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[ pdf ] Automated Manufacturing Systems PLCs 2

Automated Manufacturing Systems PLCs 2 Download
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Topic under  PLC (Programmable Logic Controller)
Source: claymore.engineer.gvsu.edu 
File size: 4.35 MB
File type: pdf
Last download on: Sun Oct 22, 2017 01:04:07 PM
Short Desciption:
765 pages, by Hugh Jack, PROGRAMMABLE LOGIC CONTROLLERS, Topics: Objectives: Know general PLC issues To be able to write simple ladder logic programs Understand the operation of a PLC

Summary:
ROGRAMMABLE LOGIC CONTROLLERS 14 1.1 INTRODUCTION 14 1.1.1 Ladder Logic 15 1.1.2 Programming 19 1.1.3 PLC Connections 23 1.1.4 Ladder Logic Inputs 24 1.1.5 Ladder Logic Outputs 25 1.2 A CASE STUDY 26 1.3 SUMMARY 27 1.4 PRACTICE PROBLEMS 28 2. PLC HARDWARE .30 2.1 INTRODUCTION 30 2.2 INPUTS AND OUTPUTS 31 2.2.1 Inputs 33 2.2.2 Output Modules 37 2.3 RELAYS 44 2.4 A CASE STUDY 45 2.5 SUMMARY 46 2.6 PRACTICE PROBLEMS 46 3. LOGICAL SENSORS .57 3.1 INTRODUCTION 57 3.2 SENSOR WIRING 58 3.2.1 Switches 58 3.2.2 Transistor Transistor Logic (TTL) 59 3.2.3 Sinking/Sourcing 60 3.2.4 Solid State Relays 67 3.3 PRESENCE DETECTION 67 3.3.1 Contact Switches 67 3.3.2 Reed Switches 68 3.3.3 Optical (Photoelectric) Sensors 68 3.3.4 Capacitive Sensors 76 3.3.5 Inductive Sensors 80 3.3.6 Ultrasonic 82 3.3.7 Hall Effect 82 3.3.8 Fluid Flow 83 3.4 SUMMARY 83 3.5 PRACTICE PROBLEMS 84 4. LOGICAL ACTUATORS .89 4.1 INTRODUCTION 89 4.2 SOLENOIDS 89 4.3 HYDRAULICS 90 page 2 4.4 PNEUMATICS 93 4.5 MOTORS 94 4.6 OTHERS 94 4.7 SUMMARY 95 4.8 PRACTICE PROBLEMS 95 5. LOGIC DESIGN .96 5.1 INTRODUCTION 96 5.2 BOOLEAN ALGEBRA 96 5.3 LOGIC DESIGN 100 5.4 COMMON LOGIC FORMS 107 5.4.1 Complex Gate Forms 107 5.4.2 Multiplexers 108 5.5 SIMPLE DESIGN CASES 110 5.5.1 Basic Logic Functions 110 5.5.2 Car Safety System 111 5.5.3 Motor Forward/Reverse 111 5.5.4 A Burglar Alarm 112 5.6 KARNAUGH MAPS 115 5.7 SUMMARY 118 5.8 PRACTICE PROBLEMS 119 6. PLC OPERATION 140 6.1 INTRODUCTION 140 6.2 OPERATION SEQUENCE 142 6.3 PLC STATUS 144 6.4 MEMORY TYPES 144 6.5 SOFTWARE BASED PLCS 145 6.6 SUMMARY 145 6.7 PRACTICE PROBLEMS 146 7. EVENT BASED LOGIC .147 7.1 INTRODUCTION 147 7.2 LATCHES 148 7.3 TIMERS 153 7.4 COUNTERS 161 7.5 DESIGN CASES 164 7.5.1 Basic Counters And Timers 165 7.5.2 More Timers And Counters 166 7.5.3 Deadman Switch 166 7.5.4 Conveyor 167 7.5.5 Accept/Reject Sorting 168 7.5.6 Shear Press 169 7.6 PROGRAM DESIGN METHODS 171 page 3 7.6.1 Process Sequence Bits 172 7.6.2 Timing Diagrams 174 7.7 SUMMARY 177 7.8 PRACTICE PROBLEMS 177 8. SEQUENTIAL LOGIC DESIGN .195 8.1 INTRODUCTION 195 8.2 FLOW CHARTS 196 8.3 STATE BASED MODELLING 205 8.3.1 State Diagram Example 208 8.3.2 Conversion to Ladder Logic 211 Block Logic Conversion 211 State Equations 220 State-Transition Equations 228 8.4 SUMMARY 233 8.5 PRACTICE PROBLEMS 233 9. SEQUENTIAL FUNCTION CHARTS 267 9.1 INTRODUCTION 267 9.2 A COMPARISON OF METHODS 281 9.3 SUMMARY 282 9.4 PRACTICE PROBLEMS 282 10. NUMBERS AND DATA .289 10.1 INTRODUCTION 289 10.2 NUMERICAL VALUES 290 10.2.1 Binary 290 Boolean Operations 293 Binary Mathematics 294 10.2.2 Other Base Number Systems 298 10.2.3 BCD (Binary Coded Decimal) 299 10.3 DATA CHARACTERIZATION 300 10.3.1 ASCII (American Standard Code for Information Interchange) 300 10.3.2 Parity 303 10.3.3 Checksums 304 10.3.4 Gray Code 305 10.4 SUMMARY 306 10.5 PRACTICE PROBLEMS 307 11. PLC MEMORY .313 11.1 INTRODUCTION 313 11.2 MEMORY ADDRESSES 313 11.3 PROGRAM FILES 314 page 4 11.4 DATA FILES 315 11.4.1 User Bit Memory 321 11.4.2 Timer Counter Memory 322 11.4.3 PLC Status Bits (for PLC-5s and Micrologix) 324 11.4.4 User Function Control Memory 325 11.4.5 Integer Memory 326 11.4.6 Floating Point Memory 326 11.5 SUMMARY 327 11.6 PRACTICE PROBLEMS 327 12. LADDER LOGIC FUNCTIONS .330 12.1 INTRODUCTION 330 12.2 DATA HANDLING 332 12.2.1 Move Functions 332 12.2.2 Mathematical Functions 334 12.2.3 Conversions 339 12.2.4 Array Data Functions 340 Statistics 341 Block Operations 342 12.3 LOGICAL FUNCTIONS 344 12.3.1 Comparison of Values 344 12.3.2 Boolean Functions 350 12.4 DESIGN CASES 351 12.4.1 Simple Calculation 351 12.4.2 For-Next 352 12.4.3 Series Calculation 353 12.4.4 Flashing Lights 354 12.5 SUMMARY 354 12.6 PRACTICE PROBLEMS 355 13. ADVANCED LADDER LOGIC FUNCTIONS 364 13.1 INTRODUCTION 364 13.2 LIST FUNCTIONS 364 13.2.1 Shift Registers 365 13.2.2 Stacks 366 13.2.3 Sequencers 369 13.3 PROGRAM CONTROL 372 13.3.1 Branching and Looping 372 13.3.2 Fault Detection and Interrupts 378 13.4 INPUT AND OUTPUT FUNCTIONS 382 13.4.1 Immediate I/O Instructions 382 13.4.2 Block Transfer Functions 384 13.5 DESIGN TECHNIQUES 386 13.5.1 State Diagrams 386 13.6 DESIGN CASES 389 page 5 13.6.1 If-Then 390 13.6.2 Traffic Light 391 13.7 SUMMARY 392 13.8 PRACTICE PROBLEMS 393 14. OPEN CONTROLLERS 402 14.1 INTRODUCTION 402 14.2 IEC 61131 403 14.3 OPEN ARCHITECTURE CONTROLLERS 404 14.4 SUMMARY 405 14.5 PRACTICE PROBLEMS 405 15. INSTRUCTION LIST PROGRAMMING 407 15.1 INTRODUCTION 407 15.2 THE IEC 61131 VERSION 407 15.3 THE ALLEN-BRADLEY VERSION 410 15.4 SUMMARY 415 15.5 PRACTICE PROBLEMS 416 16. STRUCTURED TEXT PROGRAMMING .417 16.1 INTRODUCTION 417 16.2 THE LANGUAGE 418 16.3 SUMMARY 432 16.4 PRACTICE PROBLEMS 432 17. FUNCTION BLOCK PROGRAMMING .433 17.1 INTRODUCTION 433 17.2 DEVELOPING FUNCTION BLOCKS 435 17.3 SUMMARY 436 17.4 PRACTICE PROBLEMS 436 18. ANALOG INPUTS AND OUTPUTS .437 18.1 INTRODUCTION 437 18.2 ANALOG INPUTS 438 18.2.1 Analog Inputs With a PLC 445 18.3 ANALOG OUTPUTS 449 18.3.1 Analog Outputs With A PLC 452 18.4 DESIGN CASES 454 18.4.1 Process Monitor 454 18.5 SUMMARY 454 18.6 PRACTICE PROBLEMS 455 19. CONTINUOUS SENSORS .462 page 6 19.1 INTRODUCTION 462 19.2 INDUSTRIAL SENSORS 463 19.2.1 Angular Displacement 464 Potentiometers 464 19.2.2 Encoders 465 Tachometers 469 19.2.3 Linear Position 470 Potentiometers 470 Linear Variable Differential Transformers (LVDT)470 Moire Fringes 472 Accelerometers 473 19.2.4 Forces and Moments 476 Strain Gages 476 Piezoelectric 480 19.2.5 Fluids and Liquids 482 Pressure 482 Venturi Valves 482 Pitot Tubes 484 19.2.6 Temperature 485 Resistive Temperature Detectors (RTDs) 485 Thermocouples 486 Thermistors 488 Other Sensors 490 19.2.7 Light 490 Light Dependant Resistors (LDR) 490 19.3 INPUT ISSUES 491 19.4 SENSOR GLOSSARY 496 19.5 SUMMARY 497 19.6 REFERENCES 498 19.7 PRACTICE PROBLEMS 498 20. CONTINUOUS ACTUATORS 501 20.1 INTRODUCTION 501 20.2 ELECTRIC MOTORS 502 20.2.1 Brushed DC Motors 503 20.2.2 AC Synchronous Motors 504 20.2.3 Brushless DC Motors 505 20.2.4 Stepper Motors 506 Velocity Profile Motion Control 507 20.2.5 Separately Excited DC Motor 510 20.3 HYDRAULICS 510 20.4 HEATING SYSTEMS 511 20.5 APPLICATION NOTES 511 20.6 MISCELLANEOUS 512 20.7 SUMMARY 512 page 7 20.8 PRACTICE PROBLEMS 512 21. CONTINUOUS CONTROL .514 21.1 INTRODUCTION 514 21.2 CONTROL OF LOGICAL ACTUATOR SYSTEMS 517 21.3 CONTROL OF CONTINUOUS ACTUATOR SYSTEMS 518 21.3.1 Block Diagrams 518 21.3.2 Feedback Control Systems 519 21.3.3 Proportional Controllers 521 21.3.4 PID Control Systems 526 21.4 DESIGN CASES 528 21.4.1 Oven Temperature Control 528 21.4.2 Water Tank Level Control 531 21.5 SUMMARY 533 21.6 PRACTICE PROBLEMS 533 22. FUZZY LOGIC .539 22.1 INTRODUCTION 539 22.2 COMMERCIAL CONTROLLERS 545 22.3 REFERENCES 545 22.4 SUMMARY 545 22.5 PRACTICE PROBLEMS 546 23. DATA COMMUNICATION 547 23.1 INTRODUCTION 547 23.2 SERIAL COMMUNICATIONS 549 23.2.1 RS-232 552 ASCII Functions 556 23.3 PARALLEL COMMUNICATIONS 560 23.4 NETWORKS 561 23.4.1 Topology 561 23.4.2 OSI Network Model 563 23.4.3 Networking Hardware 565 23.4.4 Control Network Issues 567 23.5 BUS TYPES 568 23.5.1 Devicenet 568 23.5.2 CANbus 573 23.5.3 Controlnet 574 23.5.4 Ethernet 575 23.5.5 Profibus 576 23.5.6 Proprietary Networks 577 Data Highway 577 23.6 INTERNET 581 23.6.1 Computer Addresses 582 page 8 IPV6 583 23.6.2 Phone Lines 583 23.6.3 Mail Transfer Protocols 584 23.6.4 FTP - File Transfer Protocol 584 23.6.5 HTTP - Hypertext Transfer Protocol 584 23.6.6 Novell 584 23.6.7 Security 585 Firewall 585 IP Masquerading 585 23.6.8 HTML - Hyper Text Markup Language 585 23.6.9 URLs 586 23.6.10 Encryption 586 23.6.11 Compression 586 23.6.12 Clients and Servers 587 23.6.13 Java 588 23.6.14 Javascript 588 23.6.15 CGI 588 23.6.16 ActiveX 589 23.6.17 Graphics 589 23.7 DESIGN CASES 590 23.7.1 PLC Interface To a Robot 590 23.8 SUMMARY 591 23.9 PRACTICE PROBLEMS 591 24. HUMAN MACHINE INTERFACES (HMI) 601 24.1 INTRODUCTION 601 24.2 HMI/MMI DESIGN 602 24.3 DESIGN CASES 603 24.4 SUMMARY 603 24.5 PRACTICE PROBLEMS 603 25. DESIGN AND IMPLEMENTATION .605 25.1 INTRODUCTION 605 25.2 ELECTRICAL 605 25.2.1 Electrical Wiring Diagrams 605 JIC Wiring Symbols 612 25.2.2 Selecting Voltages 615 25.2.3 Grounding 616 25.2.4 Shielding 619 25.2.5 Wiring 621 25.2.6 Connecting Large Loads 621 25.2.7 PLC Enclosures 623 25.3 FAIL-SAFE DESIGN 625 25.4 DEBUGGING 627 25.4.1 Troubleshooting 627 page 9 25.4.2 Forcing 628 25.5 PROCESS MODELLING 628 25.6 PROGRAMMING FOR LARGE SYSTEMS 632 25.6.1 Developing a Program Structure 632 25.6.2 Program Verification and Simulation 635 25.7 DOCUMENTATION 636 25.8 COMMISIONING 645 25.9 REFERENCES 646 25.10 SUMMARY 646 25.11 PRACTICE PROBLEMS 646 26. SELECTING A PLC .648 26.1 INTRODUCTION 648 26.2 SPECIAL I/O MODULES 653 26.3 SUMMARY 656 26.4 PRACTICE PROBLEMS 657 27. FUNCTION REFERENCE 658 27.1 FUNCTION DESCRIPTIONS 658 27.1.1 General Functions 658 27.1.2 Program Control 660 27.1.3 Timers and Counters 662 27.1.4 Compare 667 27.1.5 Calculation and Conversion 671 27.1.6 Logical 676 27.1.7 Move 677 27.1.8 File 678 27.1.9 List 682 27.1.10 Program Control 686 27.1.11 Advanced Input/Output 690 27.1.12 String 692 27.2 DATA TYPES 698 28. COMBINED GLOSSARY OF TERMS 705 28.1 A 705 28.2 B 708 28.3 C 713 28.4 D 719 28.5 E 724 28.6 F 726 28.7 G 728 28.8 H 729 28.9 I 730 28.10 J 733 page 10 28.11 K 733 28.12 L 734 28.13 M 736 28.14 N 738 28.15 O 740 28.16 P 742 28.17 Q 745 28.18 R 746 28.19 S 750 28.20 T 753 28.21 U 756 28.22 V 757 28.23 W 758 28.24 X 758 28.25 Y 759 28.26 Z 759 29. PLC REFERENCES .760 29.1 SUPPLIERS 760 29.2 PROFESSIONAL INTEREST GROUPS 761 29.3 PLC/DISCRETE CONTROL REFERENCES 761
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