160 mm
Control
Handling
Machining
Assembly
Control
47,3 mm
Electronics
Pneumatics
Electronics
▼
Mechanics
Sensorics
Software
88,5 mm
Plagemann
158,5 mm
English
Chinese
English
▼
French
German
Russian
195 mm
Spanish
Blue Digest
Blue Digest
on Automation
053 627
225 mm
Plagemann
Plagemann
Blue Digest
on Automation
Blue Digest on Automation
All texts, representations, illustrations and drawings included in this book are the
intellectual property of Festo AG & Co., and are protected by copyright law. All rights
reserved, including translation rights. No part of this publication may be reproduced or
transmitted in any form or by any means, electronic, mechanical, photocopying or
otherwise, without the prior written permission of Festo AG & Co.
A few years ago it was still a topic of discussion as to whether industrial PCs and
Preface programmable logic controllers were in competition with each other or were
complementary. Today, both systems have their place and are used as a matter of
course.
The focus of discussion and development has now shifted towards network technology
instead. Decentralized automation technology is once again the hot topic in
automation. The Ethernet network – an age-old fixture in the PC world but entirely new
in the field of automation – has made decentralized automation manageable. The use
of fieldbusses for decentralizing the input/output level has led to experts in automation
technology becoming familiar with the terminology and techniques of networking and
serial data transmission. This knowledge is now being combined with the experience
of the network engineers. As a result, integrating automation technology into the
networks used in manufacturing and administration is at last becoming so easy that the
technology can be put to widespread use.
For almost two decades now, Beck IPC GmbH, a subsidiary of Festo AG & Co, has
been developing industrial control technology based on PC technology. In order to
make the grade, every new development has had to meet certain requirements. Each
one must be:
This book describes examples of applications using the controllers from Beck and
Festo. We trust you enjoy browsing and reading through the book, and hope that the
descriptions might give you some ideas for new solutions of your own.
Index..............................................................................................................................105
It is certainly a pleasure to fold open a cardboard box and lovingly to pack it with
Control and handling carefully chosen Christmas presents for someone close to your heart.
technology
It is hard, tiring work to open not one cardboard box but
several hundred a day so that they can be filled with goods. This is where a
combination of mechanical systems and control technology is called for. This is where
pneumatic components are used for the drive units, in conjunction with small, fast-
acting controllers.
Starting from "little" tasks such as these right through to assembly stations, they are
still out there today: systems and installations which need control technology, using
Boolean algebra, AND and OR, steps for organising the working sequence – all this
helps get the job done. Even if public discussion tends more to focus on the networks,
the operating philosophy and many other things, there are still millions of relays
switching motors on and off, and millions of valves letting cylinders travel back and
forth.
The modular system of the IPC PS1 with its multiplicity of different input and output
modules and the modules for controlling stepping motors, servoelectric and
servopneumatic axes is ideally suited to mastering these tasks. And the mini
controllers of the Front End Controller family feel most at home in small-scale
applications, where there is always call for fast and flexible automation technology that
boosts productivity.
In this section you will find a number of examples in which the main focus is on control
technology. Enjoy your read.
Automating a task like this calls for a great deal of know-how. Because although
cardboard boxes are sturdy, they are certainly not stiff. The box gives way, moves, is
never precisely the same size, and appears in an infinite number of variants. With the
aid of a sophisticated mechanical system in conjunction with pneumatic drives and
vacuum suction devices, boxes of different sizes and different strengths can be opened
and set up automatically, and the base taped ready for the box to be filled.
As easy as it may sound to "open a cardboard box", the solution is equally elaborate
and complex. This is because a system has to be constructed that is very cost-
effective (cardboard boxes should of course cost nothing – they are "only" the
packaging) yet at the same time highly flexible. Depending on the products being
packed, the boxes have to be larger or smaller, thicker or thinner walled, stiffer or more
pliable. Not only that, no-one really has space for a Boxer, so the machine must be
compact and offer very flexible installation options – for operation from the left or the
right, or any other variant you care to think of. Rembrandt has therefore constructed the
Boxer from individual modules which can be assembled to suit the customer's specific
requirements.
Cooperation between Festo and Rembrandt has helped to make the Boxer flexible and
fast in production. Festo in Holland manufactures the entire control cabinet with the
Hardware IPC FEC FC20 Mini controller with flash memory for the application.
Software FST With FST a system of this type can be programmed in double-quick time,
because the process being controlled is a sequence of movements which are
ideal for programming with the STEP command in FST.
The device can be mounted on any injection moulding machine. After the injection
process, the device takes hold of the sprue part in the area of the opened mould and
transfers it to a container. The injection moulded part itself is separated automatically
from the sprue and drops into a different container. Within the production process, the
removal operation not only represents an unproductive length of time, it is also linked
to energy loss, because the open mould quickly cools down. The shorter the time
taken for removal, the lower the energy loss and the more productive the plant is in
operation. The electronics hardware can meet this requirement without any difficulty.
The challenge in this case is for the pneumatic components. But the control program,
_ The x-axis, which runs parallel to the ejector on the injection moulding machine. It
is implemented with two short-stroke pneumatic cylinders which allow a maximum
travel of 50 mm.
The requirements that need to be met by the control system of an arrangement of this
nature are satisfied by the PS1 system in the best possible way. All control tasks can
be mastered with the central processing unit and the digital input/output options. As
well as this, the IPC fits into the gap in the switchbox which all of the other components
leave free.
Program language One fundamental prerequisite for the choice of hardware was simple programmability.
The FST software makes the programming of step-by-step sequences easier thanks to
the STEP operation and the ability to easily administer up to 64 different
programs/tasks. The control program is modular and therefore its structure means it is
easy to maintain. The plant functions are implemented in two modules: the key
interrogation part establishes the connection to the operating personnel, while control of
the handling components is dealt with in the main program. The FST programming
software supports step control in that the steps are managed by the system and the
programmer is relieved of the task of setting up a step variable and interrogating it.
Of the 16 digital output signals which the OM10 module makes available, 4 are used to
send commands to the injection moulding machine (ejector, mould closure and core
puller).
In principle, the yards and yards of seams can also be welded by hand, but in most
cases this would make complete renewal uneconomic. Uddcomb has developed a
welding machine which automatically moves along the welds inside the container in a
suspended position. The welding machine is moved with the aid of stepping motors,
and the welding current is used as a measure of the correct distance for the welding
wire.
The control system needed for such an unusual welding machine has to be extremely
flexible. As well as this it should be small, because the entire system is forever having
to be transported from place to place. The containers that need to be repaired do not
come to Uddcomb, instead the refurbishment team always has to travel to wherever
Software FST was chosen as the programming language; it is simple and quickly adaptable,
supports the positioning task and is very well known to the people putting the project
into practice.
The Checkbox takes a new approach. In this case, no mechanical obstacles are used
but instead a camera is used to check the orientation. In a teach-in process, the control
system is taught what the "correct" part should look like. The computer compares the
captured image with the stored image and issues a command to blow out or eject those
parts that are not positioned correctly.
The particular advantage of this method is that the Checkbox is highly flexible in use.
The teach-in process takes a matter of a few minutes. The correctly oriented part has to
be passed beneath the camera several times, the computer saves the image – that's
all. In contrast, setting up a mechanical obstacle course can be a matter of hours or
sometimes even days.
The second advantage of the Checkbox is that not only can the parts be checked that
they are fed in the proper orientation, they can also be examined for entirely different
properties, such as their shape, colour, material etc. In this way, the Checkbox can
also be used for sorting, not only feeding.
Software C/C++ is the right programming language for a task such as this.
It is at this interface between fashion and automation technology that Brandtex and
Festo come together. Recently Brandtex began operation with a new generation of
automatic sewing machines, for sewing trousers and skirts. The installation is
controlled by an IPC PS1.
Firstly there is the activation of the positioning system required for the sewing process.
The power section for a stepping motor is activated directly from the inputs/outputs of
the CPU. All of the parameters for the stepping motor, such as the position, speed,
starting ramp and brake ramp etc., are entered in a module in the FST software. The
outputs specify the frequency and direction for the stepping motor directly. The inputs
read directly from the sensors on the shaft. There is no need for a separate stepping
motor controller.
Then there is the CPU and the entire IPC PS1 system. The HC01 CPU is specifically
designed for small- to medium-sized autonomous plants, and in terms of its price fits
very well into a project as critical as this.
Thirdly there is the programming software that is used. With the FST software, the
programming process is adapted to the way that the engineers think.
One particularly important factor regarding the use of an automatic sewing machine is
also that the operating personnel do not usually have much idea of electronics or
computers. The necessary operator actions must therefore be kept simple, clear and
uncomplicated. At Brandtex they use an EXOR terminal for the purpose of operator
control. This terminal is itself equipped with a computer, so it can access the control
system independently. Clear and uncluttered software allows the data and
communication rules to be entered in the simplest possible way.
Keywords HC01, positioning, stepping motor, EXOR display, valve terminals, FST, textile
industry
Software The programming makes use of the multitasking system provided by the FST software
and, in addition, the MultiCI driver, which ensures that the touch panels have direct
access to all variables in the control system.
These include:
_ Controlling every aspect of the vehicle hydraulics
_ Operator prompting via a graphics monitor for the driver
_ On larger vehicles, networking via a CAN fieldbus to the control console for the
tarring machine operator.
_ On special vehicles, networking to a hand-held terminal for personnel
accompanying the vehicle on foot
_ Complete recipe management and control of the mixtures of tar, chippings and
colouring
The complexity of the tasks calls for programming in a high-level language – in this
example it is in C – in a modular system environment.
The IPC PS1 is particularly well suited to this application. It is compact, robust,
modular and therefore flexible, programmable in a high-level language, and the special
modules are based on an open standard.
A remote maintenance facility via GSM modem has been included on many vehicles.
Configuration example for a small vehicle:
Software Programming in C
Keywords Road tarring machines, vehicle hydraulics, operator prompting, CAN, C/C++, GSM
modem, remote maintenance
Product ion o f
mass s torage devices
Further production
Pick & Place Unit s
PP1 ... PP8
For reasons of cost-saving, if no other, the clean room has to be kept as small as
possible. As many production stages as possible, therefore, should take place outside
the clean room.
One of the major manufacturers for mass storage devices produces hard disks in many
Asian countries. Festo in collaboration with an engineering company has contributed to
achieving a further automation of hard disk manufacture, and thus making it even more
productive.
This involved setting up fully automatic pick-and-place units at the end of the clean
room production process; these transfer the finished disks onto a conveyor system
which leaves the area of the clean room. On the opposite side, now under largely
normal ambient conditions, the disks are turned over, identified by barcode readers and
sent to a testing station according to type.
The IPC PS1s for the pick-and-place units are equipped with Profibus DP master
modules. The systems at the sorting gates have HC02 CPUs and digital I/O modules.
All systems are fitted with Ethernet interfaces and are networked with a central PC. A
Visual Basic program written especially for this application runs on this PC, monitoring
all of the connected stations and issuing error messages in plain text. Among other
things, these messages are based on the fact that all cylinder movements are
monitored by a timeout feature.
Software All control programs are written in FST, the monitoring PC program is written in Visual
Basic.
Keywords Clean room, pick-and-place, handling, Visual Basic, Profibus DP, Ethernet
The application described here is not responsible for the entire capacitor production
process, "only" for the attachment of the connecting wires including the predefined
break point. As is usually the case nowadays in automation technology, the primary
demands made of the system were flexibility and speed while maintaining constant
quality.
_ Flexibility means that around 100 types of capacitor have to be produced, each with
different dimensions. And flexibility in this case also means that additional type
data can be added on-line at any time. A small database administers all geometric
data applicable to the various types so that the machine is always prepared for
every job that comes along.
_ Speed means that a cycle time of less than 8 seconds per capacitor has to be
maintained.
_ Quality means that, along with technical functionality, the consideration of safety
plays a very important part. The predefined break point in the connecting wire is a
safety feature that, when the capacitor is subsequently put to use, is responsible for
the safety of much larger systems and processes.
Hardware Plümer Elektrotechnik, a company based in Berlin, is responsible for the control
section. It chose the IPC PS1 Professional because it is sufficiently flexible to satisfy
the various requirements that the system has to meet in terms of control technology.
For the purposes of our example, this means:
A sophisticated error monitoring function monitors every step of the control technology
sequence. Every cylinder movement, for example, is monitored by a timer module. If
the movement does not occur within a specified time, an error message is displayed on
the DIS1 with indication of the cylinder, limit switch and valve. To the advantage of the
maintenance personnel, therefore, all standard errors that may occur in the control
technology are carefully monitored and are displayed in plain text. Short stoppage
times are the benefit of having a monitoring program as well-devised as this.
The tube in the can Most spray cans are made in such a way that inside the can a plastic tube is attached
to the valve, extending down to the base of the can. This ensures that, provided the can
is held upright, virtually all of the contents can be used. For many applications there is
also the possibility of attaching a tube to the outside of the valve, with the aid of which
the oil, cleaning agent or whatever else the can contains can be sprayed with great
accuracy exactly where it is needed. It is these tubes which have particularly grabbed
our attention.
Fast, faster, fastest These days, nothing carries on as usual in the old, easy-going way. Of course it is not
enough to cut a tube to length and put it in position. In the PS1-controlled plants, 650
tubes per minute are cut to length, the length is checked, and the tubes are attached
and are tested in position – that is one tube every 92 ms. The combination of
sophisticated mechanical engineering and well thought-out control technology makes
these speeds possible.
The company responsible for the mechanical
engineering side is Fischer in Bad Oldeslohe. A unit that from the outside looks like a
CNC machine processes the tube material, cuts it to different lengths as required and
inserts the tubes.
The company responsible for the control technology is Däter in Hamburg. Mr.
Peemöller has put together a system that is made up of two separate PS1 systems.
Program language The entire system is programmed in MULTIPROG, the programming package that
conforms to IEC 6 1131-3.
Keywords Spray cans, cutting to length, positioning, testing, IEC 6 1131, MULTIPROG
The tree trunks delivered to the sawmill need to be sawn into boards to a thickness that
precisely matches the details of the customers' orders. The demands imposed on
board production are not so very different from the demands made on the production of
items such as valves or alarm clocks: constant quality of the end product, even if the
primary product – the tree trunks – is highly variable; high flexibility, with batch sizes
alternating between just 1 and several hundred; and speed of production. Of course, the
primary product has to be handled quite differently from products such as small screws.
The huge trunks in some cases have diameters of over 1 metre. They are placed on
trucks that remind you of railway goods wagons. There they are clamped in place and
taken to the saw. There is no-one standing by the saw holding a metre rule to measure
what thickness the board should have: instead, positioning is carried out with high-
performance frequency-controlled three-phase motors and with hydraulic shafts. The
required thickness for each order is entered at a control console, the clamping trestles
on the truck clamp the trunk and guide it with an accuracy measured in millimetres to
the band saw – or to the double band saw, if a second, offset and separately
positionable band saw is also connected. The idler wheel on the band saw alone may
have a diameter of up to 1.8 m - while the IPC PS1, in contrast, is barely larger than one
or other of the fixing bolts.
Hardware In the IPC PS1, all of these tasks are brought together. A single CPU takes care of
controlling, positioning and user guidance. Depending on the size of the saw machine,
12x or 20x busboards are used. Positioning is controlled with AM20 modules, and the
CPUs are usually 486s.
Software The software follows hot on the heels of the distribution of tasks: the control section is
programmed in S5. The S5 operating system is embedded in a multitasking kernel, so
the positioning and the user interface are written in C/C++. An ideal combination.
Because the tough sawmill environment requires a simple interface to the control
technology. And these days Step5 is also familiar to electricians at sawmills. User
prompting and positioning, on the other hand, are reserved for the PS1 engineer.
In order to boost the sales of products that are packed in cans, sometimes surprise gifts
are included with them. A drinks manufacturer, for example, arranged to include
vouchers for lavish holiday trips in the tops of their drinks cans. A customer who buys
the can with the "golden nut" and actually finds the voucher and redeems it has won a
valuable prize.
The manufacturer of the drinks cans, or rather the manufacturer of the tops for the drinks
cans, therefore has to see to it that the vouchers – a prescribed number of vouchers in
each production batch – are included in the tops. And the inclusion of the special can
tops must be done at random.
To do this, a small station was developed which inserts the tops with vouchers into the
production process according to a random principle. The top itself is of course
functionally identical to every normal top, but it has that little something extra on board
...
The IPC PS1 that controls this random insertion machine has to be able to provide
precise information, however, on when tops have been inserted, how many are still left
to be inserted and so on and so forth.
Networking with the office
via Ethernet – every CPU In addition, the controller is integrated into the company's network, because the
can do that. "golden" tops should of course only be inserted if the customer actually requires this.
Software The station is programmed in FST, because programming the automatic insertion
process is quickest in FST.
The dimensions of the tops differ depending on the production batch. The insertion arm
is therefore positioned with a servopneumatic regulator, the SPC200 from Festo.
The system is networked with the company's local area network and the company
database via Ethernet. The Festo fieldbus slave is integrated into the system because
the production master computer has a Festo fieldbus master and as a result is able to
receive status messages from the station very easily.
Keywords Random generator, Festo fieldbus, Ethernet, SPC200, EXOR, positioning, database,
FST
_ Because large projects, in particular, can quickly become confused and chaotic,
especially if they have to be constantly changed because of endless follow-up
requests, the software has to be powerful in order to support systems with
thousands of input/outputs and complex task structures.
_ The familiarisation time for beginners must be short – or really should not be
necessary at all. Everything must be self-explanatory, intuitive and simple.
The FST software approaches these compromises from a highly original angle. It
allows programming to be performed in the way that you would describe a machine.
IF ... THEN "If a part is available here, then this cylinder should advance."
OTHRW This becomes:
IF part_present
THEN SET cylA_forward
STEP What is more, because more than 80% of all machines represent a sequence control
system in automatic operation, the FST software supports the programming of such
sequences by operating independently. A typical automatic handling machine, for
example, has to guide the gripper through the following sequence:
- lower - close - raise - move - lower - open
The FST software uses the STEP operation for this purpose. This automatically forces
a program into a single step, the active one.
As a result, sequences of this type lose their terrors and can be programmed in the
twinkling of an eye.
Multitasking Although the sequence is the central element for most machines, it is far from being the
largest part of the program. Setting up, manual operation, error messages, organisation
and many other things require a due amount of attention. To allow this, the FST
software provides an easy-to-handle multitasking structure. Within each project,
program 0 enjoys a special status as it constitutes the "mother" of all of the other
programs and is launched on startup. A further 63 programs can be added as needed,
and operate simultaneously.
Networking Increasingly, however, today's automation projects are not merely large, they are also
decentralised: a large number of small controllers, each with small projects, operate in
concert. Small, clearly organised, fast, easy-to-program projects in small control
systems provide in total a more easily manageable and clearly arranged whole than a
single giant monster. The FST software supports the networking of controllers with the
assistance of traditional fieldbusses such as Profibus DP and FMS, CAN, ASi, Festo
fieldbus etc., but also now Ethernet - the fieldbus of today. With Ethernet it is possible
both to exchange data between the controllers and to program the controllers. From a
single Ethernet connection, direct access can be gained to all of the controllers out
there on the network. Central programming of distributed controllers is the key concept
here. With FST, from the mini controller to the major system, this is already reality
today.
Modules and drivers No programming software can satisfy every requirement. It is only a matter of time
before someone will ask for this or that feature that "my" job needs, but which "they"
have forgotten about. FST has an open interface for modules and drivers. New modules
can be written in C/C++, and new drivers too. In this way, FST is open to expansion,
modification, and adaptation – for small controllers just as much as for large ones.
WEB Server One example of how this open structure is used is the WEB server. A driver allows
access to the I/O level of the controller via an intranet or the Internet. On the basis of
the TCP/IP driver, the controller with the WEB server understands HTML code, the
language of the Internet.
How does it look in Well, after all is said and done, people do choose the large controller again, with many
practice? thousands of input/outputs, because it is too much trouble for them to rack their brains
about the small subgroups; and because it is too much like hard work to program every
single station individually; and because it is too complicated to network all stations
with each other and to bring up the network in the right order; and because ...
Anyone who says "decentralised" is the best option must also point out ways in which
"decentralised" can be made practicable. Anyone who says "decentralised" is the way
to go needs a network that actually supports decentralised structures and does not
simply grind to a halt when some component or other fails. Anyone who promotes the
"decentralised" theme must illustrate that programming can be carried out centrally and
that troubleshooting can be performed from a central location.
Networking with Ethernet, programming via Ethernet, operation via Ethernet, remote
maintenance via intranet and Internet, process visualisation.
In this section you will find several examples in which decentralisation is taken
seriously. Enjoy reading about them.
Pad printing brings colour Not multi-coloured but with a single-colour imprint, table-tennis balls fly across the table
into play and golf balls soar through the sky. The toy balls for children are usually larger and
also more brightly coloured. The concept that Printing International has devised with its
latest pad printing machine offers the solution for both variants: a modular system.
Every module, in this case the print head, can print both on its own and in concert with
others. If it is left on its own, just one colour is applied.
Pad printing is an indirect gravure printing process in which the subject is etched into
the plate; ink transfer takes place with the aid of a flexible medium, known as the pad.
The printing machine consists of a vertical feed unit, a Festo cylinder. This executes
the pad's printing movement. The horizontal feed unit moves the printing plate between
two fixed positions, towards the pad or towards the "ink cup". This process is repeated
after every imprint.
But how can the observation of these regulations be monitored? Or should we simply
rely on the law-abiding nature of motorised road users?
Boundary between a
pedestrian precinct and a
road
The job of raising and retracting the posts is taken care of by pneumatic cylinders. The
task of triggering the valves is the responsibility of a small controller – and the neat
thing about this solution is that the controller is connected to the local police
headquarters by modem. The cylinders are automatically raised in the morning, and in
the evening they are lowered again. Once a day the PC (the computer, not the officer!)
at police headquarters polls each controller to establish whether the cylinders are up or
down as they should be, and in order to synchronise the clock in the controllers.
The master computer at A car has been driven into the pedestrian precinct and the driver has forgotten the time.
police headquarters How can he get out? Well, the controller can be called up from the police station and in
exceptional cases the post can also be retracted during the day to allow access to the
road.
Modem
The controller is an IPC FEC FC30. A particular advantage of this is that it has two
serial interfaces. One is used for the modem, and one – during commissioning and
maintenance – for the programming unit. The police computer is a standard Windows
PC with a Visual Basic application that accesses the controllers.
The experts at Turnils do a lot of new thinking every day. What makes it more difficult
is that sun-shades and awnings, in much the same way as clothing, are highly
dependent on fashion as far as colours are concerned. And they are purely seasonal
products. If good weather is forecast in a particular area, sales rise. Persistent rain for
weeks on end leaves orders in the doldrums.
Software FST, the universal software with file handling capability and support for serial
interfaces, was once again the software used here.
When, for example, the bolts on the engine block of a new engine are tightened, it is
not only important to know that a bolt has been inserted at all but also that the bolt has
been tightened using the defined tightening torque and that bolting has therefore been
successfully completed using the defined force. Cooper Power Tools (CPT) has
developed its own bolting controller for dealing with bolting tasks of this nature. The
controller is capable of carrying out conclusive checking of the bolting during the
bolting process. The data arising for each individual bolt must be saved automatically,
and must remain available for at least 10 years.
Bol ting
server
Windows
NT
Interface PC
Ethernet
CPT has therefore networked its own bolting controller with an IPC PS1 system, and in
turn it has integrated the PS1 system into the customer's in-house Windows NT
network. The data from the bolting controllers is stored on the IPC PS1's local hard
disk; it is then transferred on a cyclical basis to the NT network, where again it is
backed up on hard disk. Every day the production data is written to CD, and the CD is
placed in storage. In addition, the NT network is regularly backed up as part of the
general data backup procedure for the IT systems.
Firstly, the local hard disk acts as a buffer store. The storage facility is actually
divided into two: in step with production, the data is initially stored in a battery-backed
RAM, then in a cycle of a few seconds it is written to the hard disk before finally in a
cycle of a few minutes being transferred to the local network.
Secondly, with the aid of its input/output modules the IPC PS1 can also carry out
control tasks "on the side". This feature has had the result that, in the course of time,
control tasks have also been transferred to the gateway, for example for belt control,
component feeding etc.
In this way, a simple gateway has turned into a controlling and storing gateway.
Software Programming is carried out in C/C++, the simplest method in a gateway optimised for
the Windows network.
Software The software was developed by AKMA Ltd (e-mail: aml@akma.spb.su), a company
based in St. Petersburg. AKMA has devised its own real-time kernel for DOS systems,
and this is used in this application. The languages it uses are C/C++ and Assembler.
An integral part of the real-time system is a monitor for troubleshooting; this allows
direct access to the variables in the CPU for development work and fault finding.
Twisting thermal wires The manufacture of thermal wires and resistance wires entails first drawing ever finer
wires, and then also twisting several fine and extra fine wires to produce the final wire.
This process of twisting a number of extremely fine wires together is performed
automatically on machines specially made for this purpose. The reels for the initial
products and end products are designed so as to enable the units to operate for up to 36
hours without interruption. The operating personnel ensures that the machines run
around the clock, 7 days a week – human intervention is only needed in order to
change the reels.
What happens, though, if shortly after the new reels are put in place a fault occurs, for
example a thread breaks or a reel becomes jammed? It used to be the case that the
plant had to wait – until help arrived more than a day later.
Automatic fault detection Mr. Eichmann is the engineer responsible for the machinery at Isabellenhütte,
especially for production of the special-purpose machines that the company builds and
programs itself. In order to reduce the length of stoppage times in the event of faults
during the "ghost shifts", Mr. Eichmann now uses a small control cabinet with an IPC
PS1. The IPC PS1 receives digital fault signals from the manufacturing equipment. The
fault groups are indicated with the output module. What is more important, though, is
that a message is sent to the responsible emergency repair service with the aid of a
modem connected to the RS232 interface.
The PS1 system calls for The fault is reported to the emergency repair team on a paging service (Scall)
help wristwatch receiver. The downtime for the machines is now reduced to the length of
time that the emergency team needs to get to the factory and repair the machinery.
Software For Mr. Eichmann, Basic is the fastest and easiest method of achieving success.
The GSM modem and the controller communicate via the second serial interface on
the FC38, the EXT interface. As a consequence the FC38 can basically be
programmed in any programming language, provided that it supports the EXT interface.
As well as this, a special software package was developed, TCM-SMS, which
evaluates SMS messages. This package firstly enables the controller to send an SMS
message. It is also possible, however, to issue commands to the controller with the aid
of SMS messages, in other words for example to switch outputs, read out inputs etc.
The software was adapted for the chewing-gum dispenser in such a way that it is
enough just to make a phone call to the machine. The call and the calling number are
logged. In this process, though, the call is not answered (that would incur call charges
for the calling mobile phone every time). The fact is merely recorded that an attempt
has been made to make a call. When a call is logged, the motor is activated to enable
the machine to give out a small gift.
Hardware
FC34 Demo IPC FEC FC34 Mini controller
DGO cylinder Linear drive
CPV valve terminals
Keywords Internet, WEB server, FST, remote control, remote maintenance, visualisation
This standard, actually adopted many years ago now, is the only internationally
recognised method of PLC programming. Not only that, it is the only PLC programming
method that is promoted, tested and distributed by an independent institution, the
PLCOpen.
At the same time, IEC 6 1131-3 allows the user a great deal of freedom. Five
programming languages are standardised:
The 5 languages of the The text-based languages Instruction List and Structured Text, the graphical languages
standard Function Block Diagram and Ladder Diagram and Sequential Function Chart for
organising sequential systems.
The IPC systems, ranging from the FEC mini controller to the large IPC PS1
Professional system, are all programmable with MULTIPROG, one of the leading IEC
1131-3-compatible software packages.
Wizards and dialog boxes MWT has not only translated the standard into practice, it has also introduced tools
which simplify handling of the standard and make it user-friendly: wizards for making
use of functions and function blocks as well as dialog boxes for the declaration of
variables – familiar to all PLC programmers as the allocation list.
Networks From the very beginning, IEC 6 1131-3 has taken account of the fact that modern
automation technology cannot work without networks. For this reason, MWT can
manage entire networks in a single project, with dozens of CPUs. When IPC central
processing units are used with Ethernet, every controller can be accessed via Ethernet
– from a central location with one Ethernet connection and one programming unit.
Data types IEC 6 1131 detaches itself from the usual data types in the PLC world. In addition to
bits, bytes and words, it supports a large number of other data types. Depending on the
possibilities offered by the particular hardware, INT, DINT, DWORD, UINT, REAL and
STRING can be used, among others. This considerably extends the potential uses of
PLC programming. MULTIPROG exploits this potential, and also offers a large number
of options for converting data types.
Local/global flags At last it is now also possible to use local and global flags in PLC programming. The
name “Start” can be used perfectly well in several programs, and in each program it
refers to a different flag – and is therefore local. This makes handling flags much
easier.
Timers and counters In traditional PLCs, the number of timers or counters that a controller provides is
specified. MULTIPROG may include just one block for an on-delay function, for
example. The block can be called as often as the application requires (and the memory
in the CPU allows). Limits are set by the application, no longer by the programming
system.
Ladder Diagram / Today’s Ladder Diagram uses NO contacts, NC contacts, coils and so on in just the
Function Block Diagram same way as Ladder Diagram has since the start of PLC development. Every block,
whether for example for a counter, a calculation, a flip-flop or any other subprogram, can
be integrated into Ladder Diagram. These blocks look precisely the same as in
Function Block Diagram. This means that the boundaries between Function Block
Diagram and Ladder Diagram are disappearing; the two can be used immediately
alongside each other in every program or block.
Discussing the sense or lack of it behind catalytic converters, diesel particle filters and
speed limits on roads is one thing. Obtaining the necessary data for a scientific
assessment is quite another.
The PC architecture underlying the entire system of IPC FEC and IPC PS1 controllers
in conjunction with optimisation for minimising power consumption provides the ideal
prerequisite for operation as a data collector.
In this section you will find various examples which concentrate on the acquisition,
storage and transmission of measurement data. Enjoy your read.
The IPS1 system in this case acts as a data logger. The data source, a conductivity
meter, makes its measured values available at the COM2 (CP30) port face every
second. The implemented software then has the task of breaking down the serial data
stream into the required data components and of converting the conductivity into the
chloride concentration. Over an interval of two hours the mean value is calculated and
the minimum and maximum values are identified. These 3 values together with the
temperature are assigned a time stamp and stored. For reasons of furnishing proof, the
momentary measured values are logged every minute for a period of 30 days in a ring
memory on the memory card. In the event of an incident, the data can be read out from
the memory card.
Five of these measuring stations are housed in a small control cabinet close to the
river bank. Every conceivable type of weather experienced in central Europe is thrown
at the PS1. In several months of continuous operation, the system successfully
passed its test in action.
On the basis of this measurement data it was possible to prove that neither fluctuations
in temperature (moisture condensation) nor decidedly chilly temperatures of below -5°C
(even over a number of days) had resulted in any failures.
The decision to choose the MC10 module with a 1MB SRAM card as the storage
medium proved to be the correct one in these harsh ambient conditions.
The COM1 (HC12) operates the trunked mobile radio unit. The switch output pin7 of the
CGA port is used to check the radio unit into the trunked radio network at least once a
day.
The COM3 takes over the role of a service interface. System parameters can be
visualised and modified on location with the aid of a notebook.
Three of these measurement systems are located far away from civilisation. They are
supplied with power from photovoltaic installations. In this instance it was important to
save every possible milliampere. This is why the HC20-40 is used, with its two serial
interfaces and the flash memory. Any components that are not required, such as VGA,
are deactivated in the setup. This offers advantages with regard to power saving.
Especially as the local fauna is unlikely to be interested in reading the measurements
on a monitor.
In order to make the measurement data accessible to the plant operator, at intervals of
two hours it is automatically transmitted via public trunked mobile radio to a mainframe
(AS/400), where it is archived. This task is dealt with by another PS1 system. It acts as
a radio server, and communicates with the AS/400 via the in-house LAN topology.
Number 1 3 3
LF340 WTW
conductivity meter X X
ZL31 1 MB SRAM X X
The consultant engineers, ISL Ing-Büro für Systemlösungen in Erfurt, use the IPC PS1
as a long-term data storage facility.
Critical measuring points include the beams of a church tower, for example, when
subject to changing wind load and the varied influences of weather.
Another application is the long-term observation of the load behaviour and response to
weathering of a historically valuable bridge. What needs to be done here is to
document the "healing success" with data from about 1 year before, during and after the
renovation of such a bridge.
The hardware basis is provided by the Spider 8 measuring instrument from HBM and
the PS1 system. The entire functionality of the Spider 8 is stored as an image in the
PS1. The Spider 8 and PS1 communicate via the COM interface using a corresponding
software protocol.
a) Direct coupling between PS1 and notebook (usually at the time of initial
installation or when adjusting the measuring bridges on location)
b) Coupling of PS1 via modem
c) Coupling of PS1 via GSM radio unit (inaccessible terrain with no infrastructure, no
230V supply, no telephone connection)
d) Coupling between PS1 and private mobile radio equipment
e) Autonomous data transfer to the server (script-controlled)
In modes a) to d) the operator obtains an image of the entire system displayed on his
PC/notebook. In remote mode he can parameterise the installation, configure it,
balance (calibrate) sensors, define filter rates and sampling rates, etc. The
measurement data is transmitted using a transfer protocol (X-modem). A formula editor
is implemented which enables the integer measured value to be presented as a
physically relevant measured quantity.
The entire functionality of the measurement system including the transfer interface was
written in C/C++.
Depending on the type of tyre, the initial pressure may be 5 bar, for example, and the
final pressure 1 bar. Inflation and to some extent pressure reduction is carried out
automatically.
The difficulty with pumping air into the tyre is that air is supplied through a valve. The
valve acts as a throttle. This has the effect that it is never possible to measure the
pressure and pump in air at the same time. Consequently, the tyre is always inflated for
only a short time, then the pressure is measured, inflated, measured...
At the Swedish manufacturer, the intelligent solution produced with the IPC PS1 has
reduced the time needed for inflation by 50%. To achieve this, the IPC recalculates the
assumed inflation time at every inflation stage on the basis of a previous inflation
process. It is only when the inflation level is calculated to have reached 90% that the
inflation process is interrupted, a measurement is taken and a new calculation is
performed, etc.
Software Programming is carried out in Pascal, because the emphasis is less on controlling the
input/outputs than on the calculation algorithm.
In Belgium a vehicle has been developed that carries out measurements of soil
compaction automatically and saves the measurement results. To do this, it measures
the force that is needed to enable a rod to penetrate the ground down to a specified
depth.
The IPC PS1 controls two of the axes, X and Y. In the X-axis a stepping motor is used
in order to obtain a series of measurement results, which are then saved. In the Y
direction the measuring rod is extended and the force is recorded. The measurement
data is stored in Excel format in the flash drive belonging to the CPU, and at the end of
a series of measurements it is read out via RS232. In the office the data is then edited
and evaluated using standard software.
Software Pascal
Hüco electronic GmbH manufactures these Tipptronic components and tests the
system with the IPC PS1 Professional. The core of the Tipptronic is a curved printed
circuit board with Hall sensors. The purpose of the test stand is to check whether the
Hall sensors correctly signal the position of the selection lever.
The various positions of the selection lever are simulated with the aid of pneumatic
cylinders, triggered by Festo valve terminals, with a magnet mounted on them. The
gear selection status is output on LEDs. The state of the LEDs is picked up by
photoresistors and is reported back to the testing system.
What was important during the development of the test stand was that the system had
to be very easy to adapt to new requirements, new shapes, and new types. From the
beginning, the test cabinet was designed to allow space for expansion.
A number of files are created for each component type, for example the job file, the limit
value file and the CAQ file, where the measured data is stored. Altogether each
measurement procedure currently amasses 37 measured values.
The measurement system is operated using a standard keyboard and monitor – as far
as the measurement itself is concerned. The photo shows the control cabinet with the
IPC PS1 together with the 14" monitor and the keyboard, as well as to the left of these
the label printer. In addition the AS11 module with its 8 pushbuttons and LEDs is used
in order to switch back and forth between various limit value files.
Software The approach to programming was split into two: the control section including the test
sequence was written in Step5, while the user interface, measured value acquisition,
evaluation and data backup were written in C/C++. The two programming systems are
connected via the real-time multitasking system on the basis of RT Kernel.
Apart from the in-process tests which every electronic module undergoes in the course
of production, a final test is absolutely essential. In the case of the Checkbox hardware
this has to be very flexible so that the test can be adapted to various versions of the
CPU.
Once again, the IPC PS1 was chosen as the centrepiece of the testing station,
although without doubt one reason for this was that the Checkbox team were already
thoroughly familiar with the IPC PS1.
An HC16 CPU, which in this case is able to concentrate entirely on testing, is quite
sufficient here. A BG20 takes care of the graphical representation of the whole testing
process, and input/output modules provide signals for the electronics under test, to
which it has to respond.
Software Programming is carried out in C/C++, because that is everyday routine for the Checkbox
team.
Inside the SDA there is an IPC PS1 Professional beavering away, which is ideally
suited to the task because it provides all of the necessary input/output modules to the
SDC, the system remains small enough and programming of the PC-based system is
no problem for the developers at Weber.
In order to reduce gas consumption and therefore also emissions in an existing gas-
fired power station in Spain, a measuring system with an IPC PS1 is installed at the
flue gas outlet header; this exchanges data with another IPC in the central control room
via an RS485 interface. In the control room the data is visualised and incorporated in
the process control system.
This feedback arrangement therefore enables process optimisation to be implemented
within power station operation.
The rugged and compact design of the PS1 system allows it to be used directly at the
measurement location (the flue gas outlet header) under the difficult ambient conditions
prevailing there for direct recording of the analog measurement signals from the gas
sensors. This results in a cost-effective measurement system.
Additional components:
Measurement system for CO and O2 (gas sensors)
Link between the two IPCs over a distance of about 200m via RS485
Software Programming was carried out in C, because in that way adaptation to the existing
system was easy and flexible.
A test station in which pneumatic cylinders are tested in various steps is controlled by
an IPC PS1. The crucial test step is the leak test performed with the cylinder at its
various operational stages (extended and retracted). The test principle used is
measurement of the pressure drop. The cylinder is pressurised and hermetically
sealed. The pressure drop within a defined period of time and depending on the size of
the cylinder must not exceed a specified value.
Various pressure levels are set with the aid of a proportional valve, depending on the
type of cylinder involved. This calls for the use of a computer-controlled D/A converter.
In order to be able to evaluate the test results in the central computer, the test system
is connected to the company's local area network and thereby to the QA computer.
After conclusion of the test phase, the program is stored in an EPROM. This means
that no mass storage is required, the system is immediately ready for operation on
startup and operational reliability is enhanced.
Software The entire program is written in Turbo Pascal. The LAN is a Novell network, so the
measuring station is a Novell client.
Keywords Quality assurance, pressure regulation by proportional valve, Ethernet, Novell, Pascal
The IPC receives the digitised measured values from a device for measuring the field
strength of radio waves, assigns a time stamp to the values and stores them. Because
umpteen thousands of measurements are taken in the course of a flight, the data is
stored on a floppy disk.
The alignment of the aerial is adjusted using an electric linear drive, which is controlled
from a digital output on the IPC. All of the indicating and operating options offered by
the IPC system are reduced to a minimum, to keep energy consumption down. The
operator actions required for starting the system are therefore performed via a key and
LED module.
IPC PS1 is predestined for this application because of its PC compatibility, its rugged
and compact design and the possibility of running it in energy-saving 12 V mode.
Software Programming was carried out with Quick Basic; this meant that the values taken from
measuring the field strength could be transferred using a simple digital interface.
Keywords Measured data acquisition, measurement of field strength of radio waves, satellite
telecommunications, energy consumption, Quick Basic
A huge range of different requirements have to be met, depending on the particular use.
And depending on these requirements, different mixtures of the parent materials have to
be used. With a great deal of experience and sophisticated calculation algorithms it is
possible to draw conclusions as to the composition of the material and the mixing ratio
of the starting materials on the basis of stress tests.
Scarabaeus is a company that has developed the know-how to perform and evaluate
slow-running automated load tests. The particular skill in this connection is to match
the temperature and the course of the stress tests to each other correctly, and to record
the material behaviour accurately in a single series of measurements. The series of
measurements with its ups and downs of material deformation and material reaction
can be evaluated mathematically. The evaluation provides an indication of whether the
material is suitable for the stated purpose or in what way the mixing ratios need to be
changed in order to better adapt the material to the requirements.
The hardware for the control system consists of two separate IPC PS1 systems. One is
responsible for controlling the stress test, and one deals with recording the
measurement data. The measurement data is sent cyclically to a higher-level
computer, which takes care of graphical representation and further evaluation of the
data.
Several versions of the entire system were programmed in C/C++, because this offers
the best flexibility in dealing with data and communications. The disadvantage of this
form of programming, though, is that troubleshooting in the program is relatively
Software MULTIPROG
The CAN bus has a particularly important part to play in the field of automobiles and
trucks. This is not solely due to the fact that CAN was originally developed for car
manufacture. It is also a fact that the CAN chip, in other words the hardware for CAN, is
particularly inexpensive thanks to mass production, and this makes CAN interesting for
large-scale applications such as cars, trucks etc.
If a manufacturer intends to supply valves for this field of work, he will usually offer an
existing valve series with the addition of a variant with a CAN interface.
The Atega box on the test ATEGA, a company based in Völklingen, near the Franco-German border, has
line developed a small test box to cope with this problem; it is simply integrated into the
existing production chain. It is only when confronted by valve types with a CAN
interface that the test does not apply directly to the valve solenoid but instead is run via
the ATEGA test box. The box uses the CAN protocol to switch, test and check the
valves. The essential advantage of this is that the manufacturer is able to retain his
established production line and simply has to slip the CAN valves in between. Thanks
to the PS1 system, the test box is small and manageable despite being equipped with
the BG10 for operator guidance.
Software All of the programming is done in C++. For this, ATEGA uses a developer CPU
equipped with a hard disk for code development, debugging and compiling. The
finished EXE file can then run in a CPU with a smaller hard disk.
International cooperation Software that was developed at an American university, the computer technology of IPC
PS1 Professional, production technology honed in a Slovenian high-tech workshop,
marketing capacity provided by an expert in Bad Homburg – all of this combined
produced the Aethalometer, an automatic measuring instrument used in environmental
protection.
How does that work? The air is directed through an optically homogeneous quartz paper. A sophisticated
system of sensors detects changes in the colour of the paper. The computer calculates
the soot content in the air from the rate of change of the blackness of the paper and the
flow of air through the paper. The data is time-stamped and saved. Depending on the
particular application, the data is temporarily stored in the system, fed directly into a
network or retrieved by modem at specified times.
Software The programming was carried out in C/C++, as would be expected from an American
university.
The IPC PS1, which records, stores and preprocesses the measured values from the
receivers, is integrated into an Ethernet network via which it is operated by remote
control.
The IPC PS1 is particularly well suited to this task thanks to its ruggedness, its PC
compatibility and its ability to work with a 12 V supply while consuming little power.
Additional components:
2 measuring receivers
Battery and charger
Software Pascal
Today's engineers who are now emerging from university or technical school are
moulded by a world of PCs, by communications and measured data, and by the
feasibility of what can be achieved with software and hardware.
Every graduate of a technical degree course today has at least some idea of what
programming in C/C++ means. And many have even done some programming
themselves and have learnt what possibilities and freedoms this language offers.
All of the central processing units of the IPC system, whether the mini controllers of the
IPC FEC or the Pentium CPU of the IPC PS1 Professional, are always a PC as well,
and as such can be programmed in C/C++.
The fact that this method of programming very much lends itself to many applications
such as gateways, user guidance, measured value processing etc. quickly becomes
quite clear. The fact that one family of controllers offers this possibility is unique. At
many points in this book there are reports of examples which are based on
programming in C/C++.
Process control engineering needs control loops, time, and repetition. The PC-based
systems of the IPC PS1 are ideally suited to tasks such as these.
In this section you will find a few examples from process control engineering. Enjoy
your read.
The Novi Sad water treatment for example works underwent modernisation in 1996. The
filtration plant consists of 2 buildings, each with 12 sand filters. Each filter has an area
of 36 m2 and a flow rate of approximately 60 l/s. Altogether, the waterworks supplies
about 1500 l/s of drinking water.
Sand filter technology A sand filter works at its best when the flow through the filter is within defined limits.
One method of regulation is to measure the flow and control the flap for clean water.
Because of the geometry of the pipes, and due to a lack of space, this is not always
possible. Flowmeters are expensive. One alternative method is to measure the water
level in the filter. The level is kept constant. The geometry and diameter of the pipes
ensures that the untreated water is distributed evenly to all filters. Maintaining a
constant level means maintaining a constant flow.
The control loops are implemented in accordance with variant 2, with good experience.
The regulators are stable. One controller controls 12 filters. A software regulator has 12
control loops. A mathematical model was specifically designed for this purpose. The
regulator parameters are optimised with technologists at the waterworks. The flaps
must not change position quickly because otherwise the water quality would
deteriorate. The parameters can be adjusted with the ViP process visualisation
system, which is also used to observe the behaviour of the control loop.
Optimum filter cleaning is achieved with a certain rate of water flow. The regulation
system was set up to ensure this. The operator can define the setpoint values for the
flow rate and the time (duration) in the ViP process visualisation system. A controller
with a software regulator assumes the function of the regulator. The values are stored
and later evaluated.
Sewer Fan
Air pressure regulation for Filter cleaning begins with the feeding of air from below. The rate of air flow is
filter cleaning regulated. Too much air can blow the sand out of the filter. The operator can define the
setpoints for the flap position and the time (duration) in the process visualisation
system. A controller with a software regulator assumes the function of the regulator. The
values are stored with an industrial data acquisition system and subsequently
evaluated.
Telemonitoring of process The distribution of water requires that the pressure and, if applicable, the flow should be
variables measured at various points and the values transmitted, visualised and stored.
The local stations are implemented with IPC PS1 modules. The data is transmitted by
telephone, over leased lines. The ViP process visualisation system is installed in the
dispatcher centre. A special-purpose communications driver takes over the data from
the remote stations. The collected data is displayed with ViP Trend2 and stored.
Test station for Keystone Before and after the Keystone drives are repaired, the customer would like to perform a
fittings test. A number of different parameters are measured. In addition, a service engineer can
test and adjust the limit switch.
Aeration for untreated The plant for aerating the untreated water comprises two buildings, each with two main
water pipes. The untreated water arrives with a flow rate of Q0 and a pressure of P0. The
regulator must maintain a constant pressure in four pipes. This ensures that the water is
evenly distributed and the plant operates at optimum efficiency. A controller and
software regulator are provided for the purpose of regulation. A PC with ViP for
visualisation and parameterisation of the plant is installed in the control room.
Q 12, P12
Q 0 , P0
Q 21, P21
Q 22, P22
Water storage tank control The level in the water storage tank is signalled to the pumping station and control
centre by radio. In the control room, this information is used for closed-loop control of
the entire system. Operation by remote control is also possible, and is used for
controlling the flaps or pumps. A separate IPC PS1 station is used for data acquisition.
A radio modem and radio transceivers are used for communications.
Well control The command centre for the wells is equipped with the system for remote control and
monitoring of the individual wells on the basis of the VIP software. BHD wells are
equipped with transmitters for water level, pressure and motor current, and with IPC and
Profibus communication modules.
Data is transmitted via Profibus. The command centre and the central control room are
linked by modem via dedicated lines.
Optimisation software analyses the values and presents the operator with a
recommendation as to what subsequent action needs to be taken.
Measured data A large number of measured values are gathered at the command centre. About 40
acquisition system analog signals are connected to a controller and are visualised and evaluated with a
ViP station. The PC with the ViP process visualisation is part of the network, and the
collected data is analysed and processed on various workstations.
Integration of control All of the control stations mentioned above should be integrated into one control
systems console. Water production (wells and the filtration plant) and distribution (pumping
stations, water storage tank and network) are integrated into a VIP WIN online database
system. All technical and real-time data is stored in one common database and is
made available to various workstations.
The maintenance team has its own workstation that
Keywords Proportional valves, waterworks, wells, filters, filter cleaning, flow rate, fans, Keystone
flaps, process control systems, telemonitoring, process visualisation, remote data
transmission via modem and radio, operational data acquisition
After a little thought, however, it very quickly becomes plain that the maturing of cheese
from milk or the process of blue cheese "going mouldy" does not just happen
"somehow", but has to be carried out under reproducible, precisely defined conditions.
One external and necessary prerequisite for reproducibility and hence also consistent
quality is the cleaning of and maintaining the cleanliness of all pipes, tubes,
connections and valves. The requirements regarding cleanliness in the food sector are
immense. On the one hand this is a matter of the actual process of cleaning, which at
heart is a relatively simple form of sequence control. A series of process steps, starting
with flushing and proceeding through heating and the addition of various cleaning
agents, has to be worked through consecutively. A particularly critical task, on the other
hand, is checking and logging the results of the cleaning work. It is not enough simply
to go through the usual tasks one after the other, it is also of the very greatest
importance to check precisely that the cleaning work has indeed brought about the
desired result, and to record that fact.
An Irish cheese producer controls and monitors every aspect of cleaning the pipes and
tubes with the IPC PS1 Professional. In collaboration with Festo Ireland, the system
was set up in such a way that an IPC is responsible for each section of piping that
belongs together. A master computer collects the data via a fieldbus, and makes it
available to a process visualisation system. The process visualisation system is
responsible for recording and storing the process data. In addition, the operating
personnel at the central visualisation station are presented with a clear overview of all
process data.
Software All of the IPC PS1s are programmed in FST, as is the master computer. The reason for
this is above all that it is very easy to program the actual cleaning process, as well as
the fact that it provides excellent support for the fieldbus and the Ethernet interface.
Special features Separate programs have to be developed for the production station and the test station,
but these are networked and exchange data between each other. Standard software is
used on the test PC.
The production station essentially contains the digital inputs and outputs required for
controlling the production machine, together with an analog input module that enables
the production machine to be monitored:
Thanks to its rugged and modular design, its compact dimensions and its ability to be
programmed in high-level languages, the IPC PS1 is a highly suitable yet at the same
time cost-effective choice for decentralised data acquisition systems of this type. As
well as this, its low energy requirements are another obvious benefit in this connection.
Software The engineering consultants Ingenieurbüro Katz, who were responsible for every aspect
of implementation of the system, used C/C++ as the programming language: above all
this offers flexibility in data management and the control of serial data transmission,
and is easy to use with the IPC PS1.
Keywords Data acquisition systems, statistical analysis, C/C++, sewage treatment plants, printer,
clock
In order to deal with the task in hand, about 20 analog and digital signals have to be
monitored, such as liquid levels, temperatures, flow rates of gas and liquid, and pH
values. The process is influenced by means of a variety of actuators: mass flow
controller, electrical and pneumatic valves and any number of pumps, the speeds of
which in some cases are controlled using frequency converters.
Software The software used for the controller is a small process control system on the basis of
WinErs, software developed by engineering consultants Ing.-Büro Dr.Schoop. The
drivers for this were developed at SEI. In addition to the possibility of allowing graphical
planning of the controller, this system also provides modules for data acquisition,
archiving and visualisation. The installation is operated from a PC running Microsoft
Windows, which is connected to the IPC either via a null modem cable, a modem or
Ethernet. This means that monitoring can also be performed from a remote location. In
standalone operation without an operating computer, the accruing measurement data is
buffered in the IPC's CPU for up to several days. Various operating modes are run
through automatically (startup, cleaning, operation), while control in manual mode is
also possible.
The illustration shows part of the control system as a
sequencer. In this way, WinErs can be used both for programming and later for
visualisation of the control system.
Keywords Biological exhaust air purification, level measurement, temperature measurement, flow
rate, pH value, process control, telemonitoring
What does the "cell state" The microorganisms are alive – a prerequisite for them being able to "work" at all. The
tell us? degree of well-being of these organisms can be identified from their consumption of
oxygen – in much the same way as with us humans. When we are fit and producing our
top performance we consume more oxygen than when we are worn out and tired.
On the basis of the level of oxygen consumption, therefore, it is possible to draw direct
conclusions as to the productivity of the system. Measurement of the oxygen provides
information on the progress of production, on the speed of production and finally on
whether production is completed – this is because at some time or other the bacteria
will start to consume the desired end product. After all, it is biodegradable.
In addition to the use of oxygen measurement within the production of materials, this
method of measurement can also be used to establish whether bacteria are capable of
decomposing certain materials: contaminated soil, mixtures of chemicals and many
other similar substances can be selectively fed to bacterial cultures to be "eaten" – the
bioactivity sensor determines whether the bacteria are able to eliminate the
contaminants.
What does the PS1 The core of the system for determining the cell state is an oxygen electrode. The
system do? electrode requires a defined voltage supply and a specific method of signal
conditioning. An independent input module was developed specially for this purpose,
and was integrated into the IPC PS1 system.
In order to obtain a meaningful analysis of the data from the oxygen electrode, a
powerful computer system is required. The program must be structured in such a way
that the test can be adapted to a range of different tasks. After the system has been
configured, the data has to be logged, stored and displayed. This is where the
openness of the PC is ideal. At the same time, it should be possible to put the system
to use directly in production or in mobile laboratory systems, which is why suitability
for industrial use was called for. The compact IPC PS1 is therefore an obvious choice.
Software Programming was carried out in C/C++ with the aid of the Borland C compiler. First a
program flowchart is drawn up by hand for the purpose of program planning, and this is
then converted into C code. The Quinn-Curtis library is used for visualisation of the
measured values.
The temperature of LNG is –161° C; it is in the liquid state at this temperature, and
must be stored in appropriately isolated tanks.
The mobile filling station that was developed and built for Messer Griesheim GmbH is
designed to deliver supplies of LNG for vehicles which are intended to prove the
suitability of LNG engines in real, everyday use.
Diehl DAS 5 Diehl Automation calls the control system DAS5. The basis for the hardware is
provided by the IPC PS1 with analog and digital I/Os in conjunction with
communication to a control system via a modem. The software uses the RT kernel to
create a real-time-capable multitasking system. Building on this, function blocks were
written for all functions of the filling station. This modular software concept makes for
easier maintenance and troubleshooting. This is because the individual functions such
as cooling, filling the tank, refuelling vehicles etc. are each provided as separate
modules.
Water comes out of the tap and disappears down the plughole. That's all. Have you
ever stopped to think about everything that is necessary to maintain the cycle of water
extraction, water distribution, water disposal and water purification? Hardly any of us
step back to give this any thought any more. To make sure that we don't have to think,
other people have done some serious thinking – and have used the PS1 system.
Wells by the Danube The extraction of drinking water in the vicinity of rivers is often based on the use of
wells. The wells, which may be more than 100 m deep, draw groundwater that has been
filtered through the sand strata in the area alongside the river. The water is pumped to a
water treatment plant, which removes contaminants which have not been trapped by the
natural sand filtering, and is finally pumped to the consumers.
Remote maintenance Festo Austria has supplied and installed the entire set of remote maintenance and
telemonitoring equipment for well installations of this type. A well installation
consisting of about 10 wells extending over an area totalling perhaps 5 km in diameter
is combined to form a single group. Each individual well is "taken care of" by an IPC
PS1. The wells are networked with each other by means of Profibus FMS, and the data
is collected in a separate IPC PS1 for each group. A small local control console
belonging to the group of wells includes a standard PC, where visualisation of the group
is provided on site with the aid of VIP, the process visualisation system from Festo
Austria.
Functions for telemonitoring, remote diagnosis, remote control and data acquisition are
all implemented on the control console.
The group IPC is connected via a modem to a higher-level control station that enables
all of the groups of wells to be brought together under one umbrella and visualised
accordingly.
As a result, in the specific project we are referring to here, in Novi Sad, it is possible for
the first time to view and manipulate well parameters from a central control room with
the aid of VIP, the visualisation of industrial processes.
Environmental conditions The unusual situation of a well installation requires special protective measures for the
electronics. Above all, there are three particular aspects that are important:
Firstly, the immediate surroundings of the well are cooled to a large extent by the water
extracted from deep in the earth. In winter, though, it can become bitterly cold and
damp. For that reason, all of the control cabinets are heated.
Secondly, in a distributed system of this nature it is quite possible for the power supply
to fail fairly frequently. Consequently, an uninterruptible power supply is fitted in the
control cabinet for each local control console; this safeguards the power supply for a
period of roughly 15 minutes. That is enough time to be sure of informing the control
centre that the power has failed.
Thirdly, in a system that is spread out over distances of several kilometres there is a
risk of lightning strikes on the connecting lines. To counter this, all sensors are
decoupled by means of surge voltage protectors, the actuators are controlled with the
aid of relays and the Profibus is run via fibre optic cable. A converter from RS485 to
fibre optic cable is provided for this purpose at every station.
The overall effect of these protective measures has stood the test excellently in
practice.
Software The systems are programmed with FST software. One of the key reasons for choosing
the FST software was the openness of the software for additional drivers. For example,
an external firm of engineering consultants, being familiar with the driver interface for
the FST software, wrote a driver for the RS485 interface to the measuring devices and a
driver for controlling the modems. To this must be added the fact that the Cl, the
interface for troubleshooting, is so simply designed that a large range of software and
devices are very easily able to access systems programmed with FST.
Keywords Well control, pump parameters, telemonitoring, remote diagnosis, RS485, Profibus,
process visualisation, lightning protection, environmental conditions
In this section you will find a few examples of edutainment applications using the very
latest automation technology. Have fun reading about them.
At the Heureka science museum in Finland, an attempt has been made to answer this
question using modern simulation technology. In 1878/79, the explorer Adolf Erik
Nordenskiöld and his crew were the first to traverse the Northeast Passage in his ship
the "Vega". A reconstruction of the forward section of the "Vega" is on show at the
Heureka science centre, mounted on a pneumatically driven platform. The system is
set in motion by means of an intelligently arranged cylinder combination in such a way
that people standing on it are given the impression of being on a ship on the high seas.
Within the controller's multitasking system, each cylinder has a separate program
dedicated to it which controls the valves. Each cylinder can be set individually, with
the settings ranging from storm to calm seas, and from light waves to full sail. A truly
impressive experience.
The octahedron of the pneumatic cylinders and the associated controller are designed
in such a way that they can create motion in all sorts of different models. As a result,
Software FST, the multitasking programming system, can provide a separate task for every
cylinder.
Visitors to the zoo can go out and observe the animals on a safari tour. To do this, they
travel in large, air-conditioned buses. To a certain extent, therefore, in this case it is the
human visitors who are sitting behind glass, while the animals live in the open.
In order to make visiting this zoo safer and more comfortable, Rambler Concept
Vehicles has developed a safari bus in which giant windows can be opened and the
doors can open up the entire side of the bus to allow people to get in and out.
Because of the large forces involved, the doors are driven with hydraulic cylinders,
while the windows are moved by very slimly built DNC cylinders. The panorama side of
the bus is controlled by an IPC FEC, which obtains its electrical supply directly from
the 24 V system available on the bus.
A particularly ingenious feature is the way the window cylinders are controlled, for
example. They are moved carefully with their own low-pressure circuit until they are
finally fully closed at the end under normal pressure.
Software FST
In a second phase, the controllers will also be used as PCs in information technology
lessons, which means that IT in general and programming in C/C++ or Pascal will not
be seen merely as theoretical toys but as tools that can be put to practical use.
Hardware IPC FEC FC34-MWT the mini controller with Ethernet, programmable with
MULTIPROG
IPC PS1 with HC02 CPU and various analog and digital input/output
modules
In this section you will find a few examples of applications with the IPC@CHIP. Enjoy
your read.
Two companies, Port GmbH and EMS Wünsche, have got together to develop an
Ethernet - CAN gateway to deal with this problem. The gateway ensures that the CAN
bus can operate without interference, while the data is made available in the Ethernet
network.
Inside the EtherCAN_186/RMD there is an IPC@CHIP doing its stuff on the Ethernet
side, and on the CAN side a Full-CAN processor.
One notable fact about the EtherCAN module is that it was developed in its entirety
within 5 months of the first delivery of the IPC@CHIP. On the one hand this proves the
degree of know-how available to the development team from Port and EMS, but at the
same time it illustrates the simplicity with which the IPC@CHIP can be put into service
if the people involved have knowledge of programming PCs.
Software C/C++ is the programming language of choice for applications of this type.
Internet http://www.port.de
Depending on how it is equipped, the printed circuit board can be used either as a low-
cost microcontroller or an embedded PC.
Optiterm, as the board is named, is ideally suited to carrying out control tasks in the
!ASCO load cells, recording measured values and making the data available on the
network for further processing.
Software C/C++
Internet http://www.asco-online.com
The aim is that the students should gain experience in the development of printed
circuit boards with microcontrollers (hardware) and in the programming of such systems.
With the IPC@CHIP, it is also possible at the same time to bridge the gap to the study
areas covering automation engineering and network technology. To help to do this, an
experimental printed circuit board was developed with the IPC@CHIP at BA Mosbach.
All of the data relating to the printed circuit board is public, which means that the
students can use it as the basis for their own developments.
Internet http://www.ba-mosbach.de
Keywords Engineering studies, experimental printed circuit board, training and further education
IPC@CHIP®
_ All systems are PC-based at their core. This means that essentially every CPU can
also be used as a DOS computer (or in the case of the 32-bit CPUs also as a
Windows computer). Most of the applications are descriptions of PLC applications,
though. Nevertheless, the PC core is always there in the background, because it is
this that opens up the possibility of easily linking with important state-of-the-art
functions such as Ethernet networking, file handling, flexibility in the use of drivers
and modules, and much more besides.
_ All systems are small – in relation to their performance capability extremely small.
Whether or not the IPC@CHIP® is in fact the world's smallest industrial PC, every
CPU is representative of the claim in its performance segment to build small, to
enable the use of small control cabinets, to save space and energy – and in this
respect is a world champion.
_ All systems are network-capable. Every CPU can be equipped with Ethernet, every
CPU – even the smallest – can be programmed via Ethernet and communicate via
Ethernet. Advanced automation technology needs the Ethernet network – all of the
CPUs in the IPC FEC range as well as the IPC PS1 range support Ethernet.
_ All systems are PLCs as much as they are PCs. Tens of thousands of CPUs are
used in the same way as traditional PLCs with the PLC programming languages.
And just as many systems could not do their job without the link to the PC world.
B Basic ..........................................................................................................................45, 65
Boolean Algebra...........................................................................................................9, 72
C C/C++.........................................................7, 17, 21, 29, 34, 43, 44, 53, 55, 59, 61, 62, 63,
..........................................................................67, 69, 70, 72, 81, 85, 95, 98, 99, 100, 101
CAN ..................................................................................................7, 8, 21, 34, 68, 69, 98
Checkbox ..................................................................................................7, 16, 17, 60, 61
CIM .................................................................................................................................. 42
Clark Electrode................................................................................................................ 85
COMX........................................................................................................................ 52, 87
F Fax .....................................................................................................................................4
Flash ....................................................................................................................43, 44, 67
FST ............................................................................ 7, 11, 13, 15, 18, 19, 20, 23, 30, 31,
................................................................................... 32, 33, 34, 37, 41, 47, 79, 90, 93, 94
G Gateway ...........................................................................................................................43
GSM ...............................................................................................................21, 46, 54, 87
H Hall Sensor.................................................................................................................58, 59
Handling .....................................................................................................................12, 13
Index 105
I IPC PS1 module
CP30..........................................................................20, 52, 53, 55, 59, 67, 69, 87, 90
CP31............................................................................................................. 41, 62, 81
CP3X ........................................................................................................................ 44
CP61....................................................................................................... 20, 30, 79, 90
CP70................................................................................................................... 62, 80
CP81......................................................................................................................... 69
DIS 2......................................................................................................................... 70
FC/FD10....................................................................................................... 41, 59, 70
FD10......................................................................................................................... 25
HC01............................................................................................................. 18, 19, 44
HC02................................................................................................................... 23, 95
HC12............................................................................... 24, 52, 53, 55, 62, 63, 64, 80
HC15................................................................................................................... 45, 85
HC16......................... 13, 15, 20, 21, 23, 27, 30, 41, 47, 56, 60, 61, 70, 79, 81, 90, 93
HC17......................................................................................................................... 57
HC20....................................................................................................... 44, 54, 55, 83
HC27............................................................................................................. 27, 69, 87
HC50......................................................................................................................... 54
HD50......................................................................................................................... 59
HD51......................................................................................................................... 43
IM10................................................................................ 13, 20, 21, 56, 63, 64, 80, 81
IM11.......................................................................... 19, 27, 30, 41, 43, 79, 83, 87, 90
IM12.......................................................................................................................... 59
IO10............................................................................................ 15, 61, 62, 79, 80, 93
IO11........................................................................................................ 63, 81, 83, 87
IO12............................................................................................ 20, 21, 57, 59, 83, 85
IO40.......................................................................................................................... 67
IO41.......................................................................................................................... 70
IO60.................................................................................................. 21, 27, 61, 83, 93
IO70.................................................................................................................... 64, 70
MC10 ................................................................................................ 45, 52, 53, 55, 87
OM10........................................................................ 13, 20, 21, 56, 63, 64, 70, 80, 81
OM11.................................................................................... 19, 23, 27, 30, 43, 59, 79
OM12........................................................................................................................ 83
OM20.................................................................................................................. 45, 57
OM21.......................................................................................... 15, 17, 44, 67, 69, 90
OM22............................................................................................................ 59, 61, 93
PS10............................... 19, 20, 21, 24, 27, 30, 41, 43, 44, 56, 64, 69, 79, 81, 83, 90
PS11......................................................................................................................... 59
SM14 ........................................................................................................................ 53
ZL31 ................................................................................................................... 53, 55
ZP11......................................................................................................................... 55
IPC@CHIP................................................................. 8, 47, 97, 98, 99, 100, 101, 102, 103
DK40......................................................................................................................... 47
SC12................................................................................................... 98, 99, 100, 101
L LNG ............................................................................................................................86, 87
106 Index
N Novell ...............................................................................................................................64
Q Quality....................................................................................................................7, 24, 64
R Random ............................................................................................................................31
Real-Time.........................................................................................................................44
RS232.................................................................. 20, 27, 45, 53, 55, 57, 59, 69, 81, 83, 87
RS485............................................................................................................ 44, 63, 89, 90
Rubber ............................................................................................................................. 66
S S5 ...............................................................................................................................29, 59
Sawmill.............................................................................................................................29
Scall ................................................................................................................................ 45
SPC200 ..................................................................................................................... 30, 31
T Telemonitoring ...........................................................................................................74, 76
Index 107
108 Index