Automatic Control System

VII.
Controller



transmitter



actuator
Structure of control system
Process

the name of
mathematical
model of
the plant

Material flow
sensors transducer
actuating
unit
actuating
drive
controller

operator desk
Visualisation software
SCADA (Supervisory control and data acquisition)
Simulation software
Control software
Standard signals
Variables
Standard industrial
I/O interface
Process controller and typical application field
Process controller
ready to use for industrial control and its possible the
hardware redundancy and integrate the functionality of
control and SCADA software.
Application field
process industry applications (paper, primary metals, food
processing, and so on.)
batch-type control (chemicotechnology, pharmaceutic
chemistry, or injection molding machines, and so on.)
Programmability
standard control languages IEC1131-3 and SCADA
depending of factory
PLC familyes
Control relays
8-20 I/O, limited memory size, only LD programming
languages with limited and not standard instructions.
Compact PLC
12-32 I/O, normal memory size, standard IL, LD, FBD
programming languages with limited instructions.
Modular PLC with compact unit
flexible arrangement up to 800 I/O, different memory size,
standard IL, LD, FBD programming languages.
Modular PLC with rack system
Higher I/O number, memory size, CPU frequency, network
ability. All standard programming languages are used.
Structure of modular PLC
Programming device
CPU module
Local extension I/O module
Network station
Remote extension I/O module
MCC
Variable Speed Drives
S800 I/O
S900 I/O (Ex)
Workplaces
Control Network
Remote Clients
System Servers
Fieldbus High Speed
Linking Devices
(FF HSE/H1, PB DP/PA)
Process Automation
Process
Automation and
Safety
Operator Engineering Maintenance
Safety
Hlzati Elrendezs


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CPU Terminal base
(TB 711F)
CPU (PM 783F)
Local I/O Modules
(Up to 8)
I/O Terminal Units
(up to 8)
FBP (Field Bus
Plug) *
RS232/485
DIAG
RS232/485
SER (MODBUS)
Field Bus Coupler
Connector *
Ethernet
(RJ-45)
24 VDC
Power connector
AC 700F kontroller V9.1
Industrial software
Simulation software
Facilities: Involving differential equations, matrix, etc.
Converting between frequency and time domain.
Charting functions.
Creating block models.
Control software
Content of control task for industrial computer (process
control), or intelligent devices in laboratory (scope,
frequency generator, power supply, etc.)
Visualisation software
Instead of classic operator desk (push button, dial indicator)
Control software
Control software needs a model of the process
Define correct interface between process and controller.
(using standard signals)
Dividing into simpler part of the process.
Choosing control strategies.
Creating control task, and define the parameters.
Standard industrial I/O interface for signals
Digital I/O
galvanic isolation
24 VDC logic (0 -7 VDC , 14 - 30 VDC)
Analogue I/O
Usually no galvanic isolation
Typically: 4-20 mA signal area
Typically resolution: 12 bit
Dimensionless technique
) (
{dim} 1
{dim} ){dim} (
min
t w
w t w

Controlled, measured
variable
feedback
signal
action
signal
manipulated
variable
A/D conversion
control task
D/A conversion
max
min
20 mA
4 mA
max
min
20 mA
4 mA
Domain of
variability
Program structure of PLC control program
Deafault
task
Periodic
task
Event
task
System
task
Priority
Program A1
Program An
Program E1
Program En
Program Rn
Program R1
Program Pn
Program P1
Function block 1
Function block N
Function N
Function x
Function 1
Data FB1/1
Data FB1/2
Data FB1/3
The system programs handle the
error, keep the connection with
operator, and so on.
Function block 2
Programs, function blocks, functions
The programs can be written any standard languages.
Different languages can be used in the project.
The function blocks and the function are well tested
subprograms.
The function blocks have more input and more output
variables, which can be catch from any programs.
The functions have more input and one output
variables. The output variables appear in the working
register of CPU and needs handle.
How the programs use the CPU
t
t
t
t
D
P
E
S
A1 A2 A3 A1
P1
A2 A3 A1 A
P
E1
P
A A A3 A1 A2 A3 A1
R1
A3 A1 A2 A3 A
Cyclic processing of the user program
not use loop instruction (for, until..)
at the end the program the processing starts again automatically
Write data
interrupt
Standby PLC
selftest
Process user program
Read data
The standard control languages
IEC1131-3
Structural Text
similar to QuickC
Instruction Line
similar to assembly
Ladder Diagram
graphical language similar to contact plan
Function Block Diagram
graphical language similar to digital circuit plan
Function Chart
graphical language and text languages by IEC848 standard
Structure of Instruction line
Label Instruction
Symbolic name
for variable
Comment
These are always required
It is used like the target of
the jump instructions.
It relates to the variable.
Jumps Label
Calls
Symbolic name
for function block
or function
Structure of jumps instructions
A
C B
D
yes
label yes
yes
jump conditional
A
no
label unconditional jump
no
jump unconditional
B
C
D
Structure of Calls instructions
User
program
Function
block
Data_1
Data_2
call name
The same type of function blocks or
functions can be called more times
with different name and so data block.

The calls instructions can be used in
the function block program too.
return
Instructions of IEC1131-3
LD, LDN
S, R
ST, STN
AND, ANDN
OR, ORN
XOR, XORN
LT, LE, EQ, EN, GE, GT
JMP, JMPC, JMPCN
CAL, CALC, CALCN
RET, RETC, RETCN
all variables
bool variables
all variables
bool variables
bool variables
bool variables
all variables (the result is bool)
label
name of function block or function

Store, Set, Reset output instructions
Store ST
In all scan the output result depends on the actual value of
the contacts.
Set S
In the first scan when the logical result of contacts actual
value equals true the output register (variable) is set high,
and remains in this state independent the contacts actual
value until a reset instruction.
Reset R
In the first scan when the logical result of contacts actual
value equals false the output register is reset
Variables of IEC1131-3
BOOL
BYTE, WORD, DWORD
integer (INT), short integer
(SINT), double integer
(DINT), unsigned integer
(UINT), ...
REAL
TIME
DATE
TIME_OF_DAY
DATE_AND_TIME
STRING
bool variables
bit sequence variables
digital variables



real number
T#0h0m0s0ms
D#1900-01-00 (YYYY-MM-DD)
TOD#00:00:00 (HH:MM:SS)
DT# 1900-01-00-00:00:00
Structure of Instruction line program
Sequence
Smallest part of a instruction line program the sequence
consisting of one or more instruction line.
Syntactic of sequence
Started one load instruction (LD, LDN) and
finished one or more result instruction (ST,
STN, S, R, JMPC, JMPCN, CALC, CALCN).
Inside the sequence the type of the variables is
the same.
JMP, CAL, RET are the one line instructions.
Bool algebra
AND
OR
XOR
The relaycoil1 is energised if the
contact1 and the contact2 are closed.
The relaycoil2 is energised if the
contact1 or contact2 are the closed.
The relaycoil3 is energised if either
the contact1 or the contact2 are
closed.
Sequence
AND
OR
XOR
LD contact1
AND contact2
ST relaycoil1
LDN contact1
OR contact2
ST relaycoil2
LD contact1
ANDN contact2
LDN contact1
AND contact2
OR
ST relaycoil3
LD contact1
XOR contact2
ST relaycoil3
Circuit connections
between ends
Logical closed
instruction series
Structure of Ladder diagram
Type

Suggested flowchart of the PLC program
If the result of the conditions is false
the actions arent processed and
begins automatically examination
of the next conditions.
The jumped actions arent processed.
It remains the latest value.
There arent conditions before JMP,
CAL instructions

Actions
conditions
conditions
conditions
Actions
Actions
Jumps label
Calls name
Steps of creating control program
Flowchart of the program
define input, output, and internal variables
Hardware topology file
Edit program file and reference file
definition of variables, edit program, syntax check
Compile editing program
convert to machine code, error massages
Transfer (download) to PLC
Test and commissioning
start/stop program running, display program in running
Modify program