Whole Number 190

Integrated Controller “MICREX-SX”

MICREX-SX Series

The integrated controller MICREX-SX series realizes program compatibility, common use of data, and a unified operation environment.● Scalable multi-controller SPH (hardware PLC)Realizes a 1-ms control by load distribution with multi-CPU structure and high-speed processing with execution time of 20ns per instruction. This controller realizes the optimum system construction in every case of control and is the next generation controller far beyond the concept of existing programmable controllers.● Software logic SPS (software PLC)Uses IEC standard language common to the SPH. Can connect to the SX bus and various I/O-level networks.● Programmable operation display SUG/software human-machine interface

SUS (hardware POD/software POD)The two lines of exclusive-use hardware SUG and personal computer-use human-machine interface SUS are available. Graphic Display data is compatible between both types.● Integrated support system SESSupports the controller and the human-machine interface in the unified operation environment.

meets Open Systems and unifies Control, Operation, and Monitoring.

Fuji Electric’s Integrated Controller

Integrated Controller

MICREX-SX Series

Scalable multi-controller SPH (hardware PLC)

Integrated support system SES

Programmable operation display SUG

(hardware POD)

Program compatibility

Program compatibility

Controller Human-machine interface (HMI)

Data compatibility

Software logic SPS (software PLC)

I/O-level networks

Panel computer

Software human-machine interface SUS (software POD)

A programming display by the human-machine interface

A programming display by the scalable multi-controller

CONTENTS

Cover Photo:At present, in the production

activity of the enterprise, globaliza-tion, total cost-down, total efficiencyup for diversified and small-quan-tity production, etc. are urgentlyneeded. Therefore, the productionsystem has strongly asked for opensystem, standardization, flexibility,and linking to information technol-ogy (IT).

Fuji Electric’s integrated con-troller “MICREX-SX” series is a con-troller aiming the opened, distrib-uted and objective system, and cangreatly contribute to innovation ofthe production system.

The cover photo shows an imageof the expanses of peripheral de-vices such as inverter and servo-drive around the central “MICREX-SX” series.

Head Office : No.11-2, Osaki 1-chome, Shinagawa-ku, Tokyo 141-0032, Japan

Integrated Controller “MICREX-SX”

Increasing Applications of Integrated Controller “MICREX-SX” 76

New Features of the Loader “D300winV2” 81

Application of Integrated Controller 85“MICREX-SX” to a Motion Control System

Block Engineering to Efficiently Improve Control Software Development 92

Automatic Program Generation Software Package “SC MATRIX” 96

Integrated Controller “MICREX-SX” System 101and FA Application Software

Real-Time Expansion of Software Programmable Logic Controllers 105

Vol. 46 No. 3 FUJI ELECTRIC REVIEW76

Ken-ichiro IdeKeiichi TomizawaMasayuki Noguchi

Increasing Applications ofIntegrated Controller “MICREX-SX”

1. Introduction

One and a half years have elapsed since the“MICREX-SX” series was introduced to the market.This series has been favorably received due to itsconcept of anticipating future needs, its application tonew fields using high-speed processing, and openarchitecture approach that match the needs of thetime. To expand the application range further, wehave improved the functions not only of the hardwarelevel, but also of the software and usability.

In this paper, we will introduce a summary ofthese improvements. Their details and applicationexamples will be described in other papers in thisspecial issue.

2. Expansion of Application Range by Integra-tion with Peripheral Modules

2.1 Integration of control, operation and monitoringrealized on an open platformThere are two types of programmable controllers

(PLCs) and programmable operation displays (PODs),a hardware type which is realized with each specifichardware, and a software type, for which functions arerealized with a personal computer on an open plat-form.

The programs of the hardware PLC (SPH) andsoftware PLC (SPS), and the hardware POD (SUG)and software POD (SUS) are designed for compatibilitywith the integration of these devices. Therefore, whendeveloping programs, effective development and devicetransition is possible without having to be conscious ofthe implementation system, and further extension ofthe application fields are intended.

Here, we have provided the following personalcomputer based ISA bus boards to utilize the expand-ability of personal computers and to construct integrat-ed systems with control components such as PLC,POD, etc.(1) OPCN-1 board which is an open network below

PLC in rank(2) SX bus board that connects the variety of devices

supported by the SX bus

(3) PLC board which integrates the equivalent func-tions of the hardware PLC (SPH300) and realizeshigh-speed processing on a personal computer

(4) Other various boards to realize organic combina-tions with components of MICREX-SX

As mentioned above, owing to the support fromboth the software and hardware due to the superiorenvironment for program development and the provi-sion of a wide variety of ISA bus boards, an optimalsystem construction is possible. In Fig. 1, the conceptof the integration of control, operation and monitoringis shown.

2.2 Enriched integrated support systemThe integrated support system (SES) of the MICR

EX-SX series is implemented under an integratedenvironment that centers around PLC support with aninternational standard language, and integrates PODsupport and function module support. The SESimproves efficiency of control program development forhigh functionality and improves the efficiency ofperipheral device support. Figure 2 shows a functionalconfiguration of the integrated support system.

Fig.1 Concept of integration of control, operation and monitor-ing

Scalable multi-controller: SPH(Hardware PLC)

Programmable operationdisplay: SUG (Hardware POD)

Integrated support system: SES

Datacompatibility

Panel computer

Program compatibility

Program compatibility

ControllerHuman-machineinterface (HMI)

Software PLC: SPS

I/O level network

Software POD: SUS

Increasing Applications of Integrated Controller “MICREX-SX” 77

We will introduce specific means to make eachsupport tool efficient, from software development tomaintenance.2.2.1 D300win in accordance with international standard

languagesThe MICREX-SX series provides a programming

support tool (D300win) that is completely based on theinternational standard languages (IEC61131-3), thatare utilized in the major advanced nations such asEurope and North America, and can prepare IECcompliant programs with a minimum knowledge.Since being brought to market, improvements to theD300win have been planned to further enhance usabil-ity, and version 2 is introduced here. [For details, referto the other paper titled, “New Features of the LoaderD300winVer.2” in this special issue.] Some of featuresof the D300win including a list of new features of thislatest version are described below.(1) Programming with each language

The D300win fully supports 5 languages (IL, ST,LD, FBD and SFC) and programs can be developedusing the most suitable language depending on theapplication.(2) Automatic allocation of memory address

Conventionally, the memory addresses of variableswere consciously allocated by a programmer when aprogram was being created. With the D300win, thisallocation is automatically performed only by designat-ing the data type and property of the variablesaccording to the specifications of IEC. Consequently,the control of memory address allocation is reducedand redundant allocations can be prevented.(3) Backup of program and data

In software development, the MICREX-SX is basedon general source management, but provides thefollowing two methods of backup of programs and datain consideration of lost source files in case of an

emergency.(a) Programs in the controller can be uploaded to

the D300win. In addition to uploading as anIL language program, conversion from IL lan-guage to LD language is possible.

(b) The entire source may be stored in and readout from memory cards in the controller. Theuser can edit documents with the same contentas was created.

(4) Creation of documentsThe objects to be made efficient are not only

software development, but from the viewpoint ofsupplying a device to an user, also include completedocuments attached to the product. D300win realizesa print level equivalent to that of commercial applica-tions running on the Windows*1, and facilitates thetask of and saves power in creating documents.2.2.2 Linking of variables between PLC and POD support

toolsIn general, the POD editor directly specifies the

PLC memory address when transferring data andsignals between the PLC and the POD. With connec-tion to the POD in the MICREX-SX, variables in bothsupport tools are automatically linked, and can beshared. Therefore, the task of address allocation inboth these support tools can be made remarkably moreefficient.

The shared variables can be allocated with 30characters, preventing careless mistakes such as re-dundant allocation.2.2.3 Integrated function module support

The operating environment and connection form ofsupport tools for function modules such as PLCposition control, fault diagnosis and communicationare made common with the D300win. Functions canbe realized simply by implementing changes at thesoftware level, enabling integration of the support toolsand facilitating management of peripheral devices.

Further, in consideration of working offline, theparameters that were set in the various support toolsare saved in the D300win project, and can be forward-ed together with the program to PLC.

2.3 Position control function implemented in softwareConventionally, since a position control system was

generally configured using a custom module (hard-ware) for each control function, it was necessary toprepare hardware for each position control function onthe user side. In the MICREX-SX, the majority of theposition control function is realized with softwareusing high-speed CPU processing and a high-speed bus(SX bus). Therefore, the user can configure variousposition control systems with minimum types of hard-ware. In Fig. 3, a configuration of the position controlmodule and software for position control is shown.

Fig.2 Functional configuration of integrated support system

*1 Windows: A registered trademark of Microsoft Corp.,USA

LDANDNST

C:=A AND NOT B Structured Text

ABC

A B

A

B

C

C

Function Block図

Ladder図

STEP1

STEP4

SFC

STEP2 STEP3

Instruction List

Pattern setting of temperature adjust

Time

Set

tin

g va

lue

Speed 100m/srpm　 150rpm

コーラ

RUN STOP

International standardprogram (IEC)

(D300win)

AutomaticprogrammingSC matrix

Positioningsupport

Thermostatsupport

PODsupport

System definitions

Integrated support system (SES)

Windows- compatible PC

Debugging

Monitoring

RAS analysis

Document

Compatibilitysupport betweenexisting machines (IEC converter)

SUG

SPS

SUS

SPH

Vol. 46 No. 3 FUJI ELECTRIC REVIEW78

This time, we have attempted to enrich thesoftware of position control by preparing approximate-ly 80 types of software. Table 1 lists the software forposition control. Application programs can be simplyconfigured by combining these types of software.

On other hand, as hardware, a servo-systemdirectly coupled to the SX bus (FALDIC-α) is newlyprovided, enabling application to fields requiring high-speed response.

In addition to the above provided products, we areplanning to provide motion control, which is a higher-grade position control, and to comply with JEM1473,“Function block for motion control of general-purposeprogrammable controller” of the Japan Electrical Man-ufacturer’s Association.

Thus, the supported range of the MICREX-SX isfurther expanded, and depending on the positioncontrol function and accuracy, the user can change themodule and software combination without having toselect a device from different device groups. Scalableexpansion can be achieved without wasting hardwareand software resources.

3. Expansion of Application Range by BlockEngineering and IEC Language

3.1 Block engineering and hierarchical design of IECIn the MICREX-SX, the whole control program can

be hierarchically divided into individual functions,from large class to small class, and made as componentparts. Fuji Electric has packaged these dividedprograms of each function unit as function blocks (FB),and configured a whole system by hierarchicallycombining these function blocks. We call this method“block engineering.”

Figure 4 shows an overview of the hierarchicaldesign and block engineering.

The packaged FBs are IEC compliant and caneasily be made with D300win by the user himself.

3.2 Effect of block engineeringThe following effects are expected with this block

engineering.(1) The composition of an original library supporting

various controls for each user, improvement ofprogram productivity by implementing hierarchi-cal design, and reduction of the system construc-tion cost are possible.

(2) System construction cost can be minimized byassembling the most suitable specific controllerthrough integrating the original library into theMICREX-SX.

(3) Systems conventionally realized with a specificcontroller can be replaced with the MICREX-SXby means of customized combination of the libraryand the high-speed and high-performance of theMICREX-SX.

Further, the parameter setting and data transferfunctions of various function modules, communicationmodules, etc. were made into FBs, and the productseries of basic components is nearly complete.

Fig.4 Overview of hierarchical design and block engineering

Fig.3 Configuration of position control module and softwarefor position control

Table 1 Software for position control

Pu

lse

outp

ut

Cou

nte

r in

put

6Basic point to point 　position controller64-axis interpolation6Electric cam position controller6Electric cam switch6Synchronous position controller for cutting machine

Position controlsupport system

SX bus

AMP

PG

AMP

SBS SBS

High-speed digital I/O

module

Pulse train output position control module

High-speed counter module

Pulse signal

AMP AMP

MMMMM

Pulse signal

Analog

Pulse train position control combined module

DedicatedLSI

High-speed I/O

SBS

Dedicated LSI

ParametersRAM

Microcomputer

CPU

PositioningFB

Operation system Kind

1-axis PTP operation

Special synchronous operation

Software for position control

Software for simple position control

Software for compact 1-axis PTP(include simple linear interpolation)

2

Software for multi-function 1-axis PTP 28

5

Software for special synchronousSoftware for multi-function 1-axis PTP

2- to 4-axis interpolation

Software for 2- to 4-axis interpolationSoftware for multi-function 1-axis PTP

13

9

79Total

Software for 1-axis PTP(include simple linear interpolation) 22

A B C

Ladder

STEP1

STEP2 STEP3

STEP4

SFC Controlprocedure

Application FB

SC matrix

Function block (FB) (Software parts)

Hardware component

Basic FB

Application

Start signalAnswer

Hie

rarc

hic

al d

esig

n

Increasing Applications of Integrated Controller “MICREX-SX” 79

In the future, it is planned to make standardcontrol functions that are similar to applications, suchas speed control, torque control, etc., into FBs.

4. Expansion of Application Range by OpenSystem

4.1 Support of standards and open network4.1.1 Global standard product group according to main

standardsThe MICREX-SX is complies with main interna-

tional standards and supports the vigorous overseasexpansion of enterprises. The MICREX-SX has re-ceived approval for CE marking, and UL/cUL and NK/LR standards. Therefore, the user does not have toselect a device according to the destination, andconsequently the unification of manufacturing draw-ings and reduction of spare parts is possible.

4.1.2 System configuration having the optimum expand-ability

To properly configure the production systems ofeach enterprise, a wide variety of open networkmodules from computer level to bit level are prepared.Adoption of an open network enables the selection ofan optimal device among manufacturers and theminimization of cost. In Fig. 5, open networks corre-sponding to the MICREX-SX are shown.

In addition to the open network modules, supportof the open networks provides a wide variety ofcorresponding devices. Therefore, by supporting anopen network, the troublesome selection of devicesamong vendors can be suppressed to a minimum.Table 2 lists equipment for open networks.

4.2 Excellent linking to general-purpose applications4.2.1 Automatic programming using Excel*2

The MICREX-SX is provided with an automaticprogramming tool, the SC MATRIX, that automaticallygenerates PLC language from a description of thecontrol process schedule in Excel 97*3 spreadsheetformat. The SC matrix realizes the process schedulemechanism with a pin board on Excel. The user canreadily understand the straightforwardness of thematrix and the clear visualization of the working state

Table 2 Equipment for open networks

Fig.5 Open networks corresponding to the MICREX-SX

Fig.6 Overview of SC MATRIX

Item

Network category

Corresponding network

Ethernet

Master module

○ Computer level

Controller level

Device level

Bit (sensor) level

○: Compatible △: In development or planning

Equipment for open networks

Interface module to expansion

－

Terminal remote I/O

－

POD

○

Inverter

－

Servo system

－

FL-net (OPCN-2) ○ － － △ － －

OPCN-1 ○ ○ ○ ○ － △

DeviceNet ○ △ △ － ○ △

PROFIBUS-DP △ △ △ △ ○ △

LONWORKS △ － △ － － －

AS-i ○ △ ○ － － －

FL-n

et (

OP

CN-2

)

AS

- i

INTE

RBU

SLo

opIN

TE

RB

US

MO

DB

US

H1

OP

CN- 1

Dev

iceN

et

LO

NW

OR

KS

PR

OF

IBU

S- D

PPR

OFI

BUS-

FMS

Con

trol

Net

EthernetTCP/IP

*1

*2

Fie

ldbu

s H

2

Japan

: Open network which can be connected with MICREX-SX

*1 Ethernet: A registered trademark of Xerox Corp., USA*2 LONWORKS: A registered trademark of Echelon Corp., USA

North America Europe

Com

pute

rle

vel

Con

trol

ler

leve

lIn

put/

outp

ut

Dev

ice

leve

lB

it le

vel Adding SC matrix

in Excel

D300winConversion into the IEC language Download

Online change

Monitor

MICREX-SXDescribing processschedule on Excelsheet

*2 Excel: A registered trademark of Microsoft Corp., USA

*3 Excel 97: A registered trademark of Microsoft Corp.,USA

Vol. 46 No. 3 FUJI ELECTRIC REVIEW80

using Excel’s editing function without being consciousof the programming language. In Fig. 6, an overview ofthe SC matrix is shown. [For details, refer to the otherpaper titled, “Automatic Program Generation SoftwarePackage “SC MATRIX”” in this special issue.]4.2.2 Linking of data to personal computers

The trend of open systems is expanding theapplication of personal computers into the control fieldand is increasing the need for users to link on-sitecontrollers and general-purpose applications in themanagement system’s personal computers. The inter-nal information of the MICREX-SX is opened to thepublic to enable the linking of general-purpose applica-tions to a PLC and the D300win at the DDE*4

(dynamic data exchange) level, etc. The user cancreate a parameter setting screen using a program-ming language such as Visual Basic*5 and closely linkthe data to a PLC and the D300win. Figure 7 showslinkage at the DDE and OCI*6 (open communication

interface) levels.

4.3 Realization of tight coupling by opening the specifica-tion of the high-speed SX busIt is possible with an open network to realize the

optimum system configuration sought by the users, butin a position control system and in the human-machineinterface connection that displays this data, there arethe cases where higher-speed processing and higherresponse speed are required and even tighter couplingis sought. To meet these user needs, Fuji Electric hasopened to the public the SX bus of the MICREX-SX,which realizes high-speed and facilitated distributedcontrol (such as a T-branch). Therefore, high-gradecustom systems can be configured on the user side, andopen network systems also can be configured easily.

Furthermore, from the viewpoint of system ex-pandability, an optical SX bus has been realized,enabling the construction of reliable systems with highnoise resistance.

Presently, devices for the open SX bus are theservo-system, inverter, human-machine interface andtemperature control unit. Hereafter, we intend tovigorously open the specifications of those devices(venders) requiring high-speed processing.

5. Conclusion

As described above, together with the enrichedhardware and software, the application range of theMICREX-SX has expanded. The objective of systemcomponents is not only in the performance of thehardware, but the larger issue is in the usefulness ofthe surrounding utilities, and we think that the usersalso expect this usefulness.

Opening and standardizing systems is the trend ofthe times, and we intend to advance the developmentof the devices as a basic concept of the MICREX-SX.

*4 DDE: Function to exchange data and messages betweenapplications

*5 Visual Basic: A registered trademark of Microsoft Corp.,USA

*6 OCI: A registered trademark of Microsoft Corp., USA

Fig.7 Linkage at DDE and OCI levels

Sheet1

Drive parameter

Sheet2 Sheet3

WRITE

READNo.1 12345No.2 6789No.3 0123

Parameterset screen

D300winDDE linkage

OCI linkage

Setting of the data, etc.

Download

Setting of the data, etc.

Monitoring of the data, etc.

MICREX-SXCreate screen withvisual basic, etc.

New Features of the Loader “D300winV2” 81

Akihide HamadaMasashi Yamada

New Features of the Loader “D300winV2”

1. Introduction

D300win is a program development support tool incompliance with IEC61131-3 and provides full supportof the programmable controller (PLC) for the first timein Japan. Functionality and performance have beenimproved continuously since the first edition, incorpo-rating the demands of many users. Fuji Electric nowoffers D300win Version 2 (D300winV2) which, basedon those demands, greatly improves the ease ofoperation by using the latest Windows*1 technology.In this report, the main features of D300winV2 areintroduced.

2. New Features of D300winV2

D300winV2 shifts completely to a 32-bit system,and provides many new features and high perfor-mance. Some of the main features are described below.

2.1 More comfortable programming support environmentAn API (application program interface) for a 32-bit

system is used to provide an interface with optimallook and feel. The main features are enumeratedbelow.(1) Quick window selection (dockable window, over

view window, etc.)(2) Toolbar customizing for desired functions.(3) Keyword emphasized display to prevent careless

mistakes.(4) User can set short cuts to each menu item.

Figure 1 shows the overall display of D300winV2.

2.2 Project handlingTo make the IEC61131-3 structure more user

friendly, the handling of projects was simplified by thefollowing functions.(1) New project view

The new project view consists of the project, POU(program organization unit), libraries, physical hard-ware, and the instances (execution object) as shown in

Fig. 2. These corresponded well with the concept of theIEC61131-3, and consequently, the overall view andpartial views can be switched quickly.(2) Easy and quick insertion of the IEC61131-3

structureThe menu and the toolbar can insert the POU,

data type, library, and the configuration (configurationof PLC) easily and quickly.(3) Project wizard

The wizard is a function to simplify the operationby providing selectable guidance choices.

Knowledge of the IEC61131-3 was indispensable inthe creation of new projects. New projects can becreated by using templates already prepared for theformer method, but with D300winV2, new productscan be created more easily by using the project wizard.

A new project outline can be created simply withseveral selections according to the dialog shown inFig. 3.

2.3 Quick IEC programming with assistance from thewizardThe edit wizard is a useful tool which facilitates

the insertion and exchange of functions and functionblocks of all languages, the keywords and statementsof ST (structured text) language, and the operands ofIL language. By using this tool, the user need not

Fig.1 Overall display of D300winV2

*1 Windows: A registered trademark of US Microsoft Corp.,USA

Edit wizard

Worksheet space

Cross reference windowWatch window

Messagewindow

Project treewindow

Vol. 46 No. 3 FUJI ELECTRIC REVIEW82

know the syntax for all statements. Moreover, the useof the edit wizard with the text editor prevents syntaxerrors such as a missing semicolon or a missing end-statement for a selection/repetition statement.

Figure 4 shows the Fuji Electric original functionblock with many parameters having been inserted intothe ST worksheet using the edit wizard. The call ofthe function block can be described by simply filling inthe variables according to the data type displayedbetween “(*” and “*)”.

2.4 Graphical editorTo improve the description, the visual check, and

the productivity of the graphic editor most often usedfor the program development, the following functionshave been added to D300winV2.(1) Automatic arrangement of graphical elements

In a graphical language worksheet, the LD (ladderdiagram), FBD (function block diagram), and SFC(sequential function chart) graphic elements are movedto the nearest grid edge automatically by the gridfunction and are automatically aligned in the horizon-tal or vertical direction.(2) User defined color settings

The color of all object types can be selected, andthe user can improve the ease of visual check.(3) Tool chip for online values

The tool chip is small help display that appearswhen the cursor is moved over a button or other object.To make online values easy to read in a worksheet thathas been miniaturized to show the overall display inD300winV2, online values are displayed within thetool chip.

Figure 5 is an example of displaying an onlinevalue with a tool chip in a miniaturized graphicalworksheet.

(4) Multiple line commentsA comment block, consisting of several lines of

comments, can be created.(5) Decrease of object collisions

Objects are automatically moved to empty spaces,decreasing the possibility of collision.(6) Clipboard for SFC elements

Copying and pasting by means of the clipboard canbe performed even with SFC elements, improving theproductivity of the SFC program.(7) Drag and drop for all objects

Similar to a circuit in the worksheet, all objectssuch as FB, contacts or variables are easily moved andcopied by means of drag and drop.

2.5 Powerful online functions(1) Powerful cross-reference function

The cross-reference function of the D300winV2 candisplay an abundance of information (use instructions,comments, R/W, etc.) as shown in Fig. 6, and hasfunctions such as sort, jump-to-code, and filter, which

Fig.3 Project wizard

Fig.4 Example of using edit wizard

Fig.2 New project view

Fig.5 Example of displaying online value using tool chip

Project

POUs

Libraries

Hardware

Instances

Complete task in six steps

Highlight corresponding position of project tree

Select the project outline

Fill in the variable between "(*" and "*)"with the displayed data type

Insert bythe wizard

Display ofonline value with the tool chip

Online worksheet

New Features of the Loader “D300winV2” 83

are very useful for debugging.The cross-reference function is available both on-

line and offline.(2) Watch window also useful for arrays and struc-

turesIn D300win, the window where the value of the

variable is displayed for debugging is called the watchwindow.

Debugging a user defined data type such as anarray or a structure has become easier with V2 thanwith V1. Figure 6 shows an example display of anarray and a structure in the watch window.(3) Improved handling of multiple CPUs

In a multi-CPU system, the user should select aresource (CPU) for online communication. With V1,the user had to select the resource from the projecttree. With V2, because the user can select the resourcevia a dialog at the beginning of online operation, thecomplexity of multi-CPU handling is reduced. Figure 7shows the resource selection dialog display after theonline mode has been selected.

2.6 Multi-lingual projectsIt is necessary to make localization (modification of

software to be suitable for a specific region) functionsmore powerful to meet the trend of globalization. InD300winV2, therefore, the following functions weredeveloped.(1) Complete support of the Japanese (double-byte

character) languageDouble-byte characters were supported with all

user interfaces including the tree part. As a result, allAsian languages can be supported, including Japanese.(2) Project language

Translated description worksheets and commentsprepared for localization can be displayed in variouslanguages. Concretely, description worksheets andcomments are exported from the project to ASCII filefirst, then translated, and then imported to the projectagain. Finally, they are displayed in the language ofthe destination country. Figure 8 shows the procedurefor switching the project language of the D300win byexporting and importing the description worksheet andcomments, and also shows an example of the switchedcomments.

2.7 Faster compilingPerformance characteristics of the display such as

the drawing speed improve due to the benefit of 32 bitscompared with the previous D300winV1 (16-bit) sys-tem. The time for compilation is less that one half thatof the previous system, due to the benefit of 32 bits andan improved algorithm.

Therefore, instances where the compilation speedis an issue will decrease under the present generalenvironment.

Table 1 shows the system requirements ofD300winV2.

3. Integrated Development Environment Basedon D300win

Following the release of V1, application develop-ment software (support tool for extended function blockfor position control, PID control, failure diagnosis,POD editor, etc.) to simplify the application develop-ment using MICREX-SX has been offered. Thissoftware is based on the functions (such as the variablename service function) provided with D300win thatenable variable information in the project to be easilyused. Of course, these basic functions are alsosupported in V2.

In addition, D300winV2 provides the following

Fig.8 Switching of project languageFig.6 Powerful cross referencing, and monitor of array/structure for easy debugging

Fig.7 Reduced complexity of multi-CPU systems by resourceselection

Jump to the code.

Cross reference window

Sortable Variegated cross reference information Monitor the array and the structure in the watch window

Name of all resources in project

Switch theproject language

Select language

and import

Expor

t

ASCIIFile

Translation

Vol. 46 No. 3 FUJI ELECTRIC REVIEW84

Table 1 D300winV2 system requirements converted into comma separated value (CSV) formatand export to a text file. Moreover, the commaseparated value text file can be converted, and importto the project.

As a result, commercial software can process anduse data easily.(2) More powerful variable name service

The range of variable name service function wasexpanded and made more powerful. That is, deriveddata types that are more complex such as arrays andstructures, and multi-variable worksheets, were addedto the range of service. As a result, applicationdevelopment is even further simplified.

The integrated development environment that cen-ters on D300win by offering the above-mentionedvariable name service has been improved.

4. Conclusion

New functions and the improved performance ofD300winV2 were introduced. The popularization inJapan of the programming environment in compliancewith IEC61131-3 has progressed steadily. Based onthe situation in Japan, Fuji Electric will continue toprovide systems that contribute to the improved appli-cation development efficiency of PLC that centers onthe programming environment in compliance withIEC61131-3.

Item

Hardware IBM-AT compatible machine or NEC PC98 series

CPUIntel pentium 133MHz or higher is recommended.

Hard disk driveMinimum one drive,minimum 100MB free disk space

Floppy disk driveMinimum one drive,media size 3.5 inches

2HD (1.25MB/1.44MB)

Resolution of display VGA 640×400 dots or higherXGA 1,024×768 dots (recommended)

Necessary memory 32MB or more

Operating system(OS) Windows 95/98/NT4.0

*2

RS-232C

Maximum rate

Ethernet*1

PortabilityAccording to the commercial portable personal computer

Languages

*1 Ethernet : A trademark of Xerox Corporation*2 Windows 95/98/NT4.0 : A trademark of Microsoft Corporation

Japanese and English

Environmentaltolerance

According to environmental condition of the commercial personal computer

ISDN

9,600bps to 38.4kbps(set default according to the resource type)

Yes

Yes

Specification

Com

mun

icat

ions

inte

rfac

e

*2 Visual Basic: A registered trademark of US MicrosoftCorp., USA

*3 Excel: A brand name of US Microsoft Corp., USA

functions that enable commercial software (VB*2 appli-cations, Excel*3, etc.) to use variable information in theproject.(1) Import/export function for variable files

Variable information from the project can be

Application of Integrated Controller “MICREX-SX” to a Motion Control System 85

Tadakatsu AidaTakashi IdaYasutaka Tominaga

Application of Integrated Controller“MICREX-SX” to a Motion Control System

1. Introduction

A scalable multi-controller SPH [hardware pro-grammable controller (PLC)] of the integrated control-ler “MICREX-SX” (hereafter referred to as SX) serieshas the features of high speed and high performance,and is suitable for the motion control of variousmachines. Historically, in the servo-system of a typicalmotion control, a high-performance position controlmodule (for example, the electronic-cam module ofMICREX-F) was required. However, in an SX system,SPH can perform the functional calculation due to therealization of a high-speed calculation feature. That is,in an SX system, the system is configured such thatonly actuator interface functions such as a D-A con-verter, pulse distributor, etc., are on the position-control module side, and the position-control calcula-tion is executed on the SPH side with an extendedfunction block (FB). With this configuration, it is easyto customize position control processing for integratinguser “know how” with the combination of extended FBfor position control and user FB (various compensationcalculations), and to support special machines. Partic-ularly, in machines performing synchronous operation,there is demand for tuning of the machine control suchas for predicting the main axis position and compen-sating the position gap of the control axis. This SX isthe most suitable controller for these machines.

In this paper, we will present an overview ofsynchronous operation processing and the controlcharacteristics during synchronous operation as anexample application of the motion control system of theSX system. Further, example application to a special-purpose cutting machine that combines a rotary axisand a linear axis using the floating point calculationfunction of the SX will be introduced.

2. Position Control Module

2.1 Basic specifications and system configurationTable 1 lists the basic specifications of the position-

control module for the SX, and Fig. 1 shows a systemconfiguration for position-control with the SX. Thefollowing three types of signal systems exist for a

servo-amplifier in an SX system.(1) Pulse reference signal system (NP1F-MP2, NP1F-

HP2, etc.)A pulse reference is output on the position-control

module side.This system is combined with the servo-amplifier

and stepping motor of the pulse reference signalsystem.(2) Analog velocity reference signal system (NP1F-

MA2)An analog voltage is output on the position-control

module side.This system is combined with the servo-amplifier

of the analog velocity reference signal system.(3) Servo-amplifier directly coupled to SX bus (L, R

and V type of FALDIC-α)This system directly signals the amplifier via the

SX bus.When combining with a FALDIC-α directly con-

nected to the SX bus, the position-control module isunnecessary.

2.2 Function block of position-control moduleFigure 2 shows a control block diagram for the

position-control module.In the function calculation unit, acceleration, decel-

eration and interpolation calculations are performed,and a position signal is output. In the position-controlmodule of the pulse reference output, the positionsignal is the number of actual pulses. Further, in theposition-control module of the analog velocity referenceoutput, position regulator calculation (error counter,gain and feedforward control calculation) is performed.In the error counter, the difference between commandposition and feedback position from the servomotor iscounted. The feedforward compensates for the re-sponse lag of the position signal, and is an importantfunction in synchronous operation. The sum of thecalculated gain value and the feedforward output valueis added to the output value of the error counter tobecome the velocity reference value for the servo-amplifier.

In the conventional MICREX-F system, the func-tion calculation unit and position-controller were en-

Vol. 46 No. 3 FUJI ELECTRIC REVIEW86

tirely integrated into a high-performance position-control module or servo-amplifier on the FALDIC-II

Table 1 Basic specifications of the position-control module

Fig.2 Control block diagram for position-control moduleFig.1 System configuration for position control

side. That is, the functional calculation was performedby the combination of a high-speed microcomputer andan LSI circuit for pulse distribution mounted on theposition-control module.

In the SX configuration, among the functional

Name

TypeItem

Occupied slot

Number of occupied words

Number of control axes

Control system

Reference signal

Analog velocity referencecompound module

NP1F-MA2

Pulse reference compound module

NP1F-MP2 NP1F-HP2 RYSxxxS3-xSS

1 slot

22 words(Input 14 words, output

8 words)

2 axes/module

Closed loop control Open loop control Open loop control Closed loop control

° Analog velocity reference° 0 to ±10.24 V

° Pulse reference (open collector)° CCW pulse+CW pulse° Max. 250 kHz

° Pulse reference (open collector)° CCW pulse+CW pulse° Max. 250 kHz

Feedback pulse

° Line driver/open collector° 90°phase difference signal (φA, φB signal)° Max. 500 kHz (×1)

° Operation signal/open collector° 90°phase difference signal (φA, φB signal) or CCW pulse+CW pulse° Max. 500 kHz (×1)

° Operation signal/open collector° 90°phase difference signal (φA, φB signal) or CCW pulse+CW pulse° Max. 500 kHz (×1)

Manual pulse generator/Main axis pulse for synchronous operation

Outside input/output signal

° Dedicated input 5 points (EMG, ±0T,beginning point LS, external interrupt)° General-purpose output 2 points

° Linear-curve accel./decel.° Continuous change of frequency° Reading the data for position-control in advance° Feedforward calculation° 2-axis simple linear interpolation

° Servo-amplifier of analog velocity reference

° Servo-amplifier of pulse reference° Driver for stepping motor

° Servo-amplifier of pulse reference° Driver for stepping motor

° Linear-curve accel./decel.° Continuous change of frequency° Reading the data for position-control in advance° Pulse number control function° 2-axis simple linear interpolation

Internal function

Actuator

FALDIC-α directly coupled to SX bus

16 wordsL, R: Input 8 words, output 8 wordsV: Input 10 words, output 6 words

1 axis/unit

° 16-bit serial encoder (integrated in motor, compatible with ABS)

° Expansion counter for manual pulse generator 1 channel (V type)

° Dedicated input 5 points (Control 1 to 5)° Dedicated output 2 points (Output 1 and 2)

° Linear position-control function (L type)° Rotation calculation function (R type)° Position reference system (V type)

1 slot

22 words(Input 14 words, output 8 words)

2 axes/module

° Line driver/open collector° 90°phase difference signal (φA, φB signal)° Max. 500 kHz (×1)

° Dedicated input 5 points (EMG, ±0T,beginning point LS, external interrupt)° General-purpose output 2 points

Pulse reference output module

1 slot

16 words(Input 8 words, output

8 words)

2 axes/module

° Dedicated input 5 points (EMG, ±0T,beginning point LS, external interrupt)° General-purpose output 2 points

° Linear-curve accel./decel.° Continuous change of frequency° Pulse number control function

MP2SX

SX bus

FALDIC-α directly coupled to SX bus

Pulsereference

Feedback pulse

Servo-amplifier of pulse reference

Servo-amplifier of analog velocityreference

Feedback pulse

Analog velocityreference

MA2

Numerical value,position or torquereference Velocity or torquemonitor

FALDIC-II with T-link

Position-control module

FALDIC-α (V type)

MA2

MP2

Functionalcalculation

Conventionalconfiguration

Applicationof PLC

Numerical value reference

Positionreference

Position feedback

Velocityreference

Move quantity,speed

Applicationof PLC

Configura-tion of SX

ExtensionFB

Servo-amplifier

Gainkp

Errorcounter

Feedforward

FALDIC-α (L, R type)

Application of Integrated Controller “MICREX-SX” to a Motion Control System 87

Table 2 Combination of extended FB for position-control and position-control module

calculation components, functions which were conven-tionally processed on the microcomputer of the posi-tion-control module side, are executed on the SPH sideas an extended position-control module. (In FALDIC-α, in addition to the V type used in combination withthe extended FB, all functional calculation featuresincluding the L type and R type are provided, similarto the FALDIC-II.)

Because the functional calculation feature is madeinto an extended FB, the user FB can be customized.

The position-control extended FBs for various

operations are provided in the SX system as shown inTable 2, and the position-control modules can bedirectly signaled from the user FBs. Figure 3 showstwo types of operating modes of the position-controlmodules.(1) Pulse generation mode

After setting the distribution pulse number andfrequency, a start signal is turned ON. At the position-control module side, the position-control-completedsignal is turned ON after completing the pulse distri-bution. (Parameter values such as acceleration/decel-eration time and high-speed limiter have been set inadvance.)(2) Position reference mode

Pulse position data are signaled every tact cycleusing a constant cycle task. In this mode, specialoperation is realized by transforming the coordinatesystem with a user FB. In the position-controlextended FB, a multi-function 1-axis PTP FB performssynchronous operation and cam operation movementby referencing this mode. (In a FALDIC-α directlycoupled to an SX bus, the V type corresponds to thismode.)

3. Application to Synchronous OperationMachine

A synchronous operation function is contained invarious machines such as a running crane and arunning cutting machine. In this chapter, we will

Fig.3 Operation mode for position-control module

1-axis PTP operation

Extended FB library name

Operating system

Compact 1-axis PTP

Objective position-control module FALDIC-α Operating CPU

NP1F-MA2

○

○

○

○

○

○

○

Function

° 1-axis PTP position-control° Linear-curve accl./decel.

° 1-axis PTP position-control° 1-axis automatic operation of motion program° Linear-curve accl./decel.

° 1-axis PTP position-control° Linear-curve accl./decel./S-form accl./decel° Operation with manual pulse generator

° Rotary shear° Flying shear° Flying cutter linear operation, rotating operation° Proportional synchronous operation

° 2-axis simple linear interpolation in a module

° 2- to 4-axis simple linear interpolation

° 4-axis linear interpolation° 2-axis circular interpolation° 4-axis automatic operation of motion program

2- to 4-axis interpola-tion

△: An interface FB is required to match the I/O signal with the position-control compound module.L-type (LSS) and R-type (RSS) FALDIC-α are integrated into an amplifier whose function corresponds to that of an extended FB.

Special synchronous operation

Compact 1-axis PTP

1-axis PTP

4-axis interpolation+

Multi-function 1-axis PTP

1-axis PTP

Multi-function 1-axis PTP

Special synchronous FB+

Multi-function 1-axis PTP

NP1F-MP2

○

○

○

○

○

○

○

○

×

×

×

○

×

SPH300

○

○

○

○

○

○

○

SPH200

○

×

×

×

○

×

×

NP1F-HP2

×

×

△

△

×

×

△

RYSxxxS3-VSS

×

Time

t1 t2 t3 t4 t5 t6 t7Time

Distributednumber of pulses

Frequency

Spe

edP

osit

ion

(a) Pulse generation mode

(b) Position reference mode

OFF ON

StartFinish

Vol. 46 No. 3 FUJI ELECTRIC REVIEW88

explain the running cutting machine, assuming that ita rotary shear type.

The rotary shear is equipment that cuts with arotating blade a product which is fed continuously asshown in Fig. 4. The rotary shear is utilized in packingmachines and printing machines. During operation ofthe rotary shear, the peripheral speed of the cutter issynchronized with the speed of the product. Further,since the cutter must rotate one turn when the productis fed by a cutting length (in the case of a single blade),the cutter shaft operates synchronously while adjust-ing the speed. If the motor that drives the main axis ofproduct feeding is independent of the controller for therotary shear control, the operation is externally syn-chronized, and the controller for the cutter unitperforms the cutting operation while calculating thefeed length of the product and feeding speed frompulses of the main axis pulse generator (PG). Thefollowing three types of errors influence cutting accura-cy in the running cutting machine.(1) Control error of the controller(2) Control error of the actuator(3) Control error on the machine side

We evaluated the synchronous characteristics ofthe SX and actuator on the assumption of rotary shearoperation, and will introduce the results of thatevaluation. The configuration of the evaluation systemis shown in Fig. 5, and a function block diagram isshown in Fig. 6.

In this system, externally synchronized operationis assumed, and the cutter is synchronously operated,utilizing the output pulses of the position-controlmodule of the pulse reference output [NP1F-MP2(hereafter called MP2)] as pulses from the main axisPG. As shown in Fig. 6, processing on the SPH side iscommanded from 1-axis PTP extended FB to MP2, butthis is independent of the synchronous calculation.Synchronized processing is performed with a combina-

Fig.5 Test system for rotary shear

Fig.6 Rotary-shear control block diagram for test system

Fig.4 Rotary-shear system for running cutting machine

Product speed

Cutter speed

Spe

ed

This area corresponds to 1 turn of the cutter

Main axis roller Rotary shearMain axis PG

Time

This area corresponds to length of product cutting

MP2SX

CH1

Main axis pulse

Feedback pulse

Directly coupled PG

Firstaxismotor

Second axismotor

Directly coupled PG

Analog velocityreference

CH2

MA2

DI16DO16

Main axispredict

calculation

SX CPU MP2 (Main axis)

Amplifier

Feedback position

Reference position

Shaded areas: Extended FBDouble frame: User FB

Position reference

Numerical value reference

Main axis positionMA2

Main axis pusle

D-Aconverter

1-axisPTP

Errormonitor

Numerous1-axis

Errorcounter

tion of the “Prediction calculation FB of main axisposition” (user FB) created for this evaluation systemand the “Multi-function 1-axis PTP FB” (extended PTPFB). This time, error pulses of the position-controlmodule of the analog velocity reference [NP1F-MA2(hereafter called MA2)] are sampled every tact cycle,and unevenness is evaluated. Further, this character-istic evaluation is performed with a combination of SXand a vector inverter (unloaded motor).

3.1 Evaluation system(1) Motor: 5.5 kW synchronous motor (trial sample)(2) Amplifier: Vector inverter FRENIC5000VG5(3) Cutter axis PG: 2,000 P/R × 4(4) Tact cycle: 3 ms(5) Position regulator (MA2) calculation cycle: 0.8 ms(6) Position regulator gain: kp = 50/s(7) Number of sampling points and cycle: 360 and 3

ms interval(8) Number of control axis: 2

Application of Integrated Controller “MICREX-SX” to a Motion Control System 89

reach the target position after the setting time (lagtime). Further, the data-receiving intervals (tactcycles) are automatically measured, and a frequencycalculation is performed so as to distribute the pulsesat the receiving intervals. By means of this system,even if the calculations of MA2 are performed with a0.8 ms cycle compared to the 3 ms tact cycle, thevelocity reference signal has no ripple and the motorcan rotate with a stable velocity. Since the signal toMA2 is the position data, the compensation of datadetected with pulses such as the length of phasecompensation for synchronous operation, lag compen-sation, etc., is simply realized by incorporating addi-tion and subtraction of the position data into the userFB.

4. Application to Special-Purpose CuttingMachine

Figure 9 shows an example of a 2-axis cuttingsystem combining a rotary axis and linear axis. Aproduct is turned by motor M1 and a torch moveslinearly with a motor M2 and ball screw. As shown inFig. 10, many machines have 2-axis orthogonal configu-rations and cut with linear interpolation and arcinterpolation functions of position-control modules, butmachines whose configuration combines a rotary axisand linear axis can be made smaller. Conventionally,the control of a machine configured as in Fig. 9required a dedicated controller. Otherwise, the linearaxis was made to synchronize with the rotary axisusing a cam pattern registered to an electronic cammodule (NC1F-EC1 of MICREX-F).

The SX performs a coordinate calculation with ahigh-speed floating-point calculation instruction, andoperates with position reference every tact cycle.Operation with the electronic cam module causes theresponse of the cam axis side to lag the main axisoperation at the time of acceleration and decelerationof the main axis because of the following action of thecam axis, even if a prediction calculation treatment ofthe main axis position is added. In contrast, in an SXsystem, there is no response lag at acceleration anddeceleration due to the calculation of commandedposition because positions are calculated for both axes.

The contents of the calculation will be explained

Fig.7 Unevenness for error pulse (evaluation result of testsystem)

Fig.8 Operation timing for position control mode

3.2 Evaluation results(1) Unevenness is within 5 pulses (refer to Fig. 7)

The ordinate in Fig. 7 shows error pulses, and thecalculated error Ep is calculated with the followingformulae:

Ep = (Rotating speed/min) × (2,000 pulses × 4) ÷(60s × kp) ...................................................... (1)

™Fig. 7(a): 600 r/minEp = (600 × 2,000 × 4) ÷ (60 × 50) = 1,600 pulses

™Fig. 7(b): 1,000 r/minEp = (1,000 × 2,000 × 4) ÷ (60 × 50) = 2,666 pulses

™Fig. 7(c): 2,000 r/minEp = (2,000 × 2,000 × 4) ÷ (60 × 50) = 5,333 pulses

There are differences between the calculated errorpulses and the measured values in Fig. 7, but this isunrelated to stability of the synchronous speed becausegain adjustments of the analog velocity referencesignals between MA2 and the amplifier are somewhatout of alignment.

In the synchronous operation function of the SX, bymeans of the position reference signal mode (refer toparagraph 2.2), target position reference signaling isperformed from the “Multi-function 1-axis FB” to theMA2 side every tact cycle. As shown in Fig. 8, thereference position data Pn calculated with SPH aresent via the SX bus to the MA2 every tact cycle. Onthe MA2 side, after receiving the data, a distributedcalculation of the reference pulses is performed so as to

1,574

(a)

(600 r/min, kp = 50/s)

1,572

1,570

1,5681 41 81 121 161 201 241 281 321

2,624

(b)

(1,000 r/min, kp = 50/s)

2,622

2,620

2,6181 41

Motor 1 turn 0.1 s (Data: 33 pieces)

Motor 1 turn 0.06 s (Data: 20 pieces)

81 121 161 201 241 281 321

5,256

(c)

(2,000 r/min, kp = 50/s)

5,254

5,252

5,2501 41

Motor 1 turn 0.03 s (Data: 10 pieces)

81 121 161 201 241 281 321

Err

or p

uls

esE

rror

pu

lses

Err

or p

uls

es

P1

Tact

Pos

itio

n

Tact cycleTime

Lag timeP2

P3

P4

Vol. 46 No. 3 FUJI ELECTRIC REVIEW90

Fig.12 Control block diagram for special-purpose cuttingmachine

with Fig. 11. Figure 11(a) shows the fed quantity of thelinear axis when the product turns by θt. Lx0 is thelength from the reference point at the start of opera-tion (center of a rectangular) to the cutting start point.If the position of the torch Lxt when the product turnsby θt, the length moved ∆L t is:

∆L t = Lxt - Lx0 ...................................................... (2)Actually, the coordinate calculation is performed

from the reference point as the product is fixed asshown in Fig. 11(b).

If the cutting velocity setting value is V, the X-axisand Y-axis coordinate positions (X t and Yt) are:

X t = Lx0 .................................................................. (3)Yt = V × t ................................................................ (4)[Calculation formula while moving toward vertical

direction in the example of Fig. 11(b)]The turning angle θt from the X-axis and Y-axis

coordinates (X t and Yt) is:θt = atan (Yt /X t) .................................................. (5)The length from the center to (X t and Yt) is:L t = Lx0 /cos (θt) .................................................. (6)orL t = √(X t2 + Yt2) ..................................................... (7)

In Fig. 11(b), the calculation formulae for X-axisand Y-axis coordinates at corners and feeding alongthe horizontal direction are different from formulae (3)and (4). However, the coordinate positions are calcu-lated first, next, the rotary axis angle and linear axisposition are calculated and then position control isperformed.

The FB configuration that was used in this cuttingmachine is shown in Fig. 12. The coordinate calcula-tions and position calculations of formulae (3) to (7)were performed with a user FB. The calculated 2-axisposition results become an input of the manual pulseoperation multi-function 1-axis PTP FB. In manualpulse operation, normally, a manual pulse generator isconnected to MA2, and position control is performedaccording to the number of the input pulses countedwith a counter in MA2. The application example inthis chapter utilizes high-speed floating-point calcula-tion, and replaces the pulse counter of the manualpulse generator with an SPH calculator (user FB) toexecute the special operation.

Fig.11 Operation patternFig.9 Combination of rotary axis and linear axis

Fig.10 System configuration for 2 orthogonal axes

(a) Overhead view

(b) Side view

Torch

Torch

M1

M2

M2

The work turns the object

Locus pattern

Torch Locus pattern

M1 M2

Velocity V

Y-axis

X-axis

(a) (b)

Lxo Lxo

Lyo

Lxt

(Xt,Yt)θt

θt

2-axis positioncalculation FB

(User FB) Manual pulseoperation FB

_MCMPS

Numerous 1-axis (Rotary axis) Rotary

axisposition

reference

RotaryaxisD-A

Manual pulseoperation FB

_MCMPS

Numerous 1-axis(Linear axis)

Linearaxis

positionreference

Manual pulse generator

Shaded areas are position-control extension FB

SPH300 MA2

Counter

LinearaxisD-A

Err

or c

oun

ter

Err

or c

oun

ter

Application of Integrated Controller “MICREX-SX” to a Motion Control System 91

5. Conclusion

This paper introduced the unevenness in theaccuracy of an SX system when applied to a synchro-nous operation machine. The synchronous accuracyrequired for running a cutting machine such as a flyingshear differs depending on the product, but theaccuracy proved in this system could be applied tomany machines. However, there are machines such asprinters for multi-color poster printing that requirehigher accuracy and higher speed response for positiondetection resolution, stability of error unevenness, etc.In the future, we intend to respond to the require-ments of high accuracy and high speed by enrichingthe compensation processing FBs that are matched to

various machines in an SX position-control system.Further, in application to special cutting machine,

we described an overview of the position-control opera-tion which was conventionally difficult in PLC posi-tion-control module. The SX system has a functionthat performs position-control by means of positionreference to MA2 and MP2. When integrating opera-tion pattern calculation with the user FB on the SPHside (similar to drawing a picture of the operationpattern on the screen of a personal computer), specialoperations can be realized easily.

The authors will be glad if this paper is useful forapplying these functions to actual machines thatrequire synchronous operation and rotary axis opera-tion, such as packing machines and various manufac-turing machines in addition to printing machine.

Vol. 46 No. 3 FUJI ELECTRIC REVIEW92

Mitsunori FukuzumiYoshiaki Shimada

Block Engineering to EfficientlyImprove Control Software Development

1. Introduction

Innovations in the design of the D300win programsupport tool has greatly improved the efficiency withwhich one may create control programs in the MICREX-SX series. In particular, the implementation offunction blocks (FBs), which allow existing controlprograms to be reused, may greatly enhance controlprogram productivity. Historically, similar programsfor individual controls had to be made from scratcheach time. Through the use of FBs, however, one canapply existing FBs to each new control element toconstruct the desired control program. Like a jigsawpuzzle, the existing FBs need only to be pieced in orderto form the desired control program. This paper firstintroduces the concept of block engineering and thendescribes in detail the efficacy of FBs in the construc-tion of control programs.

2. What is a Function Block (FB)?

A function block (FB) as prescribed in IEC61131-3involves modularizing a program into componentparts. Figure 1 shows a simple example of an FB. Tothe left of Fig. 1 a simple ON/OFF circuit is describedwith a ladder diagram. When a “Start” signal turnsthe circuit ON, an “Output” signal repeats the ON/OFFwith a cycle twice that of the specified cycle.

In the center of Fig. 1, the circuit is made into afunction block (FB). The D300win easily converts anarbitrary circuit into an FB (modularization). It isonly necessary to specify signal names of an inputterminal and an output terminal. This approach isanalogous to hardware construction, in that a combina-tion of discrete parts is coordinated into an integratedcircuit (IC). In this scenario, signal names are onlyrequired for designation of input and output terminals.So, the input-output interface can be clearly expressed.

The right side of Fig. 1 shows an example of howFBs may be used in a ladder circuit. The same FBmay be reused as another circuit by simply changingthe instance name (corresponding to the part numberof the hardware component).

3. Structured Programming in MICREX-SX

Structured programming is realized in MICREX-SX series. In this method, a whole applicationprogram is divided into blocks, each corresponding to aspecific control object (elevator machine, conveyancemachine, etc.) and a specific control purpose (carryingout action, coiling action, etc.). This block-basedstructure creates an efficient environment in whichprogramming, debugging and administrating servicesmay be performed. Furthermore, while still adheringto the hierarchical framework, each program block canbe further modularized and functions simplified.Figure 2 shows this general idea.

In this way, creating hierarchical layers for blockstructures results in programs that are easy to readand maintain. In addition, the entire program or acomponent part can easily be divided and made intoFBs. This approach allows for the program to bereused and increases the standardization of the controlfunctions.

4. Block Engineering of MICREX-SX

If control functions are prepared in advance aswell-proven FBs, most application programs will selectthe necessary FBs, and compile them together. Thistechnique greatly improves programming efficiency.This is the main objective of the block engineering ofMICREX-SX.

Fig.1 General concept of the function block (FB)

Start Stop Hold Function block(FB)

Hold

HoldXY

Output

Blink

Base_SIGDivide

T#5s

T#10ms

Start

Stop

Cycle

Output

BlinkStart

Stop

Cycle

OutputBlink

Start

Stop

Cycle

OutputCycle TON TON

XY

Input terminalStart, Stop, CycleOutput terminalOutputLocal variableHold, XY

Mak

ing

into

an

FB

Reu

se

Block Engineering to Efficiently Improve Control Software Development 93

In this respect, it is important to know in whattype of units should FBs be classified and provided.The block engineering of MICREX-SX builds an appli-cation program with hierarchical structure, and thenclassifies and provides FBs to match each hierarchy asshown in Fig. 3.

4.1 Basic FB layerWhen modularizing a real control system into

blocks (structured) with the intent to match uphardware and control purpose, the technique ultimate-ly decomposes the control system into function blocks(FBs) for a small control object and its control function.Independent of the overall control purpose of the entiresystem, the FB functions that directly control realhardware components (sensor, actuator, etc.), that is,the functions to issue command pulses to a servo-amplifier or to receive data from a bar-code reader,depend only on the object component in the whole

hardware. In light of this, a set of FBs administratingthe interface with hardware components is referred toas the basic FB layer.

4.2 Application FB layerTable 1 shows a few of the classifications for

machinery control. These classifications are for controlalgorithms, and do not theoretically depend on thecontrol object, which is a type of sensor or actuator. Asan example of the positioning control by a servo,consider the scenario in which a servo-amplifier iseither related to the pulse train interface, remote I/Ocombination or the D-I/O combination. In this in-stance, the positioning control operation algorithmwould be common. In this way, a set of FBs that areindependent of the hardware components is referred toas an application FB layer.

4.3 Application layerTo implement the machinery control shown in

Fig.2 Structured programming of the MICREX-SX Table 1 Control functions classification (partial)

Fig.3 Hierarchical structure of block engineering

Table 2 Machinery control functions for each type of business

Automatic

Abnormal

Communication

Interlock-2

Interlock

What and where is written?

Administration is difficult to implement!What is

implemented?

Too many man-hours required to compile software!

Structured layer

Structured layer

Structured layer

Function block (FB)

Automatic-2

Assets MICREX-SX

Hie

rarc

hic

al d

esig

n

A B C

Ladder

STEP1

STEP2 STEP3

STEP4SFC Operation plan

description layer

Application FB layer

SC MATRIX

Hardware components

Basic FB layer

Application layer

ReplyStart signal

Rotary shear

Flying cutter

Point-to-point

Interpolation

Calculation of rotations

Synchronous operation

Traveling cutting

Dancer control

Loop control

Positioning control

Speed control

Control operations

Measurement control

POD interface

Information control Web connection

etc.

Coiling control

Mot

ion

con

trol

Torque control

Synchronization

Ratio control

Dancer control

Tension control (tension detection type)

Tension control (coil diameter operation type)

Tension control

Torque balancing

Torque limiting

Products suppliers

Rubber and chemical manufacturing industryCar manufacturing industryOthers

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Vol. 46 No. 3 FUJI ELECTRIC REVIEW94

Table 2, the basic FBs and the application FBs arecombined to create the desired control for each custom-er and for each machinery. The layer that forms thiscontrol is called an application layer. Generally, theapplication layer puts application FBs and basic FBstogether and generates a program. The entire programor a component part can be made into an FB andregistered as an application FB.

4.4 Operation plan description layerIn block engineering, a program that specifically

describes the operation plan is extracted and separatedfrom the application layer. This program is called anoperation plan description layer. Between the opera-tion plan description layer and application layer, eventsignals (bit signals) are exchanged.

The operation plan description layer is an adminis-trative component that is designed to control step or

state transitions in the system. In other words, itdescribes a set of steps in the control procedure. Forexample, the operation plan description layer recordswhen (work arrives), what it is (a work axis) and how(to go forward) in order to issue event signals (“forwardcommand to work axis”) to the application layer.

The application layer and the other underlyinglayers receive an event signal, perform the correspond-ing action and then report the status (“action complet-ed”, etc.) of the action back to the operation plan layer.Thus, they play a role in the action execution compo-nent.

By separating the event administrating componentfrom the action execution component, the functions ofthe latter become extremely simplified. Therefore, itbecomes easier to implement structuring (modulariza-tion into blocks) and increases the standardization forprogramming.

5. Application of Block Engineering

Figure 4 to Fig. 6 illustrate the application of blockengineering to positioning control. It should beremembered that this example extracts only a generalidea for explanation.

Figure 4 shows the system configuration. Thisexample is of a positioning control with a total of 20axes of servos and inverters. Of the 20 total axes, 14axes control 1-axis PTP (point-to-point) positioning,

Fig.6 Details of function blocks (FBs)

Fig.5 Application of block engineering (hardware configuration)

Fig.4 Application of block engineering (system configuration)

Inter-polation

Inter-polation

Inter-polation

6-axis servo

2-axis inverter

2-axis servo

4-axis inverter6-axis servo

MICREX-SX

Pu

lse-

trai

n

I/F

T-L

ink

I/F

D-I

/O I

/F

Operation plan description

layer

Application FB layer

Basic FB layer

Application layer

Positioning data generation block

Head-axis1-axis position control

Work-axis2-axis positioning with interpolation

Machinery constant

PositionSpeedMode

2-axis interpolation positioning

block

PositionSpeedMode

PositionSpeedMode

PositionSpeedMode

PositionSpeedMode

1-axis positioning

block

Parameter block

SC MATRIX

Operation plan description(SC MATRIX)

Application FB layer

Application layer

Basic FB layer

Hardware components

Sensors

Actuators

SOL’s

Motors

Control parameter

Ou

tpu

t

Step

Tra

nsi

tion

co

ndi

tion

Sig

nal

Inte

rloc

k bl

ock

Rep

ly

Inte

rfac

e bl

ock

Inte

rfac

e bl

ock

Inte

rfac

e bl

ock

1-ax

is2-

axis

SC MATRIX

Interlock block

Servo 1-axis

PTP FB

Pulse train FB

Pulse train FB

Servo

Pulse train D-I/O T-Link D-I/O T-Link

Servo ServoServo

Servo 1-axis

PTP FB

Parameter selection FB

PositionSpeed Mode

StepSignal

Ou

tpu

t

OR

G1-

axis

pos

itio

nin

g bl

ock

(for

ser

vo)

1-ax

is P

osit

ion

ing

bloc

k (f

or in

vert

er)

2-ax

is p

osit

ion

con

trol

wit

h in

terp

olat

ion

FW

D

para

met

er

Com

plet

ed

Inte

rfac

e F

B

Com

plet

ed

Com

plet

ed

FW

DB

WD

OR

GF

WD

BW

D

Tra

nsi

tion

co

ndi

tion

FWD

Completed

D-I/O inverter

T-Link inverter

InverterInverter

Inverter 1-axis PTP FB

Parameter selection FB

D-I/O servo

T-Link servo

Servo 1-axis PTP FB

Completed

PositionSpeedMode

Parameter selection FB

PositionSpeedMode

Parameter selection FB

PositionSpeedMode

PositionSpeedModeF

WD

pa

ram

eter

PositionSpeedMode

Block Engineering to Efficiently Improve Control Software Development 95

while the remaining 6 axes control 2-axis interpolationof PTP positioning. Figure 5 shows the softwareconfiguration by block engineering. Each block ofFig. 5 is explained below.

5.1 Operation plan description layerThe operation plan description layer includes an

operational plan (state transition description) describ-ing the positioning, the control parameters and theconstants of the machinery for each product to bemanufactured. This example depicts the case in whichthe SC MATRIX is used. Any user, even those withoutprogramming knowledge can compile and revise con-tents of the operation plan at will by writing theoperation plan description layer with the SC MATRIX.Detailed information about the SC MATRIX is dis-cussed in another paper.

5.2 Application layerThe application layer consists of the interlock

blocks and the positioning control parameter genera-tion block program for each axis. The interlock block isa program designed to take a necessary interlock,based on command signals (head-axis DOWN, work-axis FORWARD, etc.) from the SC MATRIX, andtransfer it to the application FB layer and the otherunderlying FB layers. The positioning control parame-ter generation block is a program that analyzes datatrains (machinery constants and control parameters)downloaded from the SC MATRIX and then generatespositioning control parameters (position, speed andmode) for each axis.

5.3 Application FB layerThe application FB layer consists of 1-axis posi-

tioning blocks and 2-axis interpolation positioningblocks. The 1-axis positioning block consists of param-eter selection FBs and 1-axis positioning control FBs(Fig. 6). The parameter selection FBs select position-ing control parameters (position, speed and mode)which correspond to the bit command (forward, back-ward and return to origin) from the SC MATRIX, andthen pass it to the 1-axis positioning control FB. The1-axis positioning control FB executes positioningcontrol operation using given positioning control pa-rameters, and completes by returning the transitioncondition of the SC MATRIX.

The 2-axis interpolation positioning block adds 2-axis interpolation control FBs to the above blocks(Fig. 6). In other words, the positioning control param-eters given by the 2-axis interpolation control FB areresolved into those corresponding to each of two axes,and shared with each 1-axis positioning control FB.The processing is the same as that of the 1-axispositioning block.

5.4 Basic FB layerThe basic FB layer consists of interface control FBs

for hardware components. Corresponding to thehardware configuration of Fig. 4, the basic FB layer isconfigured from the following five types of FBs (Fig. 6).(1) Inverter control FB with T-Link interface (I/F)(2) Servo control FB with T-Link I/F(3) Inverter control FB with D-I/O I/F(4) Servo control FB with D-I/O I/F(5) Servo control FB with pulse train I/F

Connecting the appropriate basic FBs listed aboveto the 1-axis positioning FB makes the control systemcompatible with all types of actuators (inverters orservos) and interfaces (T-Link, D-I/O or pulse train).

6. Effects of Block Engineering

Construction of a control system using the configu-ration listed above produces the following favorableeffects.(1) Because FBs are divided into basic and applica-

tion FB layers, independent of the interface,common use of the control component (applicationcomponent) is possible. In Fig. 6, the interface isvaried among T-Link, D-I/O, pulse train, etc.,however, the positioning control can only common-ly use the “1-axis positioning FB”.

(2) Combining application FBs together can buildvarious functions. In Fig. 6, combining two of the1-axis positioning FBs together with one of the 2-axis positioning FBs can create 2-axis interpola-tion positioning.

(3) An application can be administrated and stan-dardized on an FB unit basis. In addition,software created in this manner is durable andcan be used in the future because FBs aredescribed in the international standard languageIEC61131-3.

(4) By separating the action component from theoperation plan component (event component), thefunctionality of the action component becomesmore simplified, making it easier to implementstructuring (modularization into blocks) andachieve standardization. Furthermore, automaticadjustment of operation can be easily made bysimply revising the event component.

7. Conclusion

The authors propose that the block engineeringmethod, in the form of a series of integrated functionblocks (FBs) based on IEC61131-3, result in an effi-cient operative method. As a consequence of thisapproach, FBs are likely to play an indispensable roleon the PLC programs of the future, as the blockmethod allows for the reuse and standardization ofFBs. The authors hope that this paper will help applythe block engineering to practical applications.

Vol. 46 No. 3 FUJI ELECTRIC REVIEW96

Mitsunori FukuzumiKenji Hirukawa

Automatic Program Generation SoftwarePackage “SC MATRIX”

Fig.1 Conventional procedure for creating a control program1. Introduction

Functionality and performance of the programma-ble controller (PLC) has been enhanced and its pricereduced. On the other hand, its control program hasbecome larger in scale and more complex. Therefore itis not unusual for the programming cost to exceed thehardware cost, and there is strong demand for themore efficient generation of control-software.

In the integrated programming support toolD300win of the MICREX-SX series, an innovativeenvironment is provided for the more efficient creationof control programs by adopting such measures as theinternational standard language IEC61131-3, intro-ducing structured programming, and improving reus-ability by modularizing the program. In this respect,the authors have recently developed an automaticprogram generation software package, the “SC MATRIX”.

2. Overview of SC MATRIX

Figure 1 shows the procedure for creating general-purpose control programs. First, a control actionspecification (an operation plan) is made. Next, thisspecification is translated into a PLC program, and isexecuted by the PLC. When changing the operationplan, the same processing is always performed in thiscycle. If a PLC program is automatically generateddirectly from the operation plan, a dramatic improve-ment in PLC program efficiency can be expected.

As automatic program generation software, the SCMATRIX is a product that is used in combination withthe D300win. More specifically, the operation planrelated to step transitions of the control procedure isdescribed in a predetermined format in a table form ineasy-to-use Microsoft Excel 97 worksheet. Based onthis table, the SC MATRIX automatically generates aprogram, i.e. a program organization unit (POU) of theSTL (structured text language) prescribed inIEC61131-3.

Even with no knowledge of ladder diagram pro-gramming and such, with approximately 1 hour ofstudy, anyone can describe an operation plan in an

easy to visualize manner by using Excel 97. Further-more, once the worksheets are described, a change ofthe operation plan specification during monitoring orwhile on-line can be made with the worksheet format.These features are quite advantageous. Figure 2 showsan overview of the SC MATRIX.

3. Functions of SC MATRIX

3.1 Function of the operation plan descriptionThe details of operation plan description in the SC

Fig.2 Overview of SC MATRIX

Description of control action

Direct input

Programming

Understanding

Program generation

PLC

Digital outputAutomatic generation of PLC software

Arrangement of pins according to machinery actions Programming knowledge not needed

Step transition description by Excel worksheets (SC MATRIX table)

MICREX-SX PLC system

Monitor screen

Windows-compatible PC

*

D300win

*Windows: A registered trademark of Microsoft Corp., USA

Digital input

¡ mark means + symbol.™ mark means - symbol.

Automatic Program Generation Software Package “SC MATRIX” 97

MATRIX are shown in Fig. 3. The serial steps in thecontrol procedure are compiled in one Excel 97 work-sheet. This is called a matrix table and a maximum of98 sheets is available. According to the matrix tables,step actions can be executed between the matrix tablessequentially or in parallel.

A matrix table lists output signal names (“output”cells) and transition conditions to the next step(“condition” cells) in the vertical direction, and thesteps in the horizontal direction.

For each step, the signal to be output at that stepis specified in the “output” cell with + (a-contact). Atthe same time, the transition condition to the next stepis specified with a + or - (b-contact) in the “condition”cell. These + and - symbols are called “pins”. A“condition” pin basically indicates an AND condition,but it also indicates an OR condition if a + pin isspecified in the “OR” cell.

Figure 4 shows an example of the main functions ofthe SC MATRIX. This table describes the operationplan of an elevator going up to the second floor anddown to the first floor, and vice versa.(1) Step transition function

The step transition function is a basic function ofthe SC MATRIX and sets the transition condition tothe next step and the output signal for each step.

The step number is described with consecutivenumbers beginning with 1. If a transition condition isestablished, the step shifts to the next number.

As shown in Fig. 4, step 1 switches ON outputsignals “braking output” and “opening door.” If thetransition condition signal “opening door completed”switches ON, step 1 shifts to step 2. Simultaneously,the output signal is replaced only by the signal“braking output” as specified by step 2.(2) Jump function

A step can jump to another step if a jumpdestination is described in the “jump” row of thematrix table. (If nothing is described, the stepswitches to the next step.)

Based on an input condition, one of several steps

can be selected and shifted to in the case where morethan one jump destination has been described for thesame step. Jumping from one matrix table to anothermatrix table is also possible.

Step 3 of Fig. 4 shows an example of a conditionaljump with three branches having three correspondingtransition conditions.

In the first condition, the step shifts to step 4 if thesignals of both “Arrival at the first floor” and “Closingdoor completed” are switched ON. In the secondcondition, the step shifts to step 6 if the signals of both“Arrival at the second floor” and “Closing door complet-ed” are switched ON. In the third condition, the stepshifts to step 1 if the signal “button input to open” isswitched ON and the signal “button input to close” isswitched OFF.(3) Step time assurance function (an action timer)

The minimum action time of the step is assured bysetting a value as an action timer in the “action timer”row of the matrix table. In other words, whenswitched to a new step, that step will remain active forthe duration of the time set with the action timer, evenif a transition condition becomes established in themeantime. The action timer can select a setting or nosetting at each step.

In the example of Fig. 4, when the state is switchedfrom step 3, 5 or 7 to step 1, it will not switch to step 2

Fig.3 Details of operation plan description in SC MATRIX Fig.4 Example of operation plan description in SC MATRIX

Table number Step name: Free description

Step number: Consecutive numbers

Jump destination step number

+:Output specification

+:a-contact-:b-contact

Output address

Input address

Table name: Free description

Action timer: guaranteed action time of step

:Specifying AND condition +:Specifying OR condition

Output variable name:(global variable)

Input variable name: (global variable)

98 sheets max.

Number of steps expandable: 98 steps max.

100 outputs max.

100 inputs max.

Step No.

MS table 1

1 2 3

+

+

+

+

+

+-

+

+

+

+

3 3 4

+

5 6 7

+ ++ +

+

+

+

+

+

+

+

++

Action timer

Jump

End

WDT detection

1 s

4 6

+

+

1

+-

1 1

2 s

WDT release

Temporary halt

Braking output

Lift start

%QX1.0.7

%QX2.0.15

%IX3.0.0

%IX3.0.1

%QX2.0.1

%QX2.0.9

%QX2.0.0

%QX2.0.8

Lift going-up direction

Lift high-speed

Opening door

Closing door

OR

Button input to open

Button input to close

Arrival at second floor

Access up to second floor

Access down to first floor

Arrival at first floor

Going-up

Going-down

Opening door completed

Closing door completed

M_ENDS

tep

nam

e

Ou

tpu

tT

ran

siti

on c

ondi

tion

open

ing

door

wai

tin

g fo

r cl

ose

butt

on

clos

ing

door

Hig

h-s

peed

goi

ng-

up

Low

-spe

ed g

oin

g-u

p

Hig

h-s

peed

goi

ng-

dow

n

Low

-spe

ed g

oin

g-do

wn

¡ mark means + symbol.™ mark means - symbol.

Vol. 46 No. 3 FUJI ELECTRIC REVIEW98

Fig.5 Example of time chart description in SC MATRIX

until one sec