Bài giảng Các hệ thống tin học công nghiệp - Chương 5: Programmable controllers

Ch. 5 Programmable Controllers

 PLC/PC Overview

 Siemens SIMATIC S7-x00 seri PLCs

 STEP 7 – 300/400 Programming

Language

 WinCC

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5.1. Khái niệm PLCs

 Lịch sử:

 1960 – 1970s: Hard wire

 1980 – 1990: Programmable Logic Controller

 1990 – nay: Programmable Controller,

Process Controller

 Các hãng sản xuất:

 USA: Allen Bradley, GE-Fanuc

 EC: Siemens, ABB, Schneider

 As-Au: Omron, Hitachi, Misubishi…

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 Cấu trúc: chia thành các modules:

 CPU, Power supply Module có cổng nối bộ

lập trình (PG)

[Expansion Memory Module (Flash, SRAM,

DRAM, BBRAM)]

Digital Input Module (mức áp dc/ac, cách ly

quang...)

Digital Output Module (relay, transistor,

triac..., Relay/Opto Isolated)

 Analog Input Module (u, i, cá ch ly...)

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Analog Output Module (u, i)

 Timer/ Counter Module (kHz, đếm xung, đo

tốc độ, chiều dài)

 Communication Module: (RS232/485;

Ethernet IEEE 802.x)

 2/3 D Positioner Module (định vị 2/ 3 chiều)

 Interface Module - dùng để mở rộng thêm

cá c Module khá c

 Function Modules: các chức năng điều khiển

PID, Servo/ Step Motors,...

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 Hoạt động của PLC:

 Hoạt động theo chu kỳ các vòng quét:

. Đọc các thông tin từ các lối vào: DI, AI, Counter,

Communication…

. Xử lý, tính toán, Update data base, update các cờ

trạng thái

. Gửi ra các port: DO, AO, Positioner,

Communication…

 Ngôn ngữ lập trình:

. Ladder

. Statement List

. Flow control

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5.2. Siemens SIMATIC S7-x00 PLC:

5.2.1. S7-200:

Hì nh 402.

PLC S7-200

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 Micro type, high-speed, compact, low-cost solution for

automation tasks within the low-end performance

range.

 Có nhiều loại CPU: 212 (214…)

 RAM for Program & data:

. 212 CPU: 1Kbyte – 512 statement, 2048 word data

. 214 CPU: 4Kbyte – 2048 statement, 2048 word data

 Execution time of 1024Statements: 1,3ms (212CPU) và

0.8ms (214 CPU)

 Bit memory: 128 (256)

 Counters, Timer: 46 (128)

 DI/DO max/onboard: 30/14 (64/24)

 AI/AO max: 8 (16)

 Communication: PPI

Real time clock: CPU 214.

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5.2.2. S7-300

Hì nh 403a – PLC S7-300

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 Mini PLC system, the custom solution for

extremely fast processes/ automation tasks

requiring additional data processing

capabilities

 Spec.:

 High computing performance,

 Complete instruction set,

 Multi Point Interface – MPI

 5 CPUs for a wide variety of requirement

 Expandability: up to 3 Expansion Racks (ERs)

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5.2.3. S7-400:

Hì nh 404a.

S7-400

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 Power PLC for automation tasks within

mid & upper range:

 High Speed, 1K statement – 200 us

 Rugged: full enclosed, for industrial

environment

 Module can be hot pluggible

 Communications power house:

. Connection to SINEC L2 or SINEC H1 or Point-to-

Point

. Fast data exchange to the distributed I/Os

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5.2.4. Programming Devices

Hì nh 405a.

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Hì nh 405b.

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5.2.5. Distributed IOs

Fig. 406. Distributed IO Modules

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 In conventionally automated Plants, IO are

plugged directly into PLC. Frequently this

leads to extensive wiring with

 High cabling cost

 Reduced flexibility in the case of modifications

and expansions

 A distributed configuration means:

 The PLCs, IO Modules and Field Devices are

connected over a single cable known as a field

bus,

 The IO Modules can be installed in the

immediate vicinity of sensors and actuators

 The process signals can be converted and

processed locally

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Fig. 406a. SINEC L2-DP with Distributed IO Modules

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 The following can be connected to the

ProFiBus-DP:

 Active Stations:

. S/M7 300 – 400 automation systems …as well as

from other manufacturers

. Programming devices and AT compatible PCs

. COROS Operator Panels

 Passive Stations:

. ET200M/L/B/C/U distributed IO Stations, S5 Seri

PLCs, DP/AS-I link transceiver

. MMI

. Additional field Devices as well as third party devices

with slave interface Modules…

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5.3. SIMATIC SOFTWARE

 STEP 7 Mini programming software

 STEP 7 Micro/DOS/Win programming

software

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5.3.1. Introdution

Application:

SIMATIC software are array of tools based on

standard for PLCs S7

 It provides all software functions required for:

. Configuring

. Programming

. Testing

. Starting up and

. Servicing PLCs

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Design:

 Feature:

.Comprehensive:

–Shared data management; All data of a

project are filled in a single central database.

–Comprehensive series of tools; for every

phase of an automation project there are user-

friendly functions: configuration,

parameterization of the hardware, creation

and documentation of programs, as well as

testing, startup and servicing.

–Openness: Imp/Exp interface ensure

connection with the PC world

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.User-friendly:

–Individual programming languages, Help

and doc. Functions

–Extensive set of command and detailed

information functions (Err that may occur

and their causes…)

. Standard: based on Windows OS,

satisfy the standard DIN EN 6.1131-3

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Package:

.STEP7 Micro/DOS/WIN: for programming

S7-200

.STEP7 Mini: for programming stand-alone

S7-300

.STEP7: the universal software for S7-300,

-400

.High level programming languages S7-

SCL: similar to PASCAL

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Technology-Oriented Software Package (w/o

knowledge of PLC, computer or programming):

S7 Graph: describing event driven processes w

sequential Operation.

S7 HiGraph: describing event driven processes

w non-sequential Operation.

Software for special applications:

COROS for parameterization of the MMI

SIMATIC S7 standard control system

Fuzzy control

….

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Fig 407a. STEP7 software package

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Fig 407c. PLC S7 seri software tools

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5.3.2. Micro/DOS/Win for s7-200

Configuring

Programming

Debugging

Testing

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5.3.3. S7-300/400

 Configuring

 Instruction Set

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5.3.3.1. The modules of S7-300

 CPU Modules:

 CPU, Mem/OS, Timer, Comm 485, onboard

I/O ports (Option)

 CPU Module: CPU 312, 314, 315,

CPU31x IMF (Integrated Function Module -

Onboard I/O & OS)

 2 Comm ports CPU - CPU 31x - DP

(Ditributed Port): the second for networking.

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Expanded Modules:

PS - Power Supply: 2, 5, 10 Amp

SM - Signal Module: In/Out signal modules:

. DI: Digital Input, 8, 16, 32

. DO: Digital Output, 8, 16, 32

. DI/DO 8/8 or 16/16

. AI: 12 bit ADC, 2/4/8 channel

. AO: 8/12 bit DAC, 2/4 channel

IM: Interface Modules: For expanding more

rack. Each rack for 8 modules max (Not

including CPU & PS). 1 CPU S7-300 can

connect to 4 racks max via IMs.

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FM: Function modules: PID controller, Step

motor, servo... modules.

CP: Communication Modules: to

communicate between PLCs and Computers

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5.3.3.2. DATA & MEMORY MAPPING:

Data types:

Elementary data types:

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. Bool

. Byte: 8 bit or ASCII character: L B#16#14 // load

byte 14h into Accu1

. word:

L W#16#32A

. Int: -32768 .. +32767:

. DInt: 4 byte

L DW#16#234F

. Real: Floating Point 4 byte

. S5T (S5TIME): interval (hh/mm/ss/ms) L

S5T#2h_1m_7s_13ms.

. TOD - Time of day: hh/mm/ss

L

TOD#12:34:40.

. DATE:

. CHAR: max 4 char

L

DATE#2004-12-31.

'HE_6'

L

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Complex data types

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Parameter data types

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 Memory: 3 parts

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 Application Program memory Part - 3 sections:

. OB: Organization Block

. FC: Function - Sub module with dummy parameters of main program

. FB: Function Block: Sub module with data exchange to/from other

modules. The data must be DB (data block)

 Data Area of OS and Application - 7 sub areas:

. I (Process Image Input): data input buffer for DI ports. CPU just read this

buffer, not ports

. Q (Process Image Output): data output buffer for DO ports. CPU just

writes this buffer, not ports

. M: Status/Conditional: bit (M), byte (MB), word (MW), double word (MD)

. T: Time buffer: preset/current time value and logic output.

. C: Counter: preset/current counter value and logic output.

. PI: I/O External Input Address for analog inputs: PIB, PIW, PID

. PQ: I/O External Output Address for analog outputs: PQB, PQW, PQD

 Data Blocks - 2 blocks:

. DB: data block, accessible by: DBX (bit), DBB, DBW, DBD

. L (Local data blocks) local data memory of OB, FC, FB. Accessible: L

(bit), LB, LW, LD.

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5.3.3.3. SCAN LOOP:

4 phases

Scan time not fix - tùy

nhiều hay ít lệnh

Interrupt Service block:

OB40, OB80... được thực

hiện tại bất kỳ thời điểm

nào - không cần trật tự.

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5.3.3.4. PROGRAM STRUCTURES:

Linear Programming

Structured Programming: OB

(Organization Blocks), FC (Program

Blocks), FB (Function Blocks), DB (Data

Blocks)

Số các module gọi lồng nhau: CPU 314: là

8, nếu quá thì STOP

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