EEM 451: Industrial Control Systems

Transcription

1 EEM 451: Industrial Control Systems Hakkı UIaş Ünal EEM 451-l4 p. 1/53

2 Outline Process Industry Process Control Relay PLC Programmable Logical Controller (PLC) Application Areas Features Structure of a PLC Relay Logic Programming Methods EEM 451-l4 p. 2/53

3 Process Industry EEM 451-l4 p. 3/53

4 Process Control Manual Control ON-OFF, PI, PID controller Direct Digital Controller (DDC) PLC, DCS EEM 451-l4 p. 4/53

5 Relays Gemlog Controls Ltd. Rated Cur. :5/10 A Rated Vol.:10/20 V DC Bosch Rated Cur. : 10/20A DC Y.GAD Tech. Elec.Co., Ltd. Max. Switch Cur. : 7A Rated Vol.:12 V DC Max. Switch Vol.: 250 V AC/ 30 V DC Rapid Electronics. Nom.Vol. :5/12VDC Nom. Power.:50/144VDC Rapid Electronics. Max Vol. :240VAC/110VDC Cont.Rate.:10A,120VAC/24VDC R.V.A.F. Co.Ltd. Rated Vol: 12V Rated Cur.: 30A EEM 451-l4 p. 5/53

6 Inside of a Relay EEM 451-l4 p. 6/53

7 Working Principle of a Relay EEM 451-l4 p. 7/53

8 EEM 451-l4 p. 8/53

9 Small Demonstration on a Bosch Relay: Step 1 EEM 451-l4 p. 9/53

10 Small Demonstration on a Bosch Relay: Step 2 EEM 451-l4 p. 10/53

11 Small Demonstration on a Bosch Relay: Step 3 EEM 451-l4 p. 11/53

12 Working Principle of a Relay EEM 451-l4 p. 12/53

13 Working Principle of a Relay EEM 451-l4 p. 13/53

14 PLCs EEM 451-l4 p. 14/53

15 Features Flexibility Surviving and Being Maintained in harsh industrial Conditions Low-Cost Systems Interfacing with existing sensors and equipments Communicating property with same PLCs EEM 451-l4 p. 15/53

16 Connection of A PLC EEM 451-l4 p. 16/53

17 Structure of A PLC EEM 451-l4 p. 17/53

18 INPUT INTERFACE CPU MEMORY UNIT ¹ OUTPUT INTERFACE EEM 451-l4 p. 18/53

19 Relay Logic EEM 451-l4 p. 19/53

20 Jack, H., Automating Manufacturing Systems with PLCs EEM 451-l4 p. 20/53

21 Programming PLC : Programming Methods Sequential Function Charts (SFC) Instruction Method Ladder Diagram EEM 451-l4 p. 21/53

22 Sequential Function Charts (SFC) Basic Elements in Sequential Function Charts step action Wait Instruction Initial Step Step Macro Step Selection Branch (OR) Simultaneous Branch (AND) EEM 451-l4 p. 22/53

23 A Simple Design in SFC Bottle damage check Start Bottle is Damaged 2 Remove the Bottle Bottle is undamaged 1 Fill the Bottle Weigh the bottle 3 Label The Bottle Count the of bottles of bottles are 10 of bottles are < 10 4 Put the filled bottled to the bottle box 5 Take the bottle box which contains 10 bottles to the transportation vehicle EEM 451-l4 p. 23/53

24 Instruction (Mnemonic) Programming Basic Commands in Instruction Programming LD LDI AND ANI OR ORI OUT ANB ORB END Load the input Load the inverse of the input AND the input with the previous ones AND the inverse of the input with the previous ones OR the input with the previous ones OR the inverse of the input with the previous one Output AND the input block with the previous ones OR the input block with the previous ones END the program EEM 451-l4 p. 24/53

25 A Simple Design in Mnemonic Method 0 LD X0 Open the Machine 1 LD X1 Program 1 2 OR X2 Program 2 3 OUT Y0 Red Light 4 LD Y0 Red Light 5 LD X0 Open the Machine 6 AND X1 Program 1 7 ANI X2 Program 2 8 OUT Y1 Green Light 9 END EEM 451-l4 p. 25/53

26 Ladder Diagram Basic Elements in Ladder Diagram LD LDI AN D AN I ORI OR OUT Ñ EEM 451-l4 p. 26/53

27 A Simple Design in Ladder Diagrams X 0 X 1 X 2 (Y 0) Y 0 X 0 X 1 X 2 (Y 1) [END] EEM 451-l4 p. 27/53

28 Corresponding in the Relay Wiring EEM 451-l4 p. 28/53

29 Boolean Algebra Status HIGH (OR ON) LOW (OR OFF) 1 0 AND Operation A B OR Operation A+B Exclusive OR Operation A B=Ā B+A B NOT Operation Ā A B AND OR XOR NOT A NOT B EEM 451-l4 p. 29/53

30 A B Z ( ) AND Operation A Z ( ) B OR Operation EEM 451-l4 p. 30/53

31 A Z ( ) NOT Operation A B Z ( ) A B XOR Operation EEM 451-l4 p. 31/53

32 Ladder to Boolean EEM 451-l4 p. 32/53

33 A+B +C EEM 451-l4 p. 33/53

34 D +Ē EEM 451-l4 p. 34/53

35 Z = (A+B +C) ( D +Ē) F Ḡ EEM 451-l4 p. 35/53

36 Boolean To Ladder Z = (A+B C) D+Ē F EEM 451-l4 p. 36/53

37 Ê... Z = (A + B C) D + Ē F Z = (A + B C) D + Ē F A + (B C) EEM 451-l4 p. 37/53

38 Ê... Z = (A + B C) D + Ē F +Ē F EEM 451-l4 p. 38/53

39 Ê... Z = (A + B C) D + Ē F + EEM 451-l4 p. 39/53

40 Z = (A+C B) D+Ē F EEM 451-l4 p. 40/53

41 Reference Letters in Ladder Diagram Bit Devices Description X: All Direct Physical Inputs to the PLC Y : All Direct Physical Outputs from the PLC T: Timing Device which is contained within the PLC C: Counting Device which is contained within the PLC M: Used as an internal operation flags within the PLC S: Used as an internal operation flags within the PLC EEM 451-l4 p. 41/53

42 Programming... LD (Load ): Initially (NO) contact operation with devices : X,Y,M,S,T,C LDI (Load Inverse): Initially (NC) contact operation with devices : X,Y,M,S,T,C OUT (Output): Finally operation type coil drive with devices : Y,M,S,T,C EEM 451-l4 p. 42/53

43 Programming... AND (AND): Serial Connection of (NO) contact with devices : X,Y,M,S,T,C ANI (AND Inverse): Serial Connection of (NC) contact with devices : X,Y,M,S,T,C OR (OR): Paralel Connection of (NO) contact with devices : X,Y,M,S,T,C ORI (OR Inverse): Parallel Connection of (NC) contact with devices : X,Y,M,S,T,C EEM 451-l4 p. 43/53

44 Some Remarks in Programming... X 1 Y 1 Y 1 Y 2 X 2 Y 1 Input Sequence Output Sequence X 1 (ON),X 2 (OFF) Y 1 (ON),Y 2 (ON),Y 1 (OFF) EEM 451-l4 p. 44/53

45 X 1 Y 1 Y 1 Input Sequence Output Sequence X 1 (ON),X 1 (OFF) Y 1 (ON),Y 1 (ON) EEM 451-l4 p. 45/53

46 Usage of Timers and Counters in Programming as an Output Tnn Kmm Cnn Khh Symbol nn Kmm Description Identification number Duration time for activating the timer coil Khh Required pulses for activating the counter coil (Tnn K10) = 1sec for 0 nn 32 (Tnn K10) = 0.1sec for 32 < nn < 56 EEM 451-l4 p. 46/53

47 X7 T1 K500 T1 Y X7 input Y0 output Time in seconds Time in seconds EEM 451-l4 p. 47/53

48 X7 C0 K5 C0 Y X7 input Y0 output Time in seconds Time in seconds EEM 451-l4 p. 48/53

49 Internal Flags M nn M nn Symbol Description nn Identification number EEM 451-l4 p. 49/53

50 Basic Operations in Ladder Diagram X0 LOAD Y X0 input Y0 output Time in seconds Time in seconds EEM 451-l4 p. 50/53

51 X1 Inverse LOAD Y X1 input Y1 output Time in seconds Time in seconds EEM 451-l4 p. 51/53

52 X2 X3 AND Y X2 input X3 input Time in seconds Time in seconds 1 Y2 output Time in seconds EEM 451-l4 p. 52/53

53 X2 X3 OR Y X2 input X3 input Time in seconds Time in seconds 1 Y3 output Time in seconds EEM 451-l4 p. 53/53