

CAN

40

Connection to sensors :

levels,

pressure,

temprature etc

Dtecteurs, fin de course

4 Volts


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TOLED

- The analog output interfaces

InsulationInternal

Bus

800

80

Connection to :

pressure regulator

heating valve etcDigital /analog

conversion

CNA8 Volts


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TOLED

- Communication interfaces

supervision PLCs, other PLCs,printers, robots, modems etc

InternalBus

Drivers +Micro-

process.

RUN

ERR.

Troubleshootingindicators

Acyclicexchange

Configurationadjustment

troubleshooting

Tables ofcyclic

variables

Process

data

CANopen,DeviceNet,Ethernet,Modbus,

Profibus etc


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TOLED

- Application specific interfaces

counting,

axis control

motion control

weighing

InternalBus

CPU.RUN

ERR.

Troubleshootingindicators

Tables ofconfiguration

troubleshootingvariables

ConfigurationSettings

Troubleshooting

Tables of cyclicvariables

Process

data


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TOLED

The PLC belongs to the Command Part in an automated system

belongs to the Operative Part in an automated system

accepts data provided by actuators

Submit Clear


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TOLED

The processor provides the electric power required by all of the PLC modules

makes it possible to connect sensors and actuators

cyclically runs the application program

Submit Clear


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TOLED

An analog output interface is used to connect

level sensors,

heating valves,

encoder wheels.

Submit Clear


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TOLED

Quiz Results{questions} out of {total-questions} were

correctYour total is {percent}%


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TOLED

PLCS SOFTWARE ARCHITECTURE

A

B

C






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TOLED

- PLC's memory structure

Processor module

Data

Program

Constants

Variables used by the applicationprogram. This data is available in

read and write modes.

Program storage

Storage of constants used by theprogram

RAMthat can be

battery backed up

RAMbacked up

or

EEPROM

Memory size depends on processor powerand on memory extensions

3 parts


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TOLED

- Data memory

Internal variables

System variables

Interface variables

Function block variables

CPU Data memory

variables intended for storing data whilethe application program is running

variables from the various application

interfaces : digital, analog or specific

variables assigned to the various functionblocks: timers, counters, monostables

variables used to inform or act on

the PLC state

4 kinds ofvariables


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TOLED

- Internal variables

Bit

Octet

Mot

Double mot

Flottant

%MW 16 bitsWord

%MD 32 bitsDouble Word

%MF 32 bitsFloating

%MB 8 bitsByte

English Syntax Format

%M 1 bitBit

French

Variousformats


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TOLED

- Process interfaces variables

Digital inputs

Digital outputs

Analog inputs

%Q XY.i.r 1 bit Contactors, relay, indicator lights

%IW XY.i.r 16 bits

%ID XY.i.r 32 bits

Temperature, speed, pressure,position, or current data

%QW XY.i.r 16 bits

%QD XY.i.r32 bits

Temperature, speed, pressure,position setting commands

Syntax Format

%I XY.i.r 1 bit Digital sensors, limit sensors

Use

Topological typeaddressing

Analog outputs

Forprocessing


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TOLED

- Interface variablesfor troubleshooting, adjusting and configuration

Internal variables

Internal constants

16 bits%MW XY.i.r Troubleshooting, adjusting orstatus determining variables

16 bits%KW XY.i.r Interface configuration

Digitaltroubleshooting

inputs

Syntax Format Use

1 bit

1 bit

%I XY.MOD.err Diagnostic at the module level

%I XY.i.err Diagnostic at each channel level

TroubleshootingAdjusting

Configuration

Topological typeaddressing


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TOLED

- Interface variable addressing

Micro and Premium addressing

%IW XY.i.r

Rack address

Interface position in the rack

Channel number on the interface

Variable position in the channel

Example : %IW 104.0.12

Variable N12on channel 0

of the interface located in slot 04

in rack N1

Rack N1Location N3channel 1 =topologicaladdressing


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TOLED

- Function block variables

Syntax Use

%Tmi .P Preset timer value

%Tmi .V Current timer value

%Ci .P Preset counter value

%Ci.V Current counter value

%Ri .I Input word of memory function block

%Ri. O Output word of memory fonction block

Function block number

Timer function

Counter

Memory block

Predefined

or usercreated


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TOLED

- System variables

Read andwrite

Cold start, hot restart, task enabling-disabling,forcing an output fallback position

Bit

Syntax Use

%S

time base, status data, PLC operating mode,I/O fault, data memory backup battery status

Readonly

Access

Word %SW

execution times (average, min. and maxvalues), the number of requests per cycle...

Readonly

Read andwrite

Control time/date stamping, configuring thecycle time, saving the data memory...

PLC statusacts on its

operation


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TOLED

- Numbering systems

Binary ( 0 and 1)Example %MW100 = 11000001011 soit %MW100 = 1547 decimal

Digitalvariables : ON OFF True - False

Hexadecimal( 0 ; 1 ; 2 ; 3 ; 4 ; 5 ; 6 ; 7 ; 8 ; 9 ; A ; B ; C ; D ; E ; F)Example %Mw100 = 60B or %MW100= 1547 decimal

Bytes, words or double words handling

man-machine interface : temperature, pressures, speeds (cycle/mn)

Decimal ( 0 to 9)

Example %MW100 = 1547%MW100 = 1547%MW100 = 11000001011%MW100 = 60B


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TOLED

- Program memory

Fueling

Module

Instruction 1

Instruction 2

Alarm control

Module

Instruction 1

Instruction 2

ClearingModule

Instruction 1

Instruction 2

Instruction 1Instruction 2

End of program

Program

memory

Backed up RAM

REPROM

EEPROM


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TOLED

PLC initialization

Reading inputs

Setting the outputs

Program

Instruction

Instruction

Instruction

- The PLC cycle

RUN !!!

Cycle time = 20 ms

Checking by watchdog

function


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TOLED

PLC initialization

Reading inputs

Setting the outputs

ProgramInstruction

Instruction

Instruction

- PLC operating modes

RUN, AUTO

STOP, MANU

STOP orRUN ???

Select operating mode

from front panel (key, pushbutton,dedicated input)

from the program,

remotely, over the network


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TOLED

- The machine cycle

Watering

5mn after full filing of the tank,watering starts for 25mn.

Operating modes of the machine

STOP to stop watering and pumping

ON to start the installation.

Tank fillingThe tank is filled by a pump.

The pump starts :

when low level is detected

when watering ends

The pump stops when full filling isreached.

STOP

ON


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TOLED

- Cold restart, hot restart

Initialization

checking the configurationSetting the various modules

Watering

Tank filling

Fertilizer adjonction

Cold restart

Drying

Hot restart


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TOLED

The data used by theapplication is stored :

in RAM

in REPROM

in EEPROM

Submit Clear


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TOLED

Variable %M15 is an internalvariable of which type:

Bit

Byte

Word

Double word

Submit Clear


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TOLED

Variable %MD100 is an internalvariable of which type:

Bit

Byte

Word

Double word

Envoyer Effacer


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TOLED

%IW104.1.10 is a variable ofwhich type: internal

system

interface function block

Submit Clear


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TOLED

Value 105A is a decimal value

is a hexadecimal value

is a value that corresponds to a byte is a value that corresponds to a word

Submit Clear

V l A


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TOLED

Value 5A equals binary value 0101 1010

equals binary value 0101 0010

equals decimal value 80 equals decimal value 90

Submit Clear

Th PLC l i


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TOLED

The PLC cycle timecorresponds

to the program run time

to the cycle time of the automated machine

to the time required to read inputs, execute the program and write the outputs

Submit Clear

Q i R l


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TOLED



Quiz Results

APPLICATION DEVELOPMENT PHASES


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TOLED

APPLICATION DEVELOPMENT PHASES

A

B

C





PLC li ti i ti


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TOLED

- PLC application various sections

Customized function blocks

producing operatingscreens for monitoring

the process

Declaring PLC modulesentering parameter settings

Program in thedifferent langages

Structuring, naming,settinginitial value of

variables

Application debugging

Generating applicationfiles for archiving

PLC t ti d i ti


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TOLED

- PLC station description

H d d ft fi ti


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- Hardware and software configuration

Hardware

and software

D t d l ti d t t


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- Datas declaration and structure

Adress Symbol Comment

%I1.0 NIV_High High level detection

Declaration

processInitialization

%MW0 to %MW50

Communicationfield

%MW200 %MW700

StructureBits

%Ix.y:Digital input (x position of themodule in the rack, y position ofdigital input)

%Qx.y: Digital output

%Mx: internal Bit (x bit address)

%Mx:n Table of n internal bits

%MWx:Xy internal word bit (y bitposition, x word adress)

Words%MWx : Internal word (x bit address)

%MWx:n Table of n words

%MDx : Word of 32 bits

%MDx:n Table of n words

%MFx (ou %FDx) : Floating word%MFx:n Table of n words

%MBx(n) : String of n characters (x :addresse of the character string)

%KWx, %KDx, %KFx: Constants

IEC Syntax

Program structure


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Module 1 (LD)

Module 2 (ST)

Module n (LD)

Basic processing

- Program structure

Mixing

Module

Instruction 1

Instruction 2

WateringModule

Instruction 1

Instruction 2

Filling

ModuleInstruction 1

Instruction 2 Module 10 (LD)

Module 12 (ST)

Module n (LD)

Eventsprocessing

Power break

Programming languages


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Ladder

ListLittral

Grafcet

FBD

- Programming languages

IEC 1131-3

The Ladder language or Diagram language : LD


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- The Ladder language or Diagram language : LD

The structured literal programming language : ST


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(* Update current cycling indicator *)

IF %M0 THENSET %M18;

ELSE RESET %M18;

END_IF;

(* RESET application *)

IF RE %M21 OR %S13 THENSET %S0;

END_IF;

(* initialization of variables : cold restart *)

IF %S0 THEN %MF502:=30.0;%MD0:=%MD2:=%MD4:=7;%MW202:=8;

END_IF;

- The structured literal programming language : ST

(* Initialization and then back to initial step *)

%L2:IF (NOT Bp_Vehicle_presence AND NOT Cycle_started)

THEN

Memo_start_cycle:=TRUE;

Memo_step6:=FALSE;

Cycle_started:=FALSE;

END_IF;

(* Time reading *)

RRTC(Timer:4);

(* Number of objects to carry *)

TOTAL:=WORKSHOP1 + WORKSHOP2;

Successionof instructions

Comments

Comments

Comments

Label

Grafcet language: SFC


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- Grafcet language: SFC

StepsTransitions

Processing

Function blocks language : FBD


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- Function blocks language : FBD

Instructions list language : IL


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- Instructions list language : IL

Program instructionsComments

Animation tables multiple window function


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- Animation tables, multiple window function

Choose the correct sequence:


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Choose the correct sequence: 1 . Data structuring

2 . PLC configuration3 . Program structuring

4 . Programming5 . Animation tables

1 . PLC configuration2 . Program structuring3 . Programming

4 . Data structuring5 . Animation tables

1 . PLC configuration2 . Data structuring3 . Program structuring4 . Programming

5 . Animation tables

Submit Clear

Animation tables let you:


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Animation tables let you: structure a program

structure data

observe and change data in real-time

Submit Clear

IF (NOT Vehicle_presence_PB AND NOT Cycle_started) THEN


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( p y )Memo_start_cycle:=TRUE;

END_IF;

Is written in List language Is written in Ladder language

Is written in Grafcetlanguage

Is written in Structured language

Submit Clear

Quiz Results


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Quiz Results

intro automation

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