- •24.3 HYDRAULICS
- •24.4 OTHER SYSTEMS
- •24.5 SUMMARY
- •24.6 PRACTICE PROBLEMS
- •24.7 PRACTICE PROBLEM SOLUTIONS
- •24.8 ASSIGNMENT PROBLEMS
- •25. 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
- •25.5 SUMMARY
- •25.6 PRACTICE PROBLEMS
- •25.7 PRACTICE PROBLEM SOLUTIONS
- •25.8 ASSIGNMENT PROBLEMS
- •26. 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
- •27. SERIAL COMMUNICATION
- •27.1 INTRODUCTION
- •27.2 SERIAL COMMUNICATIONS
- •27.2.1.1 - 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
- •28. 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
- •29. INTERNET
- •29.1 INTRODUCTION
- •29.1.1 Computer Addresses
- •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
- •29.1.16 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
- •30. 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
- •31. 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
- •32. 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 REFERENCES
- •32.8 SUMMARY
- •32.9 PRACTICE PROBLEMS
- •32.10 PRACTICE PROBLEM SOLUTIONS
- •32.11 ASSIGNMENT PROBLEMS
- •33. 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
- •34. 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
- •34.1.10 Program Control
- •34.1.11 Advanced Input/Output
- •34.1.12 String
- •34.2 DATA TYPES
plc network - 28.8
machine in charge of sending and receiving. This can be restrictive if multiple controllers are to exist on the same network. The CSMA/CD and CSMA/BA methods will both allow nodes to talk when needed. But, as the number of collisions increase the network performance degrades quickly.
28.2 NETWORK STANDARDS
Bus types are listed below.
Low level busses - these are low level protocols that other networks are built upon. RS-485, Bitbus, CAN bus, Lonworks, Arcnet
General open buses - these are complete network types with fully published standards.
ASI, Devicenet, Interbus-S, Profibus, Smart Distributed System (SDS), Seriplex
Specialty buses - these are buses that are proprietary. Genius I/O, Sensoplex
28.2.1 Devicenet
Devicenet has become one of the most widely supported control networks. It is an open standard, so components from a variety of manufacturers can be used together in the same control system. It is supported and promoted by the Open Devicenet Vendors Association (ODVA) (see http://www.odva.org). This group includes members from all of the major controls manufacturers.
This network has been designed to be noise resistant and robust. One major change for the control engineer is that the PLC chassis can be eliminated and the network can be connected directly to the sensors and actuators. This will reduce the total amount of wiring by moving I/O points closer to the application point. This can also simplify the connection of complex devices, such as HMIs. Two way communications inputs and outputs allow diagnosis of network problems from the main controller.
Devicenet covers all seven layers of the OSI standard. The protocol has a limited number of network address, with very small data packets. But this also helps limit network traffic and ensure responsiveness. The length of the network cables will limit the maximum speed of the network. The basic features of are listed below.
•A single bus cable that delivers data and power.
•Up to 64 nodes on the network.
plc network - 28.9
•Data packet size of 0-8 bytes.
•Lengths of 500m/250m/100m for speeds of 125kbps/250kbps/500kbps respectively.
•Devices can be added/removed while power is on.
•Based on the CANbus (Controller Area Network) protocol for OSI levels 1 and 2.
•Addressing includes peer-to-peer, multicast, master/slave, polling or change of state.
An example of a Devicenet network is shown in Figure 28.6. The dark black lines are the network cable. Terminators are required at the ends of the network cable to reduce electrical noise. In this case the PC would probably be running some sort of software based PLC program. The computer would have a card that can communicate with Devicenet devices. The FlexIO rack is a miniature rack that can hold various types of input and output modules. Power taps (or tees) split the signal to small side branches. In this case one of the taps connects a power supply, to provide the 24Vdc supply to the network. Another two taps are used to connect a smart sensor and another FlexIO rack. The Smart sensor uses power from the network, and contains enough logic so that it is one node on the network. The network uses thin trunk line and thick trunk line which may limit network performance.
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Figure 28.6 A Devicenet Network
The network cable is important for delivering power and data. Figure 28.7 shows a basic cable with two wires for data and two wires for the power. The cable is also shielded to reduce the effects of electrical noise. The two basic types are thick and thin trunk line. The cables may come with a variety of connections to devices.
plc network - 28.10
•bare wires
•unsealed screw connector
•sealed mini connector
•sealed micro connector
•vampire taps
power (24Vdc)
data
drain/shield
Thick trunk - carries up to 8A for power up to 500m
Thin trunk - up to 3A for power up to 100m
Figure 28.7 Shielded Network Cable
Some of the design issues for this network include;
•Power supplies are directly connected to the network power lines.
•Length to speed is 156m/78m/39m to 125Kbps/250Kbps/500Kbps respectively.
•A single drop is limited to 6m.
•Each node on the network will have its own address between 0 and 63.
If a PLC-5 was to be connected to Devicenet a scanner card would need to be placed in the rack. The ladder logic in Figure 28.8 would communicate with the sensors through a scanner card in slot 3. The read and write blocks would read and write the Devicenet input values to integer memory from N7:40 to N7:59. The outputs would be copied from the integer memory between N7:20 to N7:39. The ladder logic to process inputs and outputs would need to examine and set bits in integer memory.
plc network - 28.11
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Note: Get exact settings for these parametersXXXXXXXXXXXXXXXXX
Figure 28.8 Communicating with Devicenet Inputs and Outputs
On an Allen Bradley Softlogix PLC the I/O will be copied into blocks of integer memory. These blocks are selected by the user in setup software. The ladder logic would then using integer memory for inputs and outputs, as shown in Figure 28.9. Here the inputs are copied into N9 integer memory, and the outputs are set by copying the N10 block of memory back to the outputs.