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Introduction to Industrial Automation

to bring the basic knowledge of industrial automation systems required before moving on to implementing specialized modules for functions such as communications
B

Application development phases

PLC's software architecture

PLC's hardware architecture

Operating principles and implementation

Duration : 32 min.

Expert, Pedagogy : Philippe WARIN Realization : EFISA

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Introduction to Industrial Automation January 2005

OPERATING PRINCIPLES AND IMPLEMENTATION


D

Application development phases

PLC's software architecture

PLC's hardware architecture

Operating principles and implementation

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Introduction to Industrial Automation January 2005

- Operating principles
Operative Part
Reports

Command Part

Sensors

Commands Actuators

acts on physical values solid, liquid or gaseous products machines or processes

one or more processors controlled by man-machine interfaces

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Introduction to Industrial Automation January 2005

- The various parts


Command Part
Control

Processing

Operative Part
Sensors Process Actuators

Pre-actuators

Actuators

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Introduction to Industrial Automation January 2005

- The implementation steps (1/2)


Specifications

Analysis of the specifications

PLC configuration

Data declaration

%I100 : niveau maxi

Programming

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- The implementation steps (2/2)


Transfert of the application to the PLC

--------

Application
running

Settings

application documentation and archives

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Introduction to Industrial Automation January 2005

In an automated system:
The Command Part is made up of one or more processing units controlled by a manmachine interface, The Operative Part is made up of one or more processing units controlled by a ManMachine Interface, The Operative Part acts on physical values.

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Introduction to Industrial Automation January 2005

A sensor
changes the status of the Operative Part depending on the orders generated by the Command Part, informs the Command Part of the status of the Operative Part, acts on physical values.

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Introduction to Industrial Automation January 2005

A pre-actuator
informs the Command Part of the status of the Operative Part acts directly on the process: motor, jack... acts on a power actuator

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Introduction to Industrial Automation January 2005

An actuator
measures a physical value: pressure, temperature, motion, generates an electrical signal used to act on the Operative Part, acts directly on the process: motor, jack...

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Introduction to Industrial Automation January 2005

Quiz Results
{questions} out of {total-questions} were correct Your total is {percent}%

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Introduction to Industrial Automation January 2005

PLCS HARDWARE ARCHITECTURE

Application development phases

PLC's software architecture

PLC's hardware architecture

Operating principles and implementation

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- The PLC role


Command Part
Control Communication Processing

Supervision PCs, PLCs, printers, modems etc hardened to resist mechanical constraints electro-magnetic interference heat constraints

Operative Part
Sensors Process
Actuators

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Introduction to Industrial Automation January 2005

- PLC architecture
Processor Digital input interfaces

Digital output interfaces

Analog input interfaces

Main rack

PLC's internal bus

Power supply

Analog output interfaces

1 or more racks for the interfaces. Communication interfaces

Specialized interfaces

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- The power supply unit


Provides the electric power for all of the modules One power supply module per rack

PSU = Power Supply Unit

Indicators : OK, RUN, BAT RESET push button Backup battery to save datas/application

Relay output ( Watchdog output) Fuse

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- The processor module


Indicators
OK

Input interfaces

Internal Bus

External datas

RUN FAULT

Program processing

Output Interfaces

Internal Bus

Output state

programming terminal (a PC),

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- The digital input interfaces


Input status display
I0 I1 I2 FAULT

Internal Bus

Adapatation

5V 24 V

Insulation
Limit switches, proximity detectors

3 7 1 9
Encoder wheels, digital sensors
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- The digital output interfaces


Output status display
Q0 Q1 Q2 FAULT

Adaptation Amplification
24 V 5V

Pre-actuators

Internal Bus

Insulation
Actuators

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- The analog input interfaces

Internal Bus

400
Insulation 400
Analog / digital Conversion CAN

Connection to sensors : levels, pressure, temprature etc

4 Volts

40

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Dtecteurs, fin de course

- The analog output interfaces

Internal Bus

Insulation Connection to : pressure regulator heating valve etc


Digital / analog conversion CNA

800

8 Volts

80

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Introduction to Industrial Automation January 2005

- Communication interfaces
Troubleshooting indicators
Drivers + Microprocess. RUN ERR.

Internal Bus

CANopen, DeviceNet, Ethernet, Modbus, Profibus etc

Process data Configuration adjustment troubleshooting

Tables of cyclic variables Acyclic exchange

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

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Introduction to Industrial Automation January 2005

- Application specific interfaces


Troubleshooting indicators
CPU.

Internal Bus

RUN ERR.

Process data Configuration Settings Troubleshooting

counting,
Tables of cyclic variables Tables of configuration troubleshooting variables

axis control motion control weighing

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Introduction to Industrial Automation January 2005

The PLC
belongs to the Command Part in an automated system belongs to the Operative Part in an automated system accepts data provided by actuators

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Introduction to Industrial Automation January 2005

The processor
provides the electric power required by all of the PLC modules makes it possible to connect sensors and actuators cyclically runs the application program

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Introduction to Industrial Automation January 2005

An analog output interface is used to connect


level sensors, heating valves, encoder wheels.

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Introduction to Industrial Automation January 2005

Quiz Results
{questions} out of {total-questions} were correct Your total is {percent}%

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Introduction to Industrial Automation January 2005

PLCS SOFTWARE ARCHITECTURE

Application development phases

PLC's software architecture

PLC's hardware architecture

Operating principles and implementation

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- PLC's memory structure


Processor module
Variables used by the application program. This data is available in read and write modes.

Data

3 parts

RAM
that can be battery backed up

Program

Program storage

RAM
backed up or

Constants

Storage of constants used by the program

EEPROM

Memory size depends on processor power and on memory extensions

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- Data memory
CPU Data memory

Internal variables

4 kinds of variables intended for storing data while variables the application program is running
variables from the various application interfaces : digital, analog or specific variables assigned to the various function blocks: timers, counters, monostables variables used to inform or act on the PLC state

Interface variables Function block variables System variables

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- Internal variables
French English Syntax Format 1 bit

Bit
Octet Mot Double mot

Bit Byte Word Double Word Floating

%M

Various %MB formats


%MW %MD %MF

8 bits 16 bits

32 bits 32 bits

Flottant

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- Process interfaces variables


Syntax Digital inputs

Format
1 bit

Use
Digital sensors, limit sensors

%I

XY.i.r

Digital outputs

%Q XY.i.r %IW XY.i.r

For Contactors, relay, indicator lights 1 bit processing


16 bits
Temperature, speed, pressure, position, or current data

Analog inputs

%ID XY.i.r

32 bits

%QW XY.i.r 16 bits


Analog outputs

%QD XY.i.r

Temperature, speed, pressure, position setting commands

32 bits Topological type addressing

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- Interface variables for troubleshooting, adjusting and configuration


Syntax Digital troubleshooting inputs Internal variables %I XY.MOD.err

Format

Use

Diagnostic at the module level 1 bit Troubleshooting

%I XY.i.err
%MW XY.i.r

Adjusting Diagnostic at each 1 bit Configuration channel level


16 bits
Troubleshooting, adjusting or status determining variables

Internal constants

%KW XY.i.r

16 bits

Interface configuration

Topological type addressing

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- Interface variable addressing


Micro and Premium addressing

Example : %IW 104.0.12


Variable Rack N1 N12 on channel Location N3 0 of the interface located in slot 04 channel 1 N1 = in rack topological addressing Variable position in the channel

%IW XY.i.r

Channel number on the interface Interface position in the rack Rack address

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- Function block variables


Syntax %Tmi .P Timer function %Tmi .V %Ci .P Counter %Ci.V %Ri .I Memory block %Ri. O
Output word of memory fonction block
Current counter value

Use
Preset timer value

Predefined Current timer value or user created


Preset counter value

Input word of memory function block

Function block number

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- System variables
Syntax Access
Read only Read and write

Use
time base, status data, PLC operating mode, acts on its I/O fault, data memory backup battery status

PLC status operation

Bit

%S

Cold start, hot restart, task enabling-disabling, forcing an output fallback position execution times (average, min. and max values), the number of requests per cycle... Control time/date stamping, configuring the cycle time, saving the data memory...

Word

%SW

Read only Read and write

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- Numbering systems
Decimal ( 0 to 9)
Example %MW100 = 1547 %MW100 = 1547

man-machine interface

%MW100 = 11000001011 : temperature, pressures, %MW100 = 60B

speeds (cycle/mn)

Binary ( 0 and 1)
Example %MW100 = 11000001011 soit %MW100 = 1547 decimal
Digital variables : ON OFF True - False

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

Bytes, words or double words handling

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- Program memory
Backed up RAM REPROM

EEPROM
Program memory

Instruction 1 Instruction 2 End of program

Fueling Module Instruction 1 Instruction 2 Clearing Module Instruction 1 Instruction 2 Alarm control Module Instruction 1 Instruction 2

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- The PLC cycle


Cycle time = 20 ms
PLC initialization

RUN !!!

Reading inputs Program Instruction Instruction

Checking by watchdog function

Instruction Setting the outputs

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- PLC operating modes


STOP or RUN ???
PLC initialization

RUN, AUTO STOP, MANU

Reading inputs

Select operating mode


from front panel (key, pushbutton, dedicated input) from the program, remotely, over the network

Program Instruction Instruction

Instruction Setting the outputs

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- The machine cycle


Tank filling
STOP ON

The tank is filled by a pump. The pump starts : when low level is detected when watering ends The pump stops when full filling is reached.

Operating modes of the machine

STOP to stop watering and pumping ON to start the installation.

Watering

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

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- Cold restart, hot restart


Initialization

checking the configuration Setting the various modules

Cold restart

Tank filling

Watering
Hot restart
Fertilizer adjonction

Drying

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Introduction to Industrial Automation January 2005

The data used by the application is stored :


in RAM in REPROM in EEPROM

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Introduction to Industrial Automation January 2005

Variable %M15 is an internal variable of which type:


Bit Byte Word Double word

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Introduction to Industrial Automation January 2005

Variable %MD100 is an internal variable of which type:


Bit Byte Word Double word

Envoyer
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Introduction to Industrial Automation January 2005

%IW104.1.10 is a variable of which type:


internal system interface function block

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Introduction to Industrial Automation January 2005

Value 105A
is a decimal value is a hexadecimal value is a value that corresponds to a byte is a value that corresponds to a word

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Introduction to Industrial Automation January 2005

Value 5A
equals binary value 0101 1010 equals binary value 0101 0010 equals decimal value 80 equals decimal value 90

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Introduction to Industrial Automation January 2005

The PLC cycle time corresponds


to the program run time to the cycle time of the automated machine to the time required to read inputs, execute the program and write the outputs

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Introduction to Industrial Automation January 2005

Quiz Results
{questions} out of {total-questions} were correct Your total is {percent}%

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Introduction to Industrial Automation January 2005

APPLICATION DEVELOPMENT PHASES

Application development phases

PLC's software architecture

PLC's hardware architecture

Operating principles and implementation

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Introduction to Industrial Automation January 2005

- PLC application various sections


Declaring PLC modules entering parameter settings

Program in the different langages

Customized function blocks Structuring, naming, setting initial value of variables Application debugging Generating application files for archiving producing operating screens for monitoring the process
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- PLC station description

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- Hardware and software configuration


Hardware and software

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- Datas declaration and structure

Declaration
Adress %I1.0 Symbol NIV_High Comment High level detection

IEC Syntax

Structure

Bits
%Ix.y :Digital input (x position of the module in the rack, y position of digital input) %Qx.y : Digital output %Mx : internal Bit (x bit address) %Mx:n Table of n internal bits %MWx:Xy internal word bit (y bit position, x word adress)

Words
%MWx : Internal word (x bit address) %MWx:n Table of n words %MDx : Word of 32 bits %MDx:n Table of n words %MFx (ou %FDx) : Floating word %MFx:n Table of n words %MBx(n) : String of n characters (x : addresse of the character string) %KWx, %KDx, %KFx : Constants

process
Initialization
%MW0 to %MW50 Communication field %MW200 %MW700

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- Program structure

Filling Module Instruction 1 Instruction 2 Mixing Module Instruction 1 Instruction 2

Power break
Module 1 (LD) Module 2 (ST) Basic processing Module 10 (LD) Module 12 (ST) Events processing Module n (LD)

Watering
Module Instruction 1 Instruction 2 Module n (LD)

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- Programming languages

IEC 1131-3

Ladder Littral

FBD List

Grafcet

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- The Ladder language or Diagram language : LD

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- The structured literal programming language : ST


(* Initialization and then back to initial step *) Update current cycling indicator *) Comments %L2: THEN IF %M0 Label IF (NOT Bp_Vehicle_presence AND NOT Cycle_started) SET %M18; THEN RESET %M18; ELSE Succession END_IF;Memo_start_cycle:=TRUE; of instructions Memo_step6:=FALSE; Cycle_started:=FALSE; (* RESET application *) END_IF; IF RE %M21 OR %S13 THEN SET %S0; (* Time reading *) Comments END_IF; RRTC(Timer:4); (* initialization of variables : cold restart *) IF %S0 THEN %MF502:=30.0;%MD0:=%MD2:=%MD4:=7;%MW202:=8; Comments (* Number of objects to carry *) END_IF; TOTAL:=WORKSHOP1 + WORKSHOP2;

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- Grafcet language: SFC

Processing
Steps Transitions

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- Function blocks language : FBD

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- Instructions list language : IL

Comments

Program instructions

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- Animation tables, multiple window function

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Introduction to Industrial Automation January 2005

Choose the correct sequence:


1 . Data structuring 2 . PLC configuration 3 . Program structuring 4 . Programming 5 . Animation tables

1 . PLC configuration 2 . Program structuring 3 . Programming 4 . Data structuring 5 . Animation tables

1 . PLC configuration 2 . Data structuring 3 . Program structuring 4 . Programming 5 . Animation tables

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Animation tables let you:


structure a program structure data observe and change data in real-time

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Introduction to Industrial Automation January 2005

IF (NOT Vehicle_presence_PB AND NOT Cycle_started) THEN Memo_start_cycle:=TRUE; END_IF;


Is written in List language Is written in Ladder language Is written in Grafcetlanguage Is written in Structured language

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Introduction to Industrial Automation January 2005

Quiz Results
{questions} out of {total-questions} were correct Your total is {percent}%

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Introduction to Industrial Automation January 2005

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