Академический Документы
Профессиональный Документы
Культура Документы
Chang
6/29/2012
7- 1
T.C. Chang
FUNCTIONS OF CONTROLLERS
1) on-off control, 2) sequential control,
6/29/2012
7- 2
T.C. Chang
CONTROL DEVICES
1) mechanical control - cam, governor, etc., 2) pneumatic control - compressed air, valves,etc. 3) electromechanical control - switches, relays, a timer, counters, etc, 4) electronics control - similar to electromechanical control, except uses electronic switches. 5) computer control.
7- 3
6/29/2012
T.C. Chang
6/29/2012
7- 4
T.C. Chang
VENDORS
MODICOM - GOULD ALLEN-BRADLEY GE SQUARE-D etc.
6/29/2012
7- 5
T.C. Chang
PLC
CPU Input Input Module
Flag
System Output User Ladder Diagram Output Module
6/29/2012
7- 6
T.C. Chang
Allen-Bradley PLC-3
6/29/2012
7- 7
T.C. Chang
6/29/2012
7- 8
T.C. Chang
SWITCHES
No n-lo c king Lo c king
SPDT
Multiple Thro w
P1
DPST
Multiple P o le
P2
Ma ke -be fo re -bre a k
6/29/2012
7- 9
T.C. Chang
TERMS
Throw - number of states
Input
7- 10
T.C. Chang
TYPES OF SWITCHES
Selector switches Pushbutton switches Photoelectric switches Limit Switches Proximity switches Level switches Thumbwheel switches Slide switches RATING:
24 Volts AC/DC 48 Volts AC/DC 120 Volts AC/DC 230 Volts AC/DC TTL level (Transistor-to-transistor 5V) Isolated Input
6/29/2012
7- 11
T.C. Chang
RELAYS
A switch whose operation is activated by an electromagnet is called a "relay"
contact
coil
input
Relay coil
R1
Output contact
R1
6/29/2012
7- 12
T.C. Chang
COUNTER
Digital counters output in the form of a relay contact when a preassigned count value is reached.
input Re giste r
12
1
7- 13
T.C. Chang
TIMER
A timer consists of an internal clock, a count value register, and an accumulator. It is used for or some timing purpose.
Clock
Accumulator re se t Re giste r
Time 5 seconds.
6/29/2012
7- 14
T.C. Chang
R1
PB1 LS1
LS2
PR=5
TIMER 5
Motor R2
R1
6/29/2012
7- 15
T.C. Chang
PLC ARCHITECTURE
Programmable controllers replace most of the relay panel wiring by software programming.
PC Switche s
Proce ssor Casse tte Loade r EPROM Loade r Pe riphe rals M emory
I/O M odule s
M achine s
Powe r Supply
A typical PLC
6/29/2012
7- 16
T.C. Chang
PLC COMPONENTS
1. Processor Microprocessor based, may allow arithmetic operations, logic operators, block memory moves, computer interface, local area network, functions, etc. Measured in words. ROM (Read Only Memory), RAM (Random Access Memory), PROM (Programmable Read Only Memory), EEPROM (Electric Erasable Programmable ROM), EPROM (Erasable Programmable Read Only Memory), EAPROM (Electronically Alterable Programmable Read Only Memory), and Bubble Memory.
2. Memory
6/29/2012
7- 17
T.C. Chang
3. I/O
printer
simulator EPROM loader graphics processor
7- 18
T.C. Chang
Discrete I/O
AC Voltage I/O DC Voltage I/O numerical input and output special-purpose modules, for example, highspeed timers, and stepping motor controllers
6/29/2012
7- 19
T.C. Chang
Analog I/O
Analog inputs: Flow sensors Humidity sensors Potentiometers Pressure sensors Temperature sensors Analog outputs: Analog meters Analog valves and actuators DC and AC motor drives
6/29/2012
7- 20
T.C. Chang
Fast input
50 to 100 microsecond pulse signal detection.
ASCII I/O
Communicates with ASCII devices.
Servo interface
Control DC servo motor for point-to-point control and axis positioning.
PID control
The Proportional Integral Derivative is used for closed loop process control.
Network module
6/29/2012
7- 21
T.C. Chang
6/29/2012
7- 22
T.C. Chang
LADDER DIAGRAM
A ladder diagram (also called contact symbology) is a means of graphically representing the logic required in a relay logic system.
Rail
start PB1 emergency stop PB2 R1
Rung
R1
R1 A
6/29/2012
7- 23
T.C. Chang
A B
Input 01 02 03 20 01 20
PLC 02 20
Output 11 12 C
11
External switches
Stored program
6/29/2012
7- 24
T.C. Chang
Input Connections
AC
DC
TTL
6/29/2012
7- 25
T.C. Chang
Output Connections
AC
DC
TTL
6/29/2012
7- 26
T.C. Chang
SCAN
A PLC resolves the logic of a ladder diagram (program) rung by rung, from the top to the bottom. Usually, all the outputs are updated based on the status of the internal registers. Then the input states are checked and the corresponding input registers are updated. Only after the I/Os have been resolved, is the program then executed. This process is run in a endless cycle. The time it takes to finish one cycle is called the scan time. In some controllers the idle state is eliminated. In this case, the scan time varies depends on the program length. Output Input begin Idle Scan cycle
Resolve logic
6/29/2012
7- 27
T.C. Chang
PLC Programming
Ladder Diagram - most common Structure Text Programming (ST) Functional Block Programming (FB) Instruction List (IL) Sequential Function Chart (SFC)
6/29/2012
7- 28
T.C. Chang
6/29/2012
7- 29
T.C. Chang
LOGIC STATES
ON : TRUE, contact closure, energize, etc. OFF: FALSE, contact open , de-energize, etc.
Do not confuse the internal relay and program with the external switch and relay. Internal symbols are used for programming. External devices provide actual interface.
(In the notes we use the symbol "~" to represent negation. AND and OR are logic operators. )
6/29/2012
7- 30
T.C. Chang
R1 = PB1.AND.PB2
AND
PB3
PB4
R2 R2 = PB2.AND.~PB4
PB1
OR
PB2
6/29/2012
7- 31
T.C. Chang
PB1
R1
PB2
pb3
6/29/2012
7- 32
T.C. Chang
RELAY
A Relay consists of two parts, the coil and the contact(s). Contacts: a. Normally open b. Normally closed -| |-|/|-
-|P|-|N|() -( )-(/)-(S)-(R)7- 33
T.C. Chang
Relay (continue)
Coil: e. Retentive memory Coil f. Set retentive memory Coil g. Reset retentive memory Coil -(M)-(SM)-(RM)-
-(P)-(N)-
(set coil latches the state, reset coil deenergize the set coil. retentive coil retain the state after power failure.)
6/29/2012
7- 34
T.C. Chang
counting stop
b. Counter down
c. Counter reset
-(CTD)-(CTR)-
6/29/2012
7- 35
T.C. Chang
SEQUENCER
Sequencers are used with machines or processes involving repeating operating cycles which can be segmented into steps. Output Step A B C Dwell time
1
2 3 4
ON
ON OFF OFF
OFF OFF
ON OFF OFF ON ON OFF
5 sec.
10 sec. 3 sec. 9 sec.
6/29/2012
7- 36
T.C. Chang
A-B PLC
I/O points are numbered, they correspond to the I/O slot on the PLC.
For A-B controller used in our lab I/O uses 1-32 Internal relays use 033 - 098 Internal timers/counters/sequencers use 901-932 Status 951-982
6/29/2012
7- 37
T.C. Chang
PROGRAMMING EXAMPLE 1
Bar code re ader microswitch Part Stopper Conveyor
Robot
Machine
id MSI R1 C1 R2 R3 C2 R4 C3 C4
6/29/2012
description microswitch output to bar code reader input from bar code reader output robot output robot input from robot output to stopper input from machine input from machine
state 1 1 1 1 1 1 1 1 1
explanation part arrive scan the part right part loading cycle unloading cycle robot busy stopper up machine busy task complete
7- 38
T.C. Chang
SOLUTION
Input MS1 C1 C2 C3 C4 01 02 03 04 05 Pro grammable Controlle r PLC Outpu t 11 12 13 14 15 R1 R2 R3 R4
01
14
11
02
14
14
04
03
12
05
03
13
Rung 1. If part arrives and no part is stopped, trigger the bar code reader. Rung 2. If it is a right part, activate the stopper. Rung 3. If the stopper is up, the machine is not busy and the robot is not busy, load the part onto the machine. Rung 4. If the task is completed and the robot is not busy, unload the machine.
7- 39
6/29/2012
T.C. Chang
T.C. Chang
Data Types
SINT INT DINT LINT USINT UINT UDINT ULINT REAL LREAL short integer integer double integer long integer unsigned short integer unsigned integer unsigned double integer unsigned long integer real long real 1 byte 2 bytes 4 bytes 8 bytes 1 byte 2 bytes 4 bytes 8 bytes 4 bytes 8 bytes BOOL BYTE WORD DWORD LWORD boolean byte 16 bit bit string 32 bit bit string 64 bit bit string 1 bit 1 byte 16 bits 32 bits 64 bits
TIME time duration DATE calendar date TOD time of day DT date and time of day STRING character strings
6/29/2012
7- 41
T.C. Chang
7- 42
T.C. Chang
Variable Declarations
I,j,k : v : END_VAR
INT; REAL;
Use VAR, VAR_INPUT, VAR_OUTPUT, VAR_IN_OUT, VAR_GLOBAL, VAR_EXTERNAL for different variable types.
6/29/2012
7- 43
T.C. Chang
v := (v1 + v2 + v3)/3
6/29/2012
7- 44
T.C. Chang
Condition Statements
IF a > 100 THEN
redlight := on; ELSEIF a > 50 THEN CASE dial_setting OF 1: x := 10; 2: x := 15; 3: x := 18; 4,5: x := 20; (* 4 or 5 *) ELSE x := 30; END_CASE
yellowlight := on;
ELSE greenlight := on;
END_IF;
6/29/2012
7- 45
T.C. Chang
Iteration Statements
FOR I:= 0 to 100 BY 1 DO
light[I] := ON; END_FOR I := 0; REPEAT I := I + 1; light[I] := on; UNTIL I > 100; END_REPEAT
I := 0;
WHILE I < 100 DO I := I + 1; light[I] := on; END_WHILE
6/29/2012
7- 46
T.C. Chang
Functions
FUNCTION add_num : REAL VAR_INPUT I,J : END_VAR add_num := I + J; END_FUNCTION Call a function: x:= add_num(1.2, 5.6); Built-in Functions: REAL
ABS, SQRT, LN, LOG, EXP, SIN, COS, TAN, ASIn, ACOS, ATAN, ADD, MUL, SUB, DIV, MOD, EXPT, MOVE), logic functions (AND, OR, XOR, NOT), bit string functions (SHL, SHR shift bit string left and right , ROR, ROL rotate bit string), etc.
6/29/2012
7- 47
T.C. Chang
Programs
PROGRAM example7.1 VAR_INPUT R1 := MS1 AND (NOT R4);
MSI :
C1 C2 C3 : : :
BOOL;
BOOL; BOOL; BOOL;
C4
BOOL;
R2
R3 R4
:
: :
BOOL : FALSE;
BOOL : FALSE; BOOL : FALSE;
END_VAR
6/29/2012
7- 48
T.C. Chang
6/29/2012
7- 49
T.C. Chang
END_VAR
VAR_OUTPUT Q : BOOL;
CU R PV Q CV
CV : INT; END_VAR
IF R THEN
CV := 0; ELSEIF CU AND (CV < PV) THEN CV := CV + 1; END_IF; Q := (CV >= PV); END_FUNCTION_BLOCK
6/29/2012
7- 50
T.C. Chang
block diagram
SP PV KP TR TD AUTO XOUT XO cycle
6/29/2012
set point sensor feedback proportional error gain integral gain derivative gain calculate output to process manual output adjustment time between execution
7- 51
Vout K p E Tr Edt Td
dE dt
control algorithm
T.C. Chang
loop
LD ST ANDN
MS1 R1 C3
6/29/2012
7- 52
T.C. Chang
Operators
Operator Modifiers Description LD ST S N N load operand into register store register value into operand set operand true GT ( greater than
GE
EQ NE LE LT
(
( ( ( (
R
AND & OR XOR ADD SUB MUL DIV
6/29/2012
Modifier N means negate. ( defers the operator. C is a condition modifier, the operation is executed if the register value is true.
7- 53
T.C. Chang
C2
C3 C4
:
: :
BOOL;
BOOL; BOOL;
ANDN
ANDN ST LD ANDN
C3
C2 R2 C4 C3
END_VAR VAR_OUTPUT R1 R2 R3 R4 : : : : BOOL : FALSE; BOOL : FALSE; BOOL : FALSE; BOOL : FALSE;
ST
LD ST
R3
C1 R4
END_VAR
END_PROGRAM
6/29/2012
7- 54
T.C. Chang
7- 55
T.C. Chang
SFC
Action Qualifiers:
N
R S L D P
SD stored and time delayed DS time delayed and stored SL stored and time limited
6/29/2012
7- 56
T.C. Chang
6/29/2012
7- 57