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1、Programmable Logic Controllers (PLC)1. About Programmable Logic Controllers (PLC)Everyone knows theres only one constant in the technology world, and thats change. This is especially evident in the evolution of Programmable Logic Controllers (PLC) and their varied applications. From their introducti
2、on more than 30 years ago, PLC has become the comer stone of hundreds of thousands of control systems in a wide range of industries.At heart, the PLC is an industrialized computer programmed with highly specialized languages, and it continues to benefit from technological advances in the computer an
3、d information technology worlds. The most prominent of which is miniaturization and communications. Programmable logic controllers I/O channel specifications include total number of points, number of inputs and outputs, ability to expand, and maximum number of channels. Number of points is the sum o
4、f the inputs and the outputs. PLC may be specified by any possible combination of these values. Expandable units may be stacked or linked together to increase total control capacity. Maximum number of channels refers to the maximum total number of input and output channels in an expanded system. PLC
5、 system specifications to consider include scan time, number of instructions, data memory, and program memory. Scan time is the time required by the PLC to check the states of its inputs and outputs. Instructions are standard operations (such as math functions) available to PLC software. Data memory
6、 is the capacity for data storage. Program memory is the capacity for control software. Available inputs for programmable logic controllers include DC, AC, analog, thermocouple, RTD, frequency or pulse, transistor, and interrupt inputs. Outputs for PLC include DC, AC, relay, analog, frequency or pul
7、se, transistor, triac. Programming options for PLC include front panel, hand held, and computer. Programmable logic controllers use a variety of software programming languages for control. These include IEC 61131-3, sequential function chart (SFC), function block diagram (FBD), ladder diagram (LD),
8、structured text (ST), instruction list (IL), relay ladder logic (RLL), flow chart, C, and Basic. The IEC 61131-3 programming environment provides support for five languages specified by the global standard: Sequential Function Chart, Function Block Diagram, Ladder Diagram, Structured Text, and Instr
9、uction List. This allows for multi-vendor compatibility and multi-language programming. SFC is a graphical language that provides coordination of program sequences, supporting alternative sequence selections and parallel sequences. FBD uses a broad function library to build complex procedures in a g
10、raphical format. Standard math and logic functions may be coordinated with customizable communication and interface functions. LD is a graphic language for discrete control and interlocking logic. It is completely compatible with FBD for discrete function control. ST is a text language used for comp
11、lex mathematical procedures and calculations less well suited to graphical languages. IL is a low-level language similar to assembly .code. It is used in relatively simple logic instructions. Relay Ladder Logic (RLL), or ladder diagrams, is the primary programming language for programmable logic con
12、trollers (PLC). Ladder logic programming is a graphical representation of the program designed to look like relay logic. Flow Chart is a graphical language that describes sequential operations in a controller sequence or application. It is used to build modular, reusable function libraries. C is a h
13、igh level programming language suited to handle the most complex computation, sequential, and data logging tasks. It is typically developed and debugged on a PC. BASIC is a high level language used to handle mathematical, sequential, data capturing and interface functions. Programmable logic control
14、lers can also be specified with a number of computer interface options, network specifications and features. PLC power options, mounting options and environmental operating conditions are all also important to consider.2. INTRODUCTIONFor simple programming the relay model of the PLC is sufficient. A
15、s more complex functions are used the more complex VonNeuman model of the PLC must be used. A VonNeuman computer processes one instruction at a time. Most computers operate this way, although they appear to be doing many things at once. Consider the computer components shown in Figure 1.Figure 1 Sim
16、plified Personal Computer ArchitectureInput is obtained from the keyboard and mouse, output is sent to the screen, and the disk and memory are used for both input and output for storage. (Note: the directions of these arrows are very important to engineers, always pay attention to indicate where inf
17、ormation is flowing.) This figure can be redrawn as in Figure 2 to clarify the role of inputs and outputs.Figure 2 An Input-Output Oriented ArchitectureIn this figure the data enters the left side through the inputs. (Note: most engineering diagrams have inputs on the left and outputs on the right.)
18、 It travels through buffering circuits before it enters the CPU. The CPU outputs data through other circuits. Memory and disks are used for storage of data that is not destined for output. If we look at a personal computer as a controller, it is controlling the user by outputting stimuli on the scre
19、en, and inputting responses from the mouse and the keyboard.A PLC is also a computer controlling a process. When fully integrated into an application the analogies become;Inputs - the keyboard is analogous to a proximity switch.Input -circuits - the serial input chip is like a 24Vdc input card.Compu
20、ter - the 686 CPU is like a PLC CPU unit.Output - circuits - a graphics card is like a triac output card.Outputs - a monitor is like a light.Storage - memory in PLC is similar to memories in personal computers.It is also possible to implement a PLC using a normal Personal Computer, although this is
21、not advisable. In the case of a PLC the inputs and outputs are designed to be more reliable and rugged for harsh production environments. 3. OPERATION SEQUENCEAll PLC have four basic stages of operations that are repeated many times per second. Initially when turned on the first time it will check i
22、ts own hardware and software for faults. If there are no problems it will copy all the input and copy their values into memory, this is called the input scan. Using only the memory copy of the inputs the ladder logic program will be solved once, this is called the logic scan. While solving the ladde
23、r logic the output values are only changed in temporary memory. When the ladder scan is done the outputs will be updated using the temporary values in memory, this is called the output scan. The PLC now restarts the process by starting a self check for faults. This process typically repeats 10 to 10
24、0 times per second as is shown in Figure 3.Figure 3 PLC Scan CycleSELF TEST - Checks to see if all cards error free, reset watch-dog timer, etc. (A watchdog timer will cause an error, and shut down the PLC if not reset within a short period of time - this would indicate that the ladder logic is not
25、being scanned normally).INPUT SCAN - Reads input values from the chips in the input cards, and copies their values to memory. This makes the PLC operation faster, and avoids cases where an input changes from the start to the end of the program (e.g., an emergency stop). There are special PLC functio
26、ns that read the inputs directly, and avoid the input tables.LOGIC SOLVE/SCAN - Based on the input table in memory, the program is executed 1 step at a time, and outputs are updated. This is the focus of the later sections.OUTPUT SCAN - The output table is copied from memory to the output chips. The
27、se chips then drive the output devices.The input and output scans often confuse the beginner, but they are important. The input scan takes a snapshot of the inputs, and solves the logic. This prevents potential problems that might occur if an input that is used in multiple places in the ladder logic
28、 program changed while half way through a ladder scans. This problem could have severe effects on complex programs that are developed later in the book. One side effect of the input scan is that if a change in input is too short in duration, it might fall between input scans and be missed.When the P
29、LC is initially turned on the normal outputs will be turned off. This does not affect the values of the inputs.4The Input and Output ScansWhen the inputs to the PLC are scanned the physical input values are copied into memory. When the outputs to a PLC are scanned they are copied from memory to the
30、physical outputs. When the ladder logic is scanned it uses the values in memory, not the actual input or output values. The primary reason for doing this is so that if a program uses an input value in multiple places, a change in the input value will not invalidate the logic. Also, if output bits we
31、re changed as each bit was changed, instead of all at once at the end of the scan the PLC would operate much slower.5 The Logic ScanLadder logic programs are modelled after relay logic. In relay logic each element in the ladder will switch as quickly as possible. But in a program elements can only b
32、e examines one at a time in a fixed sequence. Consider the ladder logic in Figure 4, the ladder logic will be interpreted left-to-right, top-to-bottom. In the figure the ladder logic scan begins at the top rung. At the end of the rung it interprets the top output first, then the output branched belo
33、w it. On the second rung it solves branches, before moving along the ladder logic rung.Figure 4 Ladder Logic Execution SequenceIt also becomes important when considering output usage. Consider Figure 5, the first line of ladder logic will examine input A and set output X to have the same value. The
34、second line will examine input B and set the output X to have the opposite value. So the value of X was only equal to A until the second line of ladder logic was scanned. Recall that during the logic scan the outputs are only changed in memory, the actual outputs are only updated when the ladder log
35、ic scan is complete. Therefore the output scan would update the real outputs based upon the second line of ladder logic, and the first line of ladder logic would be ineffective.Figure 5 A Duplicated Output Errors6. PLC STATUSThe lack of keyboard and other input-output devices is very noticeable on a
36、 PLC. On the front of the PLC there are normally limited status lights. Common lights indicate;Power on - this will be on whenever the PLC has power.Program running - this will often indicate if a program is running, or if no program is running.Fault - this will indicate when the PLC has experienced
37、 a major hardware or software problem.These lights are normally used for debugging. Limited buttons will also be provided for PLC hardware. The most common will be a run/program switch that will be switched to program when maintenance is being conducted, and back to run when in production. This swit
38、ch normally requires a key to keep unauthorized personnel from altering the PLC program or stopping execution. A PLC will almost never have an on-off switch or reset button on the front. This needs to be designed into the remainder of the system.The status of the PLC can be detected by ladder logic
39、also. It is common for programs to check to see if they are being executed for the first time, as shown in Figure 6. The first scan input will be true on the very first time the ladder logic is scanned, but false on every other scan. In this case the address for first scans in a PLC-5 is S2:1/14. Wi
40、th the logic in the example the first scan will seal on light, until clear is turned on. So the light will turn on after the PLC has been turned on, but it will turn off and stay off after clear is turned on. The first scan bit is also referred to at the first pass bit.Figure 6 A programs that check
41、s for the first scan of the PLC7. MEMORY TYPESThere are a few basic types of computer memory that are in use today.RAM (Random Access Memory) - this memory is fast, but it will lose its contents when power is lost, this is known as volatile memory. Every PLC uses this memory for the central CPU when
42、 running the PLC.ROM (Read Only Memory) - this memory is permanent and cannot be erased. It is often used for storing the operating system for the PLC.EPROM (Erasable Programmable Read Only Memory) - this is memory that can be programmed to behave like ROM, but it can be erased with ultraviolet ligh
43、t and reprogrammed.EEPROM (Electronically Erasable Programmable Read Only Memory) This memory can store programs like ROM. It can be programmed and erased using a voltage, so it is becoming more popular than EPROMs.All PLC use RAM for the CPU and ROM to store the basic operating system for the PLC.
44、When the power is on the contents of the RAM will be kept, but the issue is what happens when power to the memory is lost. Originally PLC vendors used RAM with a battery so that the memory contents would not be lost if the power was lost. This method is still in use, but is losing favor. EPROMs have
45、 also been a popular choice for programming PLC. The EPROM is programmed out of the PLC, and then placed in the PLC. When the PLC is turned on the ladder logic program on the EPROM is loaded into the PLC and run. This method can be very reliable, but the erasing and programming technique can be time
46、 consuming. EEPROM memories are a permanent part of the PLC, and programs can be stored in them like EPROM. Memory costs continue to drop, and newer types (such as flash memory) are becoming available, and these changes will continue to impact PLC.8. SOFTWARE BASED PLCThe dropping cost of personal c
47、omputers is increasing their use in control, including the replacement of PLC. Software is installed that allows the personal computer to solve ladder logic, read inputs from sensors and update outputs to actuators. These are important to mention here because they dont obey the previous timing model
48、. For example, if the computer is running a game it may slow or halt the computer. This issue and others are currently being investigated and good solutions should be expected soon.9. SUMMARY A PLC and computer are similar with inputs, outputs, memory, etc. The PLC continuously goes through a cycle
49、including a sanity check, input scan, logic scan, and output scan. While the logic is being scanned, changes in the inputs are not detected, and the outputs are not updated. PLC use RAM, and sometime EPROMs are used for permanent programs.10. PRACTICE PROBLEMS Does a PLC normally contain RAM, ROM, EPROM and/