Automating Manufacturing Systems with PLCs

✍ Scribed by Hugh Jack

• Year: 2008
• Tongue: English
• Leaves: 860
• Series: Version 5.1
• Category: Library

✦ Table of Contents

1. PROGRAMMABLE LOGIC CONTROLLERS 2.1
2. PLC HARDWARE 3.1
3. LOGICAL SENSORS 4.1
4. LOGICAL ACTUATORS 5.1
5. BOOLEAN LOGIC DESIGN 6.1
6. KARNAUGH MAPS 7.1
7. PLC OPERATION 8.1
8. LATCHES, TIMERS, COUNTERS AND MORE 9.1
9. STRUCTURED LOGIC DESIGN 10.1
10. FLOWCHART BASED DESIGN 11.1
11. STATE BASED DESIGN 12.1
12. NUMBERS AND DATA 13.1
13. PLC MEMORY 14.1
14. LADDER LOGIC FUNCTIONS 15.1
15. ADVANCED LADDER LOGIC FUNCTIONS 16.1
16. OPEN CONTROLLERS 17.1
17. INSTRUCTION LIST PROGRAMMING 18.1
18. STRUCTURED TEXT PROGRAMMING 19.1
19. SEQUENTIAL FUNCTION CHARTS 20.1
20. FUNCTION BLOCK PROGRAMMING 21.1
21. ANALOG INPUTS AND OUTPUTS 22.1
22. CONTINUOUS SENSORS 23.1
23. CONTINUOUS ACTUATORS 24.1
24. CONTINUOUS CONTROL 25.1
25. FUZZY LOGIC 26.1
26. SERIAL COMMUNICATION 27.1
27. NETWORKING 28.1
28. INTERNET 29.1
29. HUMAN MACHINE INTERFACES (HMI) 30.1
30. ELECTRICAL DESIGN AND CONSTRUCTION 31.1
31. SOFTWARE ENGINEERING 32.1
32. SELECTING A PLC 33.1
33. FUNCTION REFERENCE 34.1
34. COMBINED GLOSSARY OF TERMS 35.1
35. PLC REFERENCES 36.1
36. GNU Free Documentation License 37.1
    1.1 TODO LIST
37. PROGRAMMABLE LOGIC CONTROLLERS
    2.1 INTRODUCTION
    2.1.1 Ladder Logic
    2.1.2 Programming
    2.1.3 PLC Connections
    2.1.4 Ladder Logic Inputs
    2.1.5 Ladder Logic Outputs
    2.2 A CASE STUDY
    2.3 SUMMARY
    2.4 PRACTICE PROBLEMS
    2.5 PRACTICE PROBLEM SOLUTIONS
    2.6 ASSIGNMENT PROBLEMS
38. PLC HARDWARE
    3.1 INTRODUCTION
    3.2 INPUTS AND OUTPUTS
    3.2.1 Inputs
    3.2.2 Output Modules
    3.3 RELAYS
    3.4 A CASE STUDY
    3.5 ELECTRICAL WIRING DIAGRAMS
    3.5.1 JIC Wiring Symbols
    3.6 SUMMARY
    3.7 PRACTICE PROBLEMS
    3.8 PRACTICE PROBLEM SOLUTIONS
    3.9 ASSIGNMENT PROBLEMS
39. LOGICAL SENSORS
    4.1 INTRODUCTION
    4.2 SENSOR WIRING
    4.2.1 Switches
    4.2.2 Transistor Transistor Logic (TTL)
    4.2.3 Sinking/Sourcing
    4.2.4 Solid State Relays
    4.3 PRESENCE DETECTION
    4.3.1 Contact Switches
    4.3.2 Reed Switches
    4.3.3 Optical (Photoelectric) Sensors
    4.3.4 Capacitive Sensors
    4.3.5 Inductive Sensors
    4.3.6 Ultrasonic
    4.3.7 Hall Effect
    4.3.8 Fluid Flow
    4.4 SUMMARY
    4.5 PRACTICE PROBLEMS
    4.6 PRACTICE PROBLEM SOLUTIONS
    4.7 ASSIGNMENT PROBLEMS
40. LOGICAL ACTUATORS
    5.1 INTRODUCTION
    5.2 SOLENOIDS
    5.3 VALVES
    5.4 CYLINDERS
    5.5 HYDRAULICS
    5.6 PNEUMATICS
    5.7 MOTORS
    5.8 OTHERS
    5.9 SUMMARY
    5.10 PRACTICE PROBLEMS
    5.11 PRACTICE PROBLEM SOLUTIONS
    5.12 ASSIGNMENT PROBLEMS
41. BOOLEAN LOGIC DESIGN
    6.1 INTRODUCTION
    6.2 BOOLEAN ALGEBRA
    6.3 LOGIC DESIGN
    6.3.1 Boolean Algebra Techniques
    6.4 COMMON LOGIC FORMS
    6.4.1 Complex Gate Forms
    6.4.2 Multiplexers
    6.5 SIMPLE DESIGN CASES
    6.5.1 Basic Logic Functions
    6.5.2 Car Safety System
    6.5.3 Motor Forward/Reverse
    6.5.4 A Burglar Alarm
    6.6 SUMMARY
    6.7 PRACTICE PROBLEMS
    6.8 PRACTICE PROBLEM SOLUTIONS
    6.9 ASSIGNMENT PROBLEMS
42. KARNAUGH MAPS
    7.1 INTRODUCTION
    7.2 SUMMARY
    7.3 PRACTICE PROBLEMS
    7.4 PRACTICE PROBLEM SOLUTIONS
    7.5 ASSIGNMENT PROBLEMS
43. PLC OPERATION
    8.1 INTRODUCTION
    8.2 OPERATION SEQUENCE
    8.2.1 The Input and Output Scans
    8.2.2 The Logic Scan
    8.3 PLC STATUS
    8.4 MEMORY TYPES
    8.5 SOFTWARE BASED PLCS
    8.6 SUMMARY
    8.7 PRACTICE PROBLEMS
    8.8 PRACTICE PROBLEM SOLUTIONS
    8.9 ASSIGNMENT PROBLEMS
44. LATCHES, TIMERS, COUNTERS AND MORE
    9.1 INTRODUCTION
    9.2 LATCHES
    9.3 TIMERS
    9.4 COUNTERS
    9.5 MASTER CONTROL RELAYS (MCRs)
    9.6 INTERNAL BITS
    9.7 DESIGN CASES
    9.7.1 Basic Counters And Timers
    9.7.2 More Timers And Counters
    9.7.3 Deadman Switch
    9.7.4 Conveyor
    9.7.5 Accept/Reject Sorting
    9.7.6 Shear Press
    9.8 SUMMARY
    9.9 PRACTICE PROBLEMS
    9.10 PRACTICE PROBLEM SOLUTIONS
    9.11 ASSIGNMENT PROBLEMS
45. STRUCTURED LOGIC DESIGN
    10.1 INTRODUCTION
    10.2 PROCESS SEQUENCE BITS
    10.3 TIMING DIAGRAMS
    10.4 DESIGN CASES
    10.5 SUMMARY
    10.6 PRACTICE PROBLEMS
    10.7 PRACTICE PROBLEM SOLUTIONS
    10.8 ASSIGNMENT PROBLEMS
46. FLOWCHART BASED DESIGN
    11.1 INTRODUCTION
    11.2 BLOCK LOGIC
    11.3 SEQUENCE BITS
    11.4 SUMMARY
    11.5 PRACTICE PROBLEMS
    11.6 PRACTICE PROBLEM SOLUTIONS
    11.7 ASSIGNMENT PROBLEMS
47. STATE BASED DESIGN
    12.1 INTRODUCTION
    12.1.1 State Diagram Example
    12.1.2 Conversion to Ladder Logic
    12.1.2.1 - Block Logic Conversion
    12.1.2.2 - State Equations
    12.1.2.3 - State-Transition Equations
    12.2 SUMMARY
    12.3 PRACTICE PROBLEMS
    12.4 PRACTICE PROBLEM SOLUTIONS
    12.5 ASSIGNMENT PROBLEMS
48. NUMBERS AND DATA
    13.1 INTRODUCTION
    13.2 NUMERICAL VALUES
    13.2.1 Binary
    13.2.1.1 - Boolean Operations
    13.2.1.2 - Binary Mathematics
    13.2.2 Other Base Number Systems
    13.2.3 BCD (Binary Coded Decimal)
    13.3 DATA CHARACTERIZATION
    13.3.1 ASCII (American Standard Code for Information Interchange)
    13.3.2 Parity
    13.3.3 Checksums
    13.3.4 Gray Code
    13.4 SUMMARY
    13.5 PRACTICE PROBLEMS
    13.6 PRACTICE PROBLEM SOLUTIONS
    13.7 ASSIGNMENT PROBLEMS
49. PLC MEMORY
    14.1 INTRODUCTION
    14.2 PROGRAM VS VARIABLE MEMORY
    14.3 PROGRAMS
    14.4 VARIABLES (TAGS)
    14.4.1 Timer and Counter Memory
    14.4.2 PLC Status Bits
    14.4.3 User Function Control Memory
    14.5 SUMMARY
    14.6 PRACTICE PROBLEMS
    14.7 PRACTICE PROBLEM SOLUTIONS
    14.8 ASSIGNMENT PROBLEMS
50. LADDER LOGIC FUNCTIONS
    15.1 INTRODUCTION
    15.2 DATA HANDLING
    15.2.1 Move Functions
    15.2.2 Mathematical Functions
    15.2.3 Conversions
    15.2.4 Array Data Functions
    15.2.4.1 - Statistics
    15.2.4.2 - Block Operations
    15.3 LOGICAL FUNCTIONS
    15.3.1 Comparison of Values
    15.3.2 Boolean Functions
    15.4 DESIGN CASES
    15.4.1 Simple Calculation
    15.4.2 For-Next
    15.4.3 Series Calculation
    15.4.4 Flashing Lights
    15.5 SUMMARY
    15.6 PRACTICE PROBLEMS
    15.7 PRACTICE PROBLEM SOLUTIONS
    15.8 ASSIGNMENT PROBLEMS
51. ADVANCED LADDER LOGIC FUNCTIONS
    16.1 INTRODUCTION
    16.2 LIST FUNCTIONS
    16.2.1 Shift Registers
    16.2.2 Stacks
    16.2.3 Sequencers
    16.3 PROGRAM CONTROL
    16.3.1 Branching and Looping
    16.3.2 Fault Handling
    16.3.3 Interrupts
    16.4 INPUT AND OUTPUT FUNCTIONS
    16.4.1 Immediate I/O Instructions
    16.5 DESIGN TECHNIQUES
    16.5.1 State Diagrams
    16.6 DESIGN CASES
    16.6.1 If-Then
    16.6.2 Traffic Light
    16.7 SUMMARY
    16.8 PRACTICE PROBLEMS
    16.9 PRACTICE PROBLEM SOLUTIONS
    16.10 ASSIGNMENT PROBLEMS
52. OPEN CONTROLLERS
    17.1 INTRODUCTION
    17.2 IEC 61131
    17.3 OPEN ARCHITECTURE CONTROLLERS
    17.4 SUMMARY
    17.5 PRACTICE PROBLEMS
    17.6 PRACTICE PROBLEM SOLUTIONS
    17.7 ASSIGNMENT PROBLEMS
53. INSTRUCTION LIST PROGRAMMING
    18.1 INTRODUCTION
    18.2 THE IEC 61131 VERSION
    18.3 THE ALLEN-BRADLEY VERSION
    18.4 SUMMARY
    18.5 PRACTICE PROBLEMS
    18.6 PRACTICE PROBLEM SOLUTIONS
    18.7 ASSIGNMENT PROBLEMS
54. STRUCTURED TEXT PROGRAMMING
    19.1 INTRODUCTION
    19.2 THE LANGUAGE
    19.2.1 Elements of the Language
    19.2.2 Putting Things Together in a Program
    19.3 AN EXAMPLE
    19.4 SUMMARY
    19.5 PRACTICE PROBLEMS
    19.6 PRACTICE PROBLEM SOLUTIONS
    19.7 ASSIGNMENT PROBLEMS
55. SEQUENTIAL FUNCTION CHARTS
    20.1 INTRODUCTION
    20.2 A COMPARISON OF METHODS
    20.3 SUMMARY
    20.4 PRACTICE PROBLEMS
    20.5 PRACTICE PROBLEM SOLUTIONS
    20.6 ASSIGNMENT PROBLEMS
56. FUNCTION BLOCK PROGRAMMING
    21.1 INTRODUCTION
    21.2 CREATING FUNCTION BLOCKS
    21.3 DESIGN CASE
    21.4 SUMMARY
    21.5 PRACTICE PROBLEMS
    21.6 PRACTICE PROBLEM SOLUTIONS
    21.7 ASSIGNMENT PROBLEMS
57. ANALOG INPUTS AND OUTPUTS
    22.1 INTRODUCTION
    22.2 ANALOG INPUTS
    22.3 ANALOG OUTPUTS
    22.4 ANALOG INPUTS AND OUTPUTS WITH CONTROLLOGIX
    22.4.1 ANALOG INPUTS AND OUTPUTS WITH A PLC-5
    22.4.2 Pulse Width Modulation (PWM) Outputs
    22.4.3 Shielding
    22.5 DESIGN CASES
    22.5.1 Process Monitor
    22.6 SUMMARY
    22.7 PRACTICE PROBLEMS
    22.8 PRACTICE PROBLEM SOLUTIONS
    22.9 ASSIGNMENT PROBLEMS
58. CONTINUOUS SENSORS
    14.1 INTRODUCTION
    14.2 INDUSTRIAL SENSORS
    14.2.1 Angular Displacement
    14.2.1.1 - Potentiometers
    14.2.2 Encoders
    14.2.2.1 - Tachometers
    14.2.3 Linear Position
    14.2.3.1 - Potentiometers
    14.2.3.2 - Linear Variable Differential Transformers (LVDT)
    14.2.3.3 - Moire Fringes
    14.2.3.4 - Accelerometers
    14.2.4 Forces and Moments
    14.2.4.1 - Strain Gages
    14.2.4.2 - Piezoelectric
    14.2.5 Liquids and Gases
    14.2.5.1 - Pressure
    14.2.5.2 - Venturi Valves
    14.2.5.3 - Coriolis Flow Meter
    14.2.5.4 - Magnetic Flow Meter
    14.2.5.5 - Ultrasonic Flow Meter
    14.2.5.6 - Vortex Flow Meter
    14.2.5.7 - Positive Displacement Meters
    14.2.5.8 - Pitot Tubes
    14.2.6 Temperature
    14.2.6.1 - Resistive Temperature Detectors (RTDs)
    14.2.6.2 - Thermocouples
    14.2.6.3 - Thermistors
    14.2.6.4 - Other Sensors
    14.2.7 Light
    14.2.7.1 - Light Dependant Resistors (LDR)
    14.2.8 Chemical
    14.2.8.1 - pH
    14.2.8.2 - Conductivity
    14.2.9 Others
    14.3 INPUT ISSUES
    14.4 SENSOR GLOSSARY
    14.5 SUMMARY
    14.6 REFERENCES
    14.7 PRACTICE PROBLEMS
    14.8 PRACTICE PROBLEM SOLUTIONS
    14.9 ASSIGNMENT PROBLEMS
59. CONTINUOUS ACTUATORS
    15.1 INTRODUCTION
    15.2 ELECTRIC MOTORS
    15.2.1 Basic Brushed DC Motors
    15.2.2 AC Motors
    15.2.3 Brushless DC Motors
    15.2.4 Stepper Motors
    15.2.5 Wound Field Motors
    15.3 HYDRAULICS
    15.4 OTHER SYSTEMS
    15.5 SUMMARY
    15.6 PRACTICE PROBLEMS
    15.7 PRACTICE PROBLEM SOLUTIONS
    15.8 ASSIGNMENT PROBLEMS
60. CONTINUOUS CONTROL
    25.1 INTRODUCTION
    25.2 CONTROL OF LOGICAL ACTUATOR SYSTEMS
    25.3 CONTROL OF CONTINUOUS ACTUATOR SYSTEMS
    25.3.1 Block Diagrams
    25.3.2 Feedback Control Systems
    25.3.3 Proportional Controllers
    25.3.4 PID Control Systems
    25.4 DESIGN CASES
    25.4.1 Oven Temperature Control
    25.4.2 Water Tank Level Control
    25.4.3 Position Measurement
    25.5 SUMMARY
    25.6 PRACTICE PROBLEMS
    25.7 PRACTICE PROBLEM SOLUTIONS
    25.8 ASSIGNMENT PROBLEMS
61. FUZZY LOGIC
    26.1 INTRODUCTION
    26.2 COMMERCIAL CONTROLLERS
    26.3 REFERENCES
    26.4 SUMMARY
    26.5 PRACTICE PROBLEMS
    26.6 PRACTICE PROBLEM SOLUTIONS
    26.7 ASSIGNMENT PROBLEMS
62. SERIAL COMMUNICATION
    27.1 INTRODUCTION
    27.2 SERIAL COMMUNICATIONS
    27.2.1 RS-232
    27.2.2 ASCII Functions
    27.3 PARALLEL COMMUNICATIONS
    27.4 DESIGN CASES
    27.4.1 PLC Interface To a Robot
    27.5 SUMMARY
    27.6 PRACTICE PROBLEMS
    27.7 PRACTICE PROBLEM SOLUTIONS
    27.8 ASSIGNMENT PROBLEMS
63. NETWORKING
    28.1 INTRODUCTION
    28.1.1 Topology
    28.1.2 OSI Network Model
    28.1.3 Networking Hardware
    28.1.4 Control Network Issues
    28.2 NETWORK STANDARDS
    28.2.1 Devicenet
    28.2.2 CANbus
    28.2.3 Controlnet
    28.2.4 Ethernet
    28.2.5 Profibus
    28.2.6 Sercos
    28.3 PROPRIETARY NETWORKS
    28.3.1 Data Highway
    28.4 NETWORK COMPARISONS
    28.5 DESIGN CASES
    28.5.1 Devicenet
    28.6 SUMMARY
    28.7 PRACTICE PROBLEMS
    28.8 PRACTICE PROBLEM SOLUTIONS
    28.9 ASSIGNMENT PROBLEMS
64. INTERNET
    29.1 INTRODUCTION
    29.1.1 Computer Addresses
    29.1.1.1 - IPV6
    29.1.2 Phone Lines
    29.1.3 Mail Transfer Protocols
    29.1.4 FTP - File Transfer Protocol
    29.1.5 HTTP - Hypertext Transfer Protocol
    29.1.6 Novell
    29.1.7 Security
    29.1.7.1 - Firewall
    29.1.7.2 - IP Masquerading
    29.1.8 HTML - Hyper Text Markup Language
    29.1.9 URLs
    29.1.10 Encryption
    29.1.11 Compression
    29.1.12 Clients and Servers
    29.1.13 Java
    29.1.14 Javascript
    29.1.15 CGI
    29.1.16 ActiveX
    29.1.17 Graphics
    29.2 DESIGN CASES
    29.2.1 Remote Monitoring System
    29.3 SUMMARY
    29.4 PRACTICE PROBLEMS
    29.5 PRACTICE PROBLEM SOLUTIONS
    29.6 ASSIGNMENT PROBLEMS
65. HUMAN MACHINE INTERFACES (HMI)
    30.1 INTRODUCTION
    30.2 HMI/MMI DESIGN
    30.3 DESIGN CASES
    30.4 SUMMARY
    30.5 PRACTICE PROBLEMS
    30.6 PRACTICE PROBLEM SOLUTIONS
    30.7 ASSIGNMENT PROBLEMS
66. ELECTRICAL DESIGN AND CONSTRUCTION
    31.1 INTRODUCTION
    31.2 ELECTRICAL WIRING DIAGRAMS
    31.2.1 Selecting Voltages
    31.2.2 Grounding
    31.2.3 Wiring
    31.2.4 Suppressors
    31.2.5 PLC Enclosures
    31.2.6 Wire and Cable Grouping
    31.3 FAIL-SAFE DESIGN
    31.4 SAFETY RULES SUMMARY
    31.5 REFERENCES
    31.6 SUMMARY
    31.7 PRACTICE PROBLEMS
    31.8 PRACTICE PROBLEM SOLUTIONS
    31.9 ASSIGNMENT PROBLEMS
67. SOFTWARE ENGINEERING
    32.1 INTRODUCTION
    32.1.1 Fail Safe Design
    32.2 DEBUGGING
    32.2.1 Troubleshooting
    32.2.2 Forcing
    32.3 PROCESS MODELLING
    32.4 PROGRAMMING FOR LARGE SYSTEMS
    32.4.1 Developing a Program Structure
    32.4.2 Program Verification and Simulation
    32.5 DOCUMENTATION
    32.6 COMMISIONING
    32.7 SAFETY
    32.7.1 IEC 61508/61511 safety standards
    32.8 LEAN MANUFACTURING
    32.9 REFERENCES
    32.10 SUMMARY
    32.11 PRACTICE PROBLEMS
    32.12 PRACTICE PROBLEM SOLUTIONS
    32.13 ASSIGNMENT PROBLEMS
68. SELECTING A PLC
    33.1 INTRODUCTION
    33.2 SPECIAL I/O MODULES
    33.3 SUMMARY
    33.4 PRACTICE PROBLEMS
    33.5 PRACTICE PROBLEM SOLUTIONS
    33.6 ASSIGNMENT PROBLEMS
69. FUNCTION REFERENCE
    34.1 FUNCTION DESCRIPTIONS
    34.1.1 General Functions
    34.1.2 Program Control
    34.1.3 Timers and Counters
    34.1.4 Compare
    34.1.5 Calculation and Conversion
    34.1.6 Logical
    34.1.7 Move
    34.1.8 File
    34.1.9 List
    34.1.10 Program Control
    34.1.11 Advanced Input/Output
    34.1.12 String
    34.2 DATA TYPES
70. COMBINED GLOSSARY OF TERMS
    35.1 A
    35.2 B
    35.3 C
    35.4 D
    35.5 E
    35.6 F
    35.7 G
    35.8 H
    35.9 I
    35.10 J
    35.11 K
    35.12 L
    35.13 M
    35.14 N
    35.15 O
    35.16 P
    35.17 Q
    35.18 R
    35.19 S
    35.20 T
    35.21 U
    35.22 V
    35.23 W
    35.24 X
    35.25 Y
    35.26 Z
71. PLC REFERENCES
    36.1 SUPPLIERS
    36.2 PROFESSIONAL INTEREST GROUPS
    36.3 PLC/DISCRETE CONTROL REFERENCES
72. GNU Free Documentation License
    37.1 PREAMBLE
    37.2 APPLICABILITY AND DEFINITIONS
    37.3 VERBATIM COPYING
    37.4 COPYING IN QUANTITY
    37.5 MODIFICATIONS
    37.6 COMBINING DOCUMENTS
    37.7 COLLECTIONS OF DOCUMENTS
    37.8 AGGREGATION WITH INDEPENDENT WORKS
    37.9 TRANSLATION
    37.10 TERMINATION
    37.11 FUTURE REVISIONS OF THIS LICENSE
    37.12 How to use this License for your documents