Manufacturing Control Processes – Lab Introduction

Xiangzhen SunTeaching Assistant

xs14@my.fsu.edu

COE A213

Intro to Programmable Logic Controller (PLC)

ProcessorA/D Module

I/O DevicesSimulator

Instructions

Instructions

Instructions

Memory Allocated

Variable Application of PLC Programming 1. Manufacturing / Machining

2. Food / Beverage

3. Metals

4. Power

5. Mining

6. Petrochemical / Chemical

Major Components of a Common PLC Configuration Diagram

PROCESSOR

POWERSUPPLY

I MN O P D U UT L E

O M U OT DP UU LT E

PROGRAMMING DEVICE

From SENSORSPushbuttons,

contacts,limit switches,

etc.

ToOUTPUT

Solenoids, contactors,

alarmsetc.

S7-1200: User Friendly Simulation ToolSystem Architecture

Unified hardware, human machine interface (HMI), networking and development software– eliminating barriers of interoperability between common automation devices

85.32Input value

Progress

Input

Searching point of inflexion …Status

%

85.32Output value

Output

manual%

Optimization75.00Setpoint value %

Start tuning

Uselast settings

Abort tuning

Start measurement Stop measurement34.05Input1 100.00Output1% % Setpoint1 62.00 % Time1 3780 ms

3500 4500 5500 6500ms

40

50

60

Measure cycle

Upload

%

58.05Input2 37.00Output2% % Setpoint2 62.00 % Time2 6990 ms

1000 ms

40

50

60

%

40

50

60

%

Startup tuning Tuning in run85.32Input value

Progress

Input

Searching point of inflexion …Status

%

85.32Output value

Output

manual%

Optimization75.00Setpoint value %

Start tuningStart tuning

Uselast settingsUselast settings

Abort tuningAbort tuning

Start measurementStart measurement Stop measurementStop measurement34.05Input1 100.00Output1% % Setpoint1 62.00 % Time1 3780 ms

3500 4500 5500 6500ms

40

50

60

Measure cycle

Upload

%

58.05Input2 37.00Output2% % Setpoint2 62.00 % Time2 6990 ms

1000 ms

40

50

60

%

40

50

60

%

Startup tuning Tuning in run

One Software- Common editor Engineering Station

- Instant On connectionsBuilt-In Specialty Functions- Loop Tune, Motion, Etc.

S7-1200: User Friendly Simulation ToolHardware Connection

Integrated Ethernet, Analog I/O, Motion Control I/O, with Scalable Expansion– eliminating the need for additional hardware; reducing space and cost

Built-inEthernet

RemovableDouble-Stack

Terminals

Up to 3 Specialty Modules Up to 8 Signal Module

1 Signal Board

Front panelSignal Board

SD MemoryCard

S7-1200: User Friendly Simulation ToolOne Software – One User Program: Controller, HMI, Networking

Online functionsGeneralControl panel

Commissioning

Commissioning

EnabledReferencedAxis error

Axis status

99.0 mm/s

Drive status

ReadyDrive error

Speed:Setpoints

100.0

Positive hardware limit switch activeLast error:

Position:

Actual values

250.0 123.68 mm

Enable

Take manual control

Acknowledge

Jog forwardsJog backwards

Start positioning Start referencing STOP

20.0 mm 1240.0 mm Upper position limit:

Lower position limit:

of Axis: Axis_1

Online functionsGeneralControl panel

Commissioning

Commissioning

EnabledReferencedAxis error

Axis status

99.0 mm/s 99.0 mm/s

Drive status

ReadyDrive error

Speed:Setpoints

100.0

Positive hardware limit switch activeLast error: Positive hardware limit switch activeLast error:

Position:

Actual values

250.0 123.68 mm 123.68 mm

Enable

Take manual controlTake manual control

Acknowledge

Jog forwardsJog backwards

Start positioning Start referencing STOP

20.0 mm 20.0 mm 1240.0 mm 1240.0 mm Upper position limit:

Lower position limit:

of Axis: Axis_1

85.32Input value

Progress

Input

Searching point of inflexion …Status

%

85.32Output value

Output

manual%

Optimization75.00Setpoint value %

Start tuning

Use last settings

Abort tuning

Start measurement Stop measurement34.05Input1 100.00Output1% % Setpoint1 62.00 % Time1 3780 ms

3500 4500 5500 6500ms

40

50

60

Measure cycle

Upload

%

58.05Input2 37.00Output2% % Setpoint2 62.00 % Time2 6990 ms

1000 ms

40

50

60

%

40

50

60

%

Startup tuning Tuning in run85.32Input value

Progress

Input

Searching point of inflexion …Status

%

85.32Output value

Output

manual%

Optimization75.00Setpoint value %

Start tuningStart tuning

Use last settingsUse last settings

Abort tuningAbort tuning

Start measurementStart measurement Stop measurementStop measurement34.05Input1 100.00Output1% % Setpoint1 62.00 % Time1 3780 ms

3500 4500 5500 6500ms

40

50

60

Measure cycle

Upload

%

58.05Input2 37.00Output2% % Setpoint2 62.00 % Time2 6990 ms

1000 ms

40

50

60

%

40

50

60

%

Startup tuning Tuning in run

I/O Config

Logic

HMI Config

Motion

PID Tuning

Networking

Central Navigation Portal

Programming Standards 1. LAD (ladder logic) is a graphical programming language. The representation is based on

circuit diagrams

Programming Standards 2. FBD (Function Block Diagram) is a programming language that is based on the graphical

logic symbols used in Boolean algebra

Programming Standards 3. SCL (structured control language) is a PASCAL-based (text-based), high-level programming language. SCL program blocks can include and is compatible with LAD and FBD sub-blocks.

Variable declaration

Function defination

Hardware Communications

Programming device connected to the CPU(upload your program to execute)

HMI connected to the CPU(change program via graphical interface)

CPU connected to another CPU(resembles 2-core processor, each processor addressable with preloaded programs)

Simulator Demonstration

1

2

3

Siemens S7 vs. NI LabVIEW

PLC networking Application LabVIEW HMI programming in Robotics