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1、Standardprfplan BauteilabkndigungRobotics TrainingTraining DocumentationS o f t P L CProConOS V3.xMultiprog wt 2.xKR C ControllerResponsibility of:Felix MerzCreated:16.06.01Version:1.0Copyright:LP Elektronik GmbH jjjj-02-上午 Error! Unknown document property name.Prfspezifikation Version 2 / 1HistoryD
2、ateAuthorModifiedVersion12.06.01F. MerzCreated1.01.DEVELOPMENT OF THE SOFT PLC IN THE KRC1 CONTROLLER61.1.General61.2.Advantages of a Soft PLC62.DEFINITION OF THE KUKA KRC1 WITH INTEGRATED SOFT PLC FEATURING PROCESS VISUALIZATION AND DIAGNOSTICS72.1.Runtime characteristics in respect of operating sy
3、stem and hardware82.2.Programming interface of the Soft PLC according to IEC 1131-392.3.The standard IEC 1131102.4.Objectives and benefits of the standard102.5.Manufacturers102.6.Users102.7.Components of IEC 1131113.PLCOPEN123.1.Certification123.2.Exchange format for application programs133.3.Intern
4、et address for PLCopen134.INTRODUCTION TO IEC 1131-3134.1.Structure of blocks134.1.1.Declaration of variables134.2.Instruction section of a POU144.3.The program organization unit POU154.4.Structure of a POU164.4.1.The declaration section164.4.2.The instruction section185.VARIABLES AND DATA TYPES195.
5、1.Symbolic variables and PLC addresses195.2.Data types205.3.Type check for variables205.4.Elementary data types215.4.1.Derived data types226.INSTALLATION OF THE RUNTIME SYSTEM237.THE PROCONOS TASK MODEL237.1.User tasks237.1.1.DEFAULT task237.1.2.Cyclic tasks237.1.3.Event tasks247.1.4.System tasks247
6、.1.5.Tasks and watchdogs267.2.Tasks and programs268.PROGRAMMING EXAMPLE 1: CYCLE COUNTER288.1.Program requirement:288.2.The program section289.PROGRAMMING EXAMPLE 2: ACTIVATION OF 2 LAMPS BY MEANS OF LOGIC OPERATIONS ON SWITCHES IN LD389.1.Program requirements389.2.The program section3810.FUNCTIONS
7、AND FUNCTION BLOCKS4410.1.General4410.1.1.Functions4410.1.2.Function blocks4411.PROGRAMMING EXAMPLE 3: FUNCTION AND FUNCTION BLOCK4511.1.Program requirements4511.1.1.Function4511.1.2.Function block4511.2.The program section4511.2.1.Function4511.2.2.Function block4712.LIBRARIES4912.1.Firmware librari
8、es4912.1.1.Installation4912.1.2.Integration of firmware libraries in Multiprog5012.2.User libraries5013.STEP SEQUENCE PROGRAMMING USING SFC5213.1.Introduction to SFC5213.2.Qualifiers for actions5214.PROGRAMMING EXAMPLE 4: STEP SEQUENCE PROGRAMMING5414.1.Program requirements5414.2.The program section
9、5415.PROGRAMMING EXAMPLE 5: USER-DEFINED DATA TYPES5915.1.Program requirements5915.2.Creating the user-defined data type5915.3.The program section6116.PROGRAMMING EXAMPLE 6: CONTROLLING THE AUTOMATIC EXTERNAL INTERFACE USING THE INTEGRATED SOFT PLC6216.1.Program requirements:6216.2.Adaptations in th
10、e KRC16216.3.The program section6317.WATCH WINDOW6918.PROCONOS SYSTEM INFORMATION7018.1.System flags7018.2.User task information7119.PROGRAMMING EXAMPLE 7: PROCONOS SYSTEM INFORMATION7219.1.Program requirements7219.2.The program section7220.LOGIC ANALYZER (IN MULTIPROG V2.1)7620.1.General7621.PROGRA
11、MMING EXAMPLE 8: LOGIC ANALYZER7621.1.Program requirements7621.2.The program section7622.REMANENT VARIABLES IN PROCONOS7922.1.General7922.2.ProConOS retain data on the KR C17922.3.Extending the retain data area7923.PROCONOS GATEWAY8223.1.General8223.2.Physical location of the ProConOS Gateway8223.3.
12、Configuration example with ProConOS Gateway8323.4.Starting ProConOS Gateway8323.5.User authorization in ProConOS Gateway8424.THE PROCONOS OPC SERVER8724.1.Installation8724.1.1.System requirements8724.1.2.Setup of the OPC Server8724.2.Starting the OPC Server8924.3.Automatic updating of the current pr
13、oject891. Development of the Soft PLC in the KRC1 controller1.1. GeneralRobotic automation tasks have to date been implemented by means of a Submit Interpreter SINT integrated in the KRC1. As the proportion of additional control tasks to be performed by the robot is constantly increasing, however, a
14、nd the Submit Interpreter is not designed for tasks of greater complexity, KUKA has decided to solve control tasks with the aid of an integrated PLC.1.2. Advantages of a Soft PLCThe following components and advantages are offered by the Soft PLC: Only very low costs for additional PLC hardware Parti
15、al utilization of the processor capacity additional processor with another operating system and interfaces is not necessary Easing the load on the robot controller Fast instruction execution 1 KB of instructions in approximately 20 ms Programming in accordance with the international standard IEC 113
16、1-3 Visualization elements Test and simulation of application programs off-line Good on-line functionalities Monitoring of all variables Overwriting and forcing of variables Debugging of the complete project (breakpoints, stepping, single cycle, call stack) Power flow Exchange of program blocks with
17、out any interruption Recording and graphic representation of project variables (trace function) Library management for custom libraries Import capability for S5 programs Easy interfacing to existing hardware via field buses (Interbus-S, Profibus-DP, etc.) Open interfaces with other systems (e.g. vis
18、ualization via OPC)2. Definition of the KUKA KRC1 with integrated Soft PLC featuring process visualization and diagnostics CALL-P Interface FIELD BUS CARD FIELD BUSKR C1 Robot Controller Windows 95 VxWorks BOF BASE SYSTEM CROSS Robot Task PLC Task TCP/IP TCP/IP TCP/IP Shared Memory Shared Memory Sha
19、red Memory2.1. Runtime characteristics in respect of operating system and hardwareThe basis for the following requirements is the functionality of a conventional standard PLC. The performance of the PC-based PLC must fulfil all functionalities regarding runtime characteristics, reliability and fault
20、 tolerance in respect of the real-time operating system that is used. The programming interface implemented must equally be flexible in terms of cross-compilability and simple on-line functionality. Execution of the cyclic task. Refresh rate of the process I/O image less than or equal to 20 ms. Prog
21、ram cycle time less than or equal to 20 ms. Behavior on KRC cold restart: after the kernel system has started, the PLC boot project is started after a delay (warm restart), the retain data are loaded and the cyclic PLC program is executed. Behavior on PLC cold restart: execution of the cyclic progra
22、m is started immediately. Behavior on PLC warm restart: the retain data are loaded, execution of the cyclic program is started immediately. Behavior on PLC hot restart: the states and the value of all variables are retained. Behavior on PLC stop: execution of the cyclic program is stopped. The set o
23、utputs are reset (value = 0) and the retain data are saved. Watchdog for cycle time violation (no acknowledgement NAK): error display, no system stop. On-line changes in the PLC must be possible. Software without hardware dongles. Several resources must be possible for each project. PLC specially in
24、tegrated into the robot: Crash of the robot task must not affect the PLC task Automatic saving of remanent variables independently of the GUI Use of the cyclic task must not affect the visualization Data exchange between both tasks also via I/O level Possibility of visualization on the KCP Implement
25、ation of a visualization tool (e.g. GraphPic) Possibility of a parallel visualization, e.g. Beckhoff panel2.2. Programming interface of the Soft PLC according to IEC 1131-3LanguageExplanationCross-compilabilityLDKOPLadder diagramLD FBD = ILFBDFBSFunction block diagramFBD ILILAWLInstruction listIL LD
26、SFCASSequential function chartSTSTStructured textST IL = FBD Recompilability out of the PLC, including the entire project documentation. Import/export of IEC 1131 programs Export to ASCII file Programming interface as component part of the runtime license Cross-compilability of the programming langu
27、ages Graphic programs can be mixed within a POU Cross-reference list (functionality corresponding to Simatic-S5) Manual and automatic rewiring (functionality corresponding to Simatic-S5)KUKA-internal programming rules must be supported with regard to: Simple specification of standard formats Read pr
28、otection of blocks with KUKA know-how (library functions) Operator guidance for error recovery Sequence diagnosis Unity of controller and visualization modules2.3. The standard IEC 1131The five-part standard comprises definitions of the requirements to be met by modern PLC systems. The requirements
29、concern the PLC hardware and the programming system. The standard encompasses both common concepts of present PLC programming and new programming methods.The standard was drawn up by the working group SC65B WG7 (initially: SC65A WG6) of the international standardization body IEC (International Elect
30、rotechnical Commission), which is composed of representatives of various PLC manufacturers, software companies and users. This has the advantage that the standard is accepted as a guideline by most PLC manufacturers.2.4. Objectives and benefits of the standardThe continually increasing complexity of
31、 PLC systems results in rising costs for: the training of applications programmers the creation of programs that are constantly becoming larger the implementation of ever more complex programming systemsThe PLC programming systems follow, with a time lag, this trend of the mass software market of th
32、e PC world. As in this sector, the pressure on costs can be alleviated above all by means of standardization and synergies. Both manufacturers and users profit from IEC 1131 on account of the extensive harmonization of the previously highly manufacturer-specific systems.2.5. ManufacturersA group of
33、manufacturers can invest jointly in the software costing many million deutschmarks to develop with the functionality demanded by the market nowadays.The fundamental character of a programming system is defined by the standard to a large extent. Basic software can be used jointly, with the exception
34、of specific elements such as code generators or on-line modules. Market differentiation results from so-called supplementary modules added to the basic package, which are required in specific market segments, and from the PLC hardware.2.6. UsersUsers often work with PLC systems of various manufactur
35、ers at the same time. Whereas personnel have hitherto had to attend several programming courses, IEC 1131-3 systems only require training in operation of the individual programming systems and additional special features of the PLCs. It is therefore possible to save on system specialists and trainin
36、g personnel; PLC programmers can be deployed with greater flexibility.The definition of requirements in the standard facilitates the selection of suitable programming systems, since it has become easier for them to be compared.Even if in the short term it will still not be possible for complete appl
37、ication programs to be exchanged between different PLC systems, the language elements and program structure are nevertheless the same in the various IEC systems. This enhances portability to other systems.2.7. Components of IEC 1131The standard IEC 1131 constitutes a summary and updating of various
38、standards. It refers to 10 international standards: IEC 50 IEC 559 IEC 617-13 IEC 848 ISO/AFNOR ISO/IEC 646 ISO 8601 ISO 7185 ISO 7498It contains rules on the character code to be used, definitions of the nomenclature or the structure of graphic representations.A number of attempts at establishing a
39、 standard for PLC programming technology have already been undertaken in the past. IEC 1131 is the first standard to find international (and industrial) acceptance.The standard comprises a total of five parts with the following subdivision:IEC 11311: General informationPart 1 contains general defini
40、tions and typical functional characteristics that distinguish a PLC from other systems. This includes standard features, such as the cyclic execution of the application program with the stored image of the input and output values or the division of tasks between the programming, automation, and oper
41、ator control and monitoring functions.IEC 1131-2: Equipment requirements and testsThis part defines the electrical, mechanical and functional requirements to be met by the equipment and also corresponding type tests. The environmental conditions (temperature, air humidity, etc.) and stress classes o
42、f the controllers and programming units are specified.IEC 1131-3: Programming languagesPart 3 contains a harmonized and forward-looking revision of the PLC programming languages in use throughout the world. IL (Instruction List) LD (Ladder Diagram) FBD (Function Block Diagram) SFC (Sequential Functi
43、on Chart) ST (Structured Text)IEC 1131-4: User guidelinesThe fourth part is designed as a guideline providing the PLC user with advice in all phases of an automation project. The practically oriented tips and information extend from systems analysis via equipment selection up to maintenance.IEC 1131
44、-5: Communication (in preparation at IEC)This part deals with the communication of PLCs of different manufacturers with each other and with other devices.3. PLCopen3.1. CertificationPLCopen was established in 1992 and is an international association independent of any particular manufacturers or pro
45、ducts. Its members include many PLC manufacturers, software companies and independent institutes in Europe and overseas. The object of PLCopen is to promote the development and use of compatible PLC software. The certification tests are intended to demonstrate the conformity of programming systems t
46、hat have been implemented in accordance with IEC 1131-3. For this purpose, a list of requirements has been drawn up that have to be met by a PLC programming system in order to qualify for the PLCopen certificate Conformity with IEC 1131-3. This test is conducted by independent institutes with the aid of test programs and checks.Each of the programming languages in IEC 1