Services of GEM4Tools SECS PLC

GEM4Tools comprises a starter application, which gives a fundamental graphical user interface that realizes all GEM-required user interactions; you can begin GEM communications, upload/download recipes, set host control, and so on. On the other hand, you can set in GEM capabilities effortlessly into your system using a flexible and straightforward API that runs in any environment of COM-enabled. To expand your equipment’s capabilities ahead of the GEM standard, you can also utilize the API to write custom services as required. And established for more than a decade.

GEM4Tools is a steady and production established appliance in the field for more than a decade and established on over 500 tool examples. Whether your equipment is employed for batch processing or single substrate, back-end processes, or metrology, GEM4Tools brings the functionality you require, consistently and efficiently.

Architecture
GEM4Tools is developed on three main components, which make simpler design and implementation, reduce maintenance overhead, and improve reliability.

Communication driver of SECS
The communication driver of SECS gives the interface of equipment-to-host, automatically managing all SECS-II host communications and messages required by the services of GEM. GEM4Tools supports both the HSMS and SECS-I standards, for TCP/IP Ethernet® or RS-232 serial connectivity to the plant MES.

Services of GEM4Tools SECS
The services of SECS communicate with the OPC server equipment and handle all logic and messaging as identified by the standard of GEM. Every service communicates to a GEM capability, and realizes all scenarios identified for that capability. If your tools has functionality that exceed the standard of GEM, you can utilize the GEM4Tools API to make your own custom services, in any language of COM-enabled (Component Object Model), including .NET.

The database of GEM4Tools saves all configuration of GEM and runtime information for the services of SECS. It allows you easily and quickly characterize your tools define the status variables, collection events, alarms, and equipment stables it supports. You can allow GEM capabilities, modify your HSMS or SECS-I communication parameters at any time, and modify your characterization of equipment, simply by update the database.

Select which protocol the tools will use to correspond with the host of SECS-I or HSMS, and configure needed settings. Choose the capabilities of GEM you want to realize immediately. Allow only the services you require, with the freedom to allow others whenever they’re required. Characterize your tools by charting the OPC Items accessible in your equipment’s OPC Server with the suitable SECS-II data items, involving status variables, alarms, collection events, and equipment constants. GEM4Tools handles all SECS-II messaging automatically once you construct the required data items.

PLC Controls Systems in Industrial Sector

People today may not realize the importance of PLC controls systems that make everything runs smoother, easier, and faster. The PLC system is basically the automatic computer program that makes machinery runs automatically. When industry uses this kind of program, they only need to do checking once in a while, without having to monitor everything all the time. Thanks to the PLC system, it’s possible to have such vast and fast industrial development and economical increase because it’s possible to have large mass scale production. Because of PLC system, the industrial sector can also benefit a lot from the application.

PLC Controls Systems and Industrial Control System
In industry, there’re many control systems incorporated inside it. Everything is set up and designed to produce the required result and product. Inside industrial control system, there will be SCADA system or Supervisory Control and Data Acquisition, DCS system or distributed Control Systems, and also PLC system or Programmable Logic Controller. They’re all important for industrial work and vita infrastructure. The industrial control system is often used in gas, water, and electrical data. The basic mechanism is like this: remote stations or field devices will send out information, and then automatic supervisory command drive will respond and send control commands to the remote stations. The command include closing or opening breakers and valves, collecting information and data from sensory systems, and checking and monitoring local condition for any alarm waning, such as natural disasters or other possible threats.

PLC Controls Systems Installation and Usage
PLC system can be used by individuals or companies. But since the PLC system is very complicated and difficult, it’s important to install and operate everything correctly ad properly. This installation can’t be done by regular people. It needs to be done by the experts, or everything can fall apart easily. PLC experts are the one who have dealt with the PLC operation for years, not only someone who just finish his PLC course. In big companies, they like to hire PLC experts to deal with the system maintenance and care because immediate actions can be taken right away if something is wrong. That’s why in industrial control system, there’re so many experts working on the different departments and controls.

Industrial world depend so much on the different control systems to make everything work properly and efficiently. Without the development in industrial sector, development in economy and technology is impossible to reach. That’s why people need to realize the importance of PLC controls systems and never take it for granted.

PLC based Control Design

There are some key issues in the PLC design according to the control systems that have to be addressed. The PLC design based control system is distinguished by long development and uncertainty time. Improbability comes out from the huge value of specific requirements, for example hazard analysis requirements, quality of software, and the hardware specifications obliged from the system of mechanical to be controlled. More than 50% of the operator assigned for the design of control system is scheduled for debugging and testing in order to cope with uncertainty. The long design lead-time is an effect of a severity sequential of process design in industrial practice, in case system developers do concern a methodology of system at all. In many cases the mechanical manufacturing design or transport system and the control system are surpassed on to different subcontractors with no or less communication.

A main problem, pushing the need for a methodology of systematic design, is the rising software difficulty in major projects alongside with the enduringly rising part of software life-cycle cost. An ordinary application of PLC has frequently to handle complicated systems with over 10,000 control nodes. 80-90% of the costs are going into software debugging, maintenance, expansion, and adaptation to meet changing customer requirements in industrial automation. The improved demand for re-configurability of manufacturing systems in fast response-markets forces an additional requirement on control systems. The increasing speed of changes in the manufacturing systems needs frequent adjustments of control programs. A main challenge is consequently to supply enabling technologies that can cost-effectively reconfigure control systems of manufacturing in reaction to changing new opportunities and needs.

Therefore, the requirement to struggle for higher quality of software, to manage with enlarged complexity, and to allow the economical and quick manufacturing control reconfiguration systems need advanced recent organize technologies, simultaneous design concepts, and design tools and new modeling of computer-aided. This article describes a design approach to plan PLC based control systems in order to lessen the reservations in managing the development of control software, rising the systems flexibility, and facilitating the simulation technology use for systems validation. The design advance comprises formal top-down modeling methods that are well known in control research real-time, but less known in industrial practice. A moved ahead methodology of design also implies incorporated the control system and the manufacturing system modeling. The manufacturing system modeling facilitates off-line testing and the control system simulation and should not cause extra cost although it may further require design time.

CANopen Fieldbus Topology TWIDO PLC

Firstly built up for the borne systems of automotive vehicle, the CAN communication bus is currently applied in a lot of areas, such as:
• building,
• industrial control,
• transport,
• devices of moving part,
• devices of medical.

The benefits of the system of CAN are:
• the allocation system of bus,
• reliability of data exchange,
• error detection.

Structure of master/slave
The bus of CAN has a structure of master/slave for bus management. The master controls
• communication errors,
• slave initialization,
• status of slave.

Communication of peer to peer
Communications on the bus are created peer to peer; at any time, every device can propel a request on the bus and the relevant devices respond. The requests circulating priority on the bus is decided by an identifier at each message level.

CAN identifiers
Open switches of CAN PDOs at link level utilize extensive identifiers more than 29 bits for CAN standard V2.0B. CAN standard V2.0A with 11 bit identifiers can only be applied for transmitting and receiving.

CANopen Fieldbus Topology
The architecture of CANopen a Twido system contains of:
• a compact base or modular base of Twido PLC,
• a master module of CANopen fieldbus or TWDNCO1M module installed on the expansion bus2 of Twido PLC’s,
• slave devices3,4 of CANopen.

NOTE:
1. The master module of TWDNCO1M CANopen is carried by the Twido base controllers.
2. Only single master module of TWDNCO1M CANopen can be installed on expansion bus of the Twido system.
3. The master module of TWDNCO1M CANopen can handle up to 16 CAN slave devices on a bus segment.
4. The CANopen fieldbus of TWDNCO1M does not support extensive addressing for slave devices of CAN.
The master of TWDNCO1M CANopen enables up to 16 devices of slave in the bus. The speed of transmission depends severely on the type of cable and the length of bus used. Baud Rate versus Cable Length will describes the relationship between the maximum transmission speed and the bus length (on a single CAN segment without repeater).

Cable Type and Impedance versus Baud Rate and Cable Length
The below table explains the correlation between the maximum speed of transmission for a given bus length in relative to the cable type used, cable gauge and impedance.
Maximum baud rate of transmission .......... Bus length
500 Kbit/s............................................. 100 m
250 Kbit/s............................................. 250 m
125 Kbit/s............................................. 500 m

PLC Diagnostic Software for PLC System Care

When people want to have reliable and long lasting PLC system, they need to have all the required software, including the PLC diagnostic software. Without it, it’s impossible for the system to work well because users won’t know when something happens or when malfunction occurs. If they have been warned of the possible issues, they can take preventive actions to deal with the problems.

PLC Diagnostic Software: Its Main Importance
When people want to be sure that their system is working well and there’s no problem at all, they should install PLC diagnostic software within their PLC computer system. The diagnostic application will provide warning alarm in case something happens within the system. The diagnostic system basically has three main important functions: to track and check if something is wrong, to locate the faults and isolate the faults, and to solve the problems. If people don’t have any diagnostic system within their PLC computers, they may not know if there’s something wrong with it, until it’s too late.

The Vital Role of PLC Diagnostic Software in PLC System
PLC or Programmable Logic Controller is the one responsible for machineries automation. Without this PLC system, it’s impossible to have automatic machineries and system. Without any PLC system, it’s impossible for industry to have large mass production which can lead to economical development. Although people often take this system for granted, they need to realize that without this system, everything in industrial and economical sector will run very slowly and manually. However, this handy system has complicated internal parts and elements, which requires very skilled and handy PLC system to set up and operate the system. That’s why it’s necessary to have reliable PLC diagnostic software that can flare up warning alarm whenever something is wrong. Even is the problem isn’t serious, it never hurts to be precautious.

It’s true that most of the PLC applications and software are usually used in heavy weight industrial field. But thanks to the development of technology, the application of PLC system has spread out quickly. Now, almost every mechanical operation and system are using PLC technology to make them run well. The use of PLC system has reached automotive industry and even entertainment and show biz industry. That’s why it’s important to have the diagnostic software and applications at hands because they’ll be the ones finding out faults and inform the users about it. Without good PLC diagnostic software, forget having reliable and safe PLC system.

PLC-Based Equipment Controllers of GEM4Tools SECS/GEM

GEM4Tools offers the equipment controllers of HMI/PLC-based comprehensive the of SECS/GEM that will convince the semiconductor requirements, LED, solar, or the manufacturing facility of MES. You can incorporate GEM4Tools to your OPC server of equipment controller’s in a substance of days.
• Controls the popular OPC standard for easy and fast integration.
• Can be applied in the control solution of equipment, or any software package of HMI/SCADA that backing OPC.
• Furthermost capabilities of GEM are accessible out-of-the box. They are simply implemented with the configuration of straight-forward and without coding.
• A simple, powerful API creates it simple to enlarge GEM4Tools to contain any requirements ahead of the standard of GEM.
• GEM4Tools realizes the basic communications of SECS/GEM and control as well as more moved forward alarm reporting, recipe management, and data collection.

Getting the most from the standard of OPC
GEM4Tools was specially built up for PLC/HMI --based equipment controllers, by using the standard of OPC as its basis. OPC is the choice interface for many factory automation/process and OEMs control solution providers, worldwide, which indicates your solution will respite on an established standard and best practices. GEM4Tools runs with any DA 2.0 of OPC server compliant, whether you have built up your own, or are using one of the many packages of HMI/SCADA available, such as:
• National Instruments of Labview
• iFix or Cimplicity of GE
• Intouch (Wonderware)
• SIMATIC WinCC (Siemens)
• RSView32 or FactoryTalk View (Rockwell)

Characteristically, the applications of SECS and GEM suppliers have an interface of proprietary that have to be used to make GEM capabilities into the control software of equipment. Incorporation time can acquire months, and needs a broad background in the standards of SEMI. GEM4Tools needs no coding or the standards detailed knowledge to realize any capability of GEM. As an OPC client, it basically needs to be constructed to communicate with your OPC server of equipment controller’s.

The Specification of OPC is a non-proprietary technical specification that identifies a standard interfaces set based upon the technology of Microsoft’s OLE/COM. The OPC standard interface application makes probable interoperability between the applications of automation/control, business/office applications and field systems/devices. Conventionally, every software or the developer of application was required to write down a custom interface, or server/driver, to swap over the data with the field devices of hardware. OPC decreases this requirement, by significant of high performance interface a common, that allows this work to be done once, and then simply reused by SCADA, HMI, custom applications and Control.

The AS-Interface Bus for TWIDO PLC

The bus of AS-Interface (Actuator-Sensor-Interface) is a field bus, level 0, and can be applied to connect actuators or sensors. This lets "discrete" or information of analog type to work between the device of sensor/actuator type slave and bus master. AS-Interface is built up of three main essential elements:
• A master of bus,
• A specific contribute providing a 30 VDC voltage,
• One or more devices slave such as sensors, actuators and others.
These components are interrelated by dedicated a two-wire cable to power supply and data transmission.

The Sensors and Actuators major types
Type of sensor describes as following:
1. Sensors and actuators, well-matched with AS-Interface: Thanks to the incorporated feature of AS-Interface, they join directly to the bus of AS-Interface via a connection or T a passive dispatcher.
2. Traditional sensors and actuators, not compatible with AS-Interface: They join to the bus through an interface of AS-Interface (active dispatcher). These interfaces join the traditional actuators and sensors to the bus of AS-Interface and supply them with dialog capacity on the bus.

The AS-Interface V2 Bus Major Specifications
AS-Interface is a system in which switch over management is guaranteed by a single master which, by the bus scanning, calls each sensed slave in succession and awaits a reaction. The master is controlling the parameters, inputs/outputs, and identity each slave codes, as well as their addressing. The frame of serial communications carries for slaves with AS-Interface V2 typical addressing:
• 4 bits data (D0 to D3), which are the inputs or outputs image according to the interface type,
• 4 bits parameter (P0 to P3), which are applied to set the interface operating modes.

The frame of communication series for slaves with extensive addressing settings:
• 4 bits data (D0 to D3), which are the inputs or outputs image according to the interface type,
• 3 bits parameter (P0 to P2), which are applied to set the interface operating modes.

All devices which are used to set the interface of operating modes slave linked to the bus of AS-Interface are recognized by at least one ID code and one I/O Code which completes the slave functional identification. Some slaves have a code of ID1 and ID2, which describe the slave internal functions: on analog slaves, for instance, ID2 demonstrates the slave's analog channel number. The outputs are positioned and input devices of AS-Interface are sent back in the slave's response in the master request of AS-Interface.

PLC Controls Systems: Different Machines and Types

Everyone knows that industry relies so much on PLC controls systems because the systems make the automation process possible. Can anyone imagine how it will be when the machines have to be operated manually? How many human labors are needed and how many hours spent for the monitoring and working process? Not to mention that large scale productions will be difficult to achieve since everything has to be done manually. That’s why PLC systems are very important for the industrial development and operation.

PLC Controls Systems: Industrial Control System
PLC system is very important and mostly used in industrial world, although some of them are also used in entertainment industry and others. The main application of the PLC system, however, still focuses on industry. That’s why there’re lots of automatic machines with PLC based designed and created. There’re also many service companies providing their service in setting up and maintaining the PLC system. When it comes to industrial control system, the service companies will provide the following services:
• designing, manufacturing, and installing the industrial controls system
• integrating the system with other machineries or elements
• programming and supporting HMI options
• programming PLC system and also control panel system
• programming the PLC service
• maintaining and taking care of the PLC system
Those kinds of services can be applied for all kinds if industries, starting from process industry and packaging line to pharmaceutical production and automatic projects.

Different Types of Industrial PLC Controls System Machines
Although there’re many types of industrial PLC control system, their main principle is the same: to make automation process possible and to provide easiness and flexibility for better operation. Since most PLC systems are used in harsh environmental, people need solid and sturdy device that won’t easily break down due to shake or bump. That’s why PLC machines are designed. They may look like regular computers but they’re sturdier and stronger. Knowing that PLC machines will be used and installed in harsh condition, the makers design the machines to be resistant to all kinds of bump, shock, shake, liquid, and temperature. There’re several popular PLC machines, such as: FX3U from Mitsubishi, System Q, or Micro PLC SIMATIC S7-200. Of course, people can always use other machines, if they want to. But remember to use the special designed PLC machines.

It doesn’t matter what kind of PLC machines people use, as long as they understand their needs and they can find the machines that suit their needs best. Choosing good and reliable industrial PLC controls systems is a good long term investment.

Zone Triggering of PLC for Powder Automation

The efficiency Improvement of a powder coating line is very important. Those manufacturing taking the time to examine and execute new tools and concepts of automation will discover their products being produced with a better looking finish while recognizing improved performance in finishing line of operation costs. A lot of users of powder apparatus have taken the time to assess recovery booth technology, new spray gun, and automation. Those that have spent in these items take in many advantages like decreased material usage got better film control, lesser operating costs and extensive equipment life.

Another solution to improve efficiency is to operate automation. Automation comprises the utilize of a programmable logic controller (or PLC) to operate gun positioning, airflow controls, gun controls, and other system variables. The PLC’s is more accepted with many users of new powder systems and powder paint. But a great portion of the industry is not applying automated controls to advance upon their systems efficiency. There is existent value in having the value of powder guns moving out and in or powder guns turn off and on. A lot of users don’t recognize these benefits and choose to disregard them.

Zone triggering submits to triggering the guns according to the part profile. A characteristic application applies photo sensors to examine the product as it comes in the booth of powder-coating. The information of photo sensor is saved in the PLC and makes a product digital “image”. This information is saved in a register of logical shift and transferred through the memory of PLC in sync with the conveyor move. An encoder placed to the conveyor is utilized to supply movement of conveyor information. As the product advances the guns of powder coating, the data in the PLC move register is examined. Every gun can be independently triggered depend on its nearness to the product. The gun is activated on when the product achieves a preset space to the gun.

This space can be negative or positive and is in relative to the product leading edge. The gun is activated off when the product straggling edge accomplishes another preset distance to the gun. By adapting these distances of Lag and Lead, the request can be optimized to get better move efficiency and deposition of powder. The sensors of photo characteristically stand for the Zones. If a booth has 5 photo sensors, made them vertically, it is assumed to have five zones. The gun will only activate when the product has gone through the particular zone by allocating active zones to every gun. This enables only the guns required for a particular product to be activated, which again gets better transfer efficiency.

Twido Programmable Controller

Twido TWD LCAp 40DRF TWD and LCpA ppDRF compact programmable base controllers include:
1. Two hinged block of connection terminal involves for contact to the terminals.
2. An access door of hinged.
3. A serial port connector of the type of RS 485 mini-DIN (permitting the programming terminal connection).
4. A slot for the display module of digital maintenance/diagnostic TWD XCP ODC.
5. A terminal block screw for connection of the input sensors for c 24 V supply to the sensors. and
6. A I/O expansion modules connector of TWD Dpp, NOI 10M3, and TWD App (maximum of 7 modules on 40 I/O base controllers and 4 modules on 24 I/O base controllers).
- A block showing display:
- The controller status such as STAT, PWR, RUN, and ERR,
- The inputs and outputs called as INp and OUTp.
7. A terminal block of screw for the output pre-actuators connection.
8. Two adjustment points of analogue (a tip for models of 16 and 10 I/O).
9. A connector of extension for the adding of a 2nd serial port of RS 485 or RS 232C using TWD NAC ppp adapter.
10. A terminal block of screw for link of the AC 19.2...30 V power supply or 100...240 V.
11. A connector for:
• Cartridge of real-time clock TWD XCP RTC or cartridge of TWD XCP MFK32 memory for TWD LCpA ppDRF base controllers,
• Incorporated clock of real-time TWD XCP RTC and Cartridge of memory TWD XCP MFK64 for base controllers of TWD LCAp 40DRF.
12. The connector of RJ45 for connection to the network of Ethernet, only on TWD LCAE 40DRF base controller. Modular base controllers are placed on a symmetrical 5 rail. Fixing equipment TWD XMT5 lets panel or plate mounting (2 x Ø 4.3 holes).

Compact base controllers characteristics
• Operation Temperature: 0…+ 55°C. Storage: - 25…+ 70°C
• Relative humidity: 30 to 95 %, without condensation
• Protection degree: 20 IP
• Storage: 0…3000 m
• Operation Altitude: 0…2000 m
• Resistance of Vibration: placed on 5 rail 10… 57 Hz, acceleration 57…150 Hz 2 9.8 m/s (1 gn), amplitude 0.075 mm
• Shock resistance: 147 m/s (15gn) for 11 milliseconds
• Panel or plate placed: 39.2 m/s2 (4 gn)
• Backup battery Data Internal RAM: counters, shift registers, internal words and bits, internal variables, timers,...
• Approximately Operating time: 30 days at 25°C
• Battery type: not interchangeable Lithium battery
• Approximately Charging time 15 h to charge from 0...90% of the full charge

Choosing the Right PLC Diagnostic Tools

If people want to be sure that their PLC system works well, they need to have reliable PLC diagnostic tools that will help them check on everything. When they have reliable tools at hand, they can always monitor the overall operation and they can find out problems immediately so they can come up with the solutions right away. Without the right tools, they won’t be able to maintain everything perfectly.

What Are PLC Diagnostic Tools?
As the name suggest, the diagnostic tools are the tools that can monitor the overall operation of a system. When something wrong happens, the tools will immediately “pick up’ the signs and inform the users about the issues. By doing so, users can find out what’s wrong with the system, what causes it, and the right solution to deal with it. Some diagnostics tools are provided for free through the internet, but people need to be thorough about it because not all tools can be used just like that. Some of them are invented in package, which means that they need to be used with the required programs. If the programs are different, the tools can’t work well. Some of the tools are available in separated entity but they may require certain configurations or systems. Finding the perfect and suitable diagnostic tools can be difficult, but if people know what to do and what to expect, they can always find it easily.

Paid or Free PLC Diagnostic Tools?
As it’s mentioned before, some diagnostic tools are available for free; while others are available within packages. Most people will get complete package of PLC systems and tools when they buy the PLC machines. It’s like when people buy a new computer and they get the free software, the same thing is also applied to PLC machines and tools. If they don’t want to go through all the hassles and complicated procedure, they should buy the PLC machines that will go along with the suitable PLC diagnostic tools. But if they have deep and vast skills in computer and programming, and they know what to do, they can always find the free diagnostic tools.

In short, when it comes to the right and reliable diagnostic tools, people need to think about it carefully and thoroughly. If they have very little understanding about the PLC system, it’s better to play it safe. They can also hire PLC experts that can help them designing and maintaining their system. But if they are more skilled and experienced, they can choose whatever PLC diagnostic tools they like.

Twido PLC Protocols

Twido PLC bases have one, or a second optional, serial port that is applied for real-time or services of system management. Four communications types can be applied with Twido controllers:
• Connection of AS-Interface bus
• Connection of CANopen fieldbus
• Connection of Ethernet Network
• Connection of Modem
The services of real-time offer the functions of data distribution for exchanging data with I/O devices and functions of messaging for communicating to external devices. The services of system management configure and manage the base throughout TwidoSuite. Moreover serial port is applied for any services but just serial port 1 is communicating with TwidoSuite. There are three protocols existing on every base, to provide these services:
• Modbus
• ASCII
• Remote Link

Additionally, the compact of TWDLC•sE40DRF bases attribute a fixed communications port of Ethernet RJ45 allow all the communications of real-time and system management tasks through the network. Ethernet communications realizes the following protocol:

AS-Interface Connection
The bus of AS-Interface is a level 0field bus, and can be applied to connect actuators/sensors. This enables discrete or type information of analog to operate between the master bus devices and type slave of sensor/actuator. AS-Interface is built up of three main basic elements:
• one or more slave devices such as sensors, actuators and others,
• a specific supply supplying a 30 VDC voltage,
• a master of bus.
These parts are interrelated by a two-wire cable dedicated to power supply and data transmission.

CANopen Fieldbus Connection
The architecture of CAN open a Twido system contains of:
• a Twido PLC 1,
• a master module of CANopen fieldbus installed on the expansion of Twido PLC’s bus2,
• CANopen slave of devices3,4.

NOTE:
1. The master module of TWDNCO1M CANopen is carried by the Twido base controllers as following:
• Compact bases: series of TWDLC-40DRF and TWDLC-A24DRF
• All bases of modular: series of TWDLMDA40- and TWDLMDA20-
2. Only 1 master module of TWDNCO1M CANopen can be installed on the expansion bus of Twido system.
3. The master module of TWDNCO1M CANopen can handle up to 16 devices of CAN slave on a single bus segment.
4. The fieldbus of TWDNCO1M CANopen does not support extensive addressing for devices of CANopen slave.
5. The bus baud rate depends on the bus length and the type of cable used. .

Ethernet Network Connection
Even though direct cable connection that is using an Ethernet crossover cable, is supported between the Twido TWDLCDE40DRF or TWDLCAE40DRF and the PC running of TwidoSuite programming software, it does not recommend it. Hence, you should always support a connection through an Ethernet network of hub/switch.

PLC based on SC1x3-IEC and SC23-IEC

This application note provides a description how to make a programmable logic controller based on the programming system of CoDeSys and the IPC@CHIP®. Thus functionality, specifications and usage is explained. A programmable logic controller is a device designed for industrial processes automation. Characteristic examples for concerning a PLC are:
• room automation
• observation of process
• machinery control
• process of production
Usually PLCs contain of the microcontroller unit including memory, processor, and a variety of hardware interfaces. Outstanding of a PLC features can comprise:
• inputs and outputs standardization
• programming of platform independent
• temperature range of industrial
• management of power fail
• memory of non-volatile
• capability of real time
The standardization programming with the international standard of IEC 61131-3 for PLCs recommends portability of the programs between processor types and different platform.

Requirements :
To begin with this function the software and hardware required is described as below.
Hardware:
• Any development kits and evaluation kits of the IPC@CHIP®, such as DK61, DK55.. is sufficient to recognize this application.
Software:
• programming system of CoDeSys v2.3 for IPC@CHIP
• @CHIPTOOL
• Release of CoDeSys@CHIP-SDK Edition 10.2007

Digital Inputs With Isolation of Galvanic:
PLCs are frequently utilized in a manufacturing atmosphere. To care for the PLC from equalizing current or transient voltages because of different mass potentials an isolation of galvanic can help decreasing those problems. There are some incorporated devices that offer a termination for the signal plus of digital the current limitation feature and overshoot protection. As an instance there is the CLT3-4BT6 from ST.

Digital Outputs Without Isolation of Galvanic:
If no isolation of galvanic required, it offers an easy method to switch PLC levels of 24 V. For security against inductive load a diode of freewheeling is use similar to GL34G from Vishay.

Real Time Clock:
In a real time clock of PLC is applied to provide the system with a time capacity which is autonomous from power supply. In case of a power loss in the system, the RTC continue the time information. This can be particularly helpful, if there is a power loss in the system which is date stamping the files. For instance, we get the device of Maxim DS1307, which can be related through the interface of I2C. The RTC is powered by the connected battery or capacitor in case the 5 V power supply drops below the 3.2 V level. Time can be improved throughout the RTC via I2C when the power is up again.

The Basic Understanding of PLC Controls System

When it comes to automatic industry monitoring and supervising, people will turn to PLC controls system that will allow everything to happen automatically. Without such system, it’s impossible for industry to operate in large scale and produce large mass of products. In short, the PLC system is the one responsible for the growth in economy and industry.

Why Use PLC Controls Systems?
In case people don’t really understand what PLC is, it’s the short of Programmable Logic Controller. It’s basically an automated program which allows machines to work on its own. As long as people provide the input or data, the execution or series of programs, and the output result, they can hope the PLC system to work well. Many people may not realize that the automatic machines they often use also use this type of PLC programs. Without PC program, it’s impossible to have such work and efficient automation. Everything needs to be done manually. People will have to pay attention to everything they do in details. They will have to observe and monitor everything, which is impossible to do when they’re hoping to produce large mass products. That’s why the PLC program is the one responsible for the growth of industry and the development of economy.

The Mechanism of PLC Controls Systems
PLC programs are basically the same as other programs. They’re designed and built with automation process so that they can work individually without too much interfere from human. Sure, the PLC experts are responsible for setting up the programs and observe the PLC programs work once in a while, but other than that, the system can work on its own without people have to monitor it all the time. When the PLC experts want the computer to operate on its own, they only need to make sure that they’ve included the three main elements of input, process, and output. Everything needs to work together well so that the machine can perform well enough. The input needs to work together with the process in order to produce the required output. If something is wrong, none of the elements can work perfectly. Since the PLC programs are mostly used in harsh environment, like industrial or plantation, they need to be stored within strong and sturdy machines or computers. Regular computers won’t do because they’re not designed for impact or harsh condition. Industrial people need to have their own PLC system computers which are durable, solid, and strong.

Most people may not realize this, but PLC system is very important for the overall production process because it can work on its own. People only need to monitor the machine performance once in a while. The PLC controls systems are very handy and helpful for industry and also for the economy.

Software Installation Configuration of IPC@CHIP®

The IPC@CHIP® contains a management of built-in power fail. The data in the IPC@CHIP® keep area are stored to the flash when a power fail break off happens in case of a power outage. The boards of IPC@CHIP® have a power fail break off simulator pushing the button of "PFI" on each board for simulation. Please refer to the hardware manual of SC23 and the hardware manual respective of SC1x3 for the required capacitor of power supply for power fail management in an actual environment.

Installation Installation of PC Software:
• Install of software CoDeSys in your PC. You are proposed to download the newest version from the download center of Beck IPC.
• Extract the software archive plc.zip of IPC@CHIP® and go into your board of IPC@CHIP® subdirectory such as DK61_PLC.
• Install the equivalent the Package of Target Support from the executing of the install.bat in the directory of TSP. The directory of TSP can be establish within the folder with the same name as the file of .xml Before you install this application on your IPC@CHIP® you must configure the controller.

Configuration of IPC@CHIP®:
• Install the @CHIPTOOL.
• Join ethernet cable and power supply to your board of IPC@CHIP®. Your development PC must be also linked to the similar ethernet.
• Begin the @CHIPTOOL. After a few seconds the @CHIPTOOL demonstrates your IPC@CHIP®.
• Open the menu of pop-up with a right button of mouse click on your IPC@CHIP® and select ‘IP Configuration’.
• Construct your IPC@CHIP®.

Software Installation of IPC@CHIP®:
• Open the pop-up menu of @CHIPTOOL with click the right button mouse on your IPC@CHIP® and select ‘FTP’.
• Enter username and password and then click on ‘Connect’
• Go into the directory of Image. The Image_a is enclosed within the IPC@CHIP® board subdirectory,
• Download all Image directory to the IPC@CHIP®.
• Lock the Window of @CHIPTOOL FTP-Client.
• Re-boot your IPC@CHIP®.

First time start:
• Begin CoDeSys and open the project file of PLC.pro for the equivalent board (e.g. DK61). The folder of IEC_PLC is enclosed within the of your IPC@CHIP® board subdirectory.
• Choose the Parameters of Online-Communication and menu point select either the link from a fallow serial port via cable of null modem using the baudrate settings: 38400, one stop bit, no parity, no Motorola byte and no flow control order. Plug in the cable of null modem to the serial interface of COM0(EXT) of the DK60, correspondingly COM2 for the DB54.

Process Control Software Design

Imprison all kind of design choices during the process of development needs a variety of notations, each of them representing a certain point of view. Usually, three views are chosen to explain the functionality, the structure and behavior of a software design.

The functionality designates the what-to-do in the system to be planned, and might be stand for with the notations of functional-oriented, for example SA-RT, SADT, or charts of activity in a decayed hierarchical tree structure. The hierarchy of activity together with the flow of information comprises the view of functional.

The behavioral view indicates the dynamics of the system that is to declare when and in reaction to what event the activities are activated. The behavior could be stand for with state charts, a variety of types of Petri nets, or the temporal logic of formalized. The view of structural offers a hierarchical disintegration into the modules and the communication between them. Generally, those modules correspond to a natural mapping from actually existing objects, for example network nodes, devices, and the subsystems of manufacturing. In current research on official modeling, started to merge the modeling of real-time and plan with the formalism of object-oriented. Similarly, Douglass expanded the Unified Modeling Language with the techniques of instantaneous description. Stewart et al. built up a port-based model focusing on the real-time control systems of structural design.

The notations of visual modeling are vital to communicate design decisions and design ideas. They also assist to assign the design parameters and the functional requirements. In this article, it is utilizing state charts to explain the behavior and module-charts, which are identical to those projected to point out the structure of system. The state charts as well as module-charts are layering and orthogonal, independent state or module regions. Consequently, both notations are helpful for a design process of hierarchical decomposable. A module chart is at all times attended with a state chart. In all-purpose, the models of state transitions are beneficial because they support straight a cognitive mapping from the requirements of functional to design parameter, here into states. Additionally, the models of state transition may handle dependent behavior in a way of natural. As a third notation, the charts of ladder logic are applied to explicitly identify the conjunctions of Boolean between incoming events. Although the ladder logic could be observed as a redundant description to state charts, it will re-evaluate it because of its high approval in industry.

The Design Process Steps
The important design steps are summarized as following. Step 1 and 2 according to the manufacturing system design process, while step 3 and 4 specify the procedure of mapping from domain of the CSD-FR to the CSD-DP.

Step 1a. Make the MSD-FR and MSD-DP module architecture:
The modular architecture of manufacturing system specifies the devices to be monitored. The architecture of modular is not accessible a structural breakdown of the system shows the components dynamic.

Step 1b. The system structural decomposition to be managed:
The recognized physical components structural decomposition increases elementary functional actors or modules. I/O ports are employed to identify the margin of each module. They designate the flow of data between functional units and refer to the event/sensor of incoming or event/actuator of outgoing signals.

Step 2. Make an ontology to recognize the task-neutral system’s behavior of MSD-DP:
Identify an appropriate set of task-neutral visible states, in which the controlled system of manufacturing could be. By this means, the ontology about the system controlled is produced. The states of system are a disjoint states set of system components to be controlled, for example rotary actuators, gripper, linear drives, and shuttle.

Step 3. Categorize task-oriented CSD-FR and understand them into states transition of CSD-D):
Categorize the preferred high-level functional specifications on highest level and understand them into states transition. For example CSD-FRx = move pat bin from A to B with CSD-DPx = move state. Each recognized module has predefined high-level states, for example recovering state, Initializing state, on/off-state, requesting state, etc.

Step 4. Decomposition behavioral:
State charts support the decomposition of behavioral visually. The CSD-FRs describes the planned activities and controls that will be together with this within states of CSD-DPs. The activities and states of subordinate are recognized throughout a zigzagging procedure between the domains of CSD-DP and CSD-FR. A state is always attended by a triggering event and an action of internal or external. An action of external control makes a state or motion change of the system of manufacturing.

Step 5. Decouple of the design:
Customized design matrices, indicated as tables of state transition, have been built to model and examine the modules and states interdependencies. The decoupling process separates the design into a structure of software with modules having fewer communication of inter-modular, but high interaction of intra-modular. Additionally, openly modeling the modules and states interdependencies increases the design robustness. The procedure of decoupling helps to find a stable states set of among the frequently many possible the control system states.

Coding Rules PLC Programming Languages

[CR 1] It is a general rule that all possible should be executed throughout coding rather than by configuration. Some characteristics can be realized by simply configuring the CPU with nearly no coding. It may enlarge development time to favor coding, but coding as some benefits:
• It is easier to track modifications of code than modifications of configuration. Maintenance will be simpler especially where some users succeed each other for the program maintenance.
• The project will face a least one improve to the Siemens PLCs next generation. Code will be moveable in the main, but no statements regarding configuration of CPU can be made. Favoring coding is a good method to lessen the risks of migration.

[CR 2] In LD or in FBD Programming must be done in the same method as if it was an electrical or an electronic diagram. The coils or latches writing must be unique. Setting spreading and variables resetting through the code is forbidden.

[CR 3] In SCL (“FOR”, “WHILE”, …) loops should be utilized instead of backward jumps in IL. Backward jumps are difficult and dangerous to troubleshoot, in the same method as any instruction of goto.

[CR 4] The arguments or passing from one block to other will be completed throughout the FBs interface or FCs: Output Variable, Input Variable. Use of joint DB global variables straightly in the control block is forbidden. Nevertheless, this is not always technically probable, so exemptions will be obviously stated in PCDH This rule will:
• Create the portable code.
• Shorten the variables length inside the blocks.
• Create easier blocks unit testing.

[CR 5] Use only joint DB variables, instead of mementos. The benefit of using DBs is that variables can be functionally grouped. This helps in the code structuring. Therefore the use of mementos is forbidden.

[CR 6] Use memories clock as far as possible. Memories clock can be utilized to produce up to 50 ms delay. This is delay is adequate to control most industrial control problems. This creates the code easier and more portable to unit test.

[CR 7] Organization blocks will comprise only calls to manage blocks. The logic implementation in the OBs is forbidden.
[CR 8] Each variable, block must be commented.
[CR 9] No programming of logic in LST. Use FBD/LD.
[CR 10]Every network: Maximum 1 landscape page of A4. If not possible, use Variables of intermediate TEMP.
[CR 11] The use of the inputs of “Enable” blocks of FBD and LD is forbidden.
[CR 12] No use instruction of “OPN DB”. Use the complete absolute joint DB variable: WFC. PL1-C, …
[CR 13] No explicit to use the instructions of address register in IL.

Languages in PLC Core Application

The languages allowed in the PLC core application will be those defined in IEC 61131-3:
• ST (Structured Text)
• SFC (Sequential function Chart)
• IL (Instruction list)
• LD (Ladder Diagram)
• FBD (Function Block Diagram)
Flow Charts of Siemens CFC will not be permitted in the controllers of conventional. However, CFC will be applied for redundant architectures, organized in the systems of interlock and safety. Siemens HiGraph, Petri Nets, will not be permitted either, because they are not defined in IEC 61131-3.

It is nearly possible to apply anything in any language, nevertheless, each language has its own typical and has been generated in order to solve exacting issues. The below rules must be executed in order to maintain the program of PLC as clean and readable as possible:
• SFC will be utilized to execute sequences (GRAFCET), but output will not be written straightly in GRAFCETS.
• ST will be utilized to execute complicated numerical algorithms, loop algorithms, machines of complex state or Petri nets where a sequence is insufficient. As ST is a structured language, quite similar to Pascal, it is more readable than IL.
• IL will be avoided to use it because assembler is not easy to maintain or read by user who did not create the code. It will be applied only in cases where, for instance, a particular instruction is not existing in ST or performance optimization is required.
• FBD and LD will be utilized to execute the logic Boolean and interlocking. Characteristically all the logic requisite to start or stop a device will be realized in LD. No complicated numerical calculation is allowed in FBD and LD. The option of FBD or LD is left to the programmer. Generally electronic engineers use FBD and electrical engineers use LD. The option is subjective since the representation can be switched LD to FBD in STEP7.

Languages organization in STEP7
The basic language in STEP 7 is IL. All other meta-languages and graphical languages are developed as the STL language abstraction. If a program is built in LD, FBD, ST or SFC, it will lastly end up in blocks of LIST after collection. The same editor is used to program in LD, FBD and IL. It is probable to change very easily from the graphical languages FBD and LD to LIST without recompilation. The other method is not so clear, IL can only be exposed in FBD or LD if certain rules are appreciated. SFC utilizes a specific editor of graphical: S7 Graph. After editing, the code is collected in uncommented blocks of IL. These blocks can be analyzed in IL, but any adjustment will damage the representation of graphical.

Peripheral Blocks Development of STEP7 PLC

CODAC Interface
The interface of CODAC is based on raw communication socket between the PSH and the PLC from a protocol point of view. This communication is executed in the PLC throughout the blocks of “Open Communications IE”. This family of block is offered only on CPUs which have an Interface of Ethernet embedded. This option is based on a communications assessment of possibilities for Siemens STEP 7 PLCs. This interface will support 4 information types:
• Simple commands
• Collaborative data
• State variables
• Configuration variables
Every data type will be transferred in one DB which has 8 kBytes maximum size. Configuration and states will use the same connexion of TCP, simple instructions and data collaborative will have their own connections of TCP.

Every DB will be developed with UDTs. Every UDT will stand for the type of interface such as states, configuration, commands, of one control function for the plant system FBSs. The block organization and dependencies for the function control of “CWSDHLT-WFC” in the System of Cooling Water.

Generation procedure
The different components of STEP 7 explained previously will be incorporated in source files automatically produced by the SDD. SDD is a toolkit of CODAC used to explain the interface with a PLC and the files of STEP 7 and PSH needed to build this interface are produced automatically. The toolkit of SDD produces a set of plant system specific files of symbol table (*.sdf) and a file of STL (*.awl). These files apply the data blocks of CodacStates, CodacConfiguration and CodacCommands and initialize the data block of CodacChannels. The editor of SDD produced files for the System of Cooling Water. The use of SDD is illustrated after the SPSS is built, the file of symbol table (*.sdf) and the file of STL (*.awl) should be imported to the project of STEP 7 as explained below.
1. Open the table symbol and import the system of plant specific file symbol table (*.sdf) and save.
2. Insert external source from the system of plant specific file SDD generated ‘*.AWL’ in the folder of CPU | S7 Program | Sources and compile.

System Health Monitoring
The health monitoring implementation is still TBD. In sequence to avoid breaks down of the PLC, the below OBs will be loaded in the PLC:
• OB122 : access interrupt of I/O error.
• OB121 : error interrupt of programming.
• OB86 : failure interrupt of IO-Device.
• OB82 : interrupt of diagnostic.

The Importance of PLC System

No one will doubt the importance of having PLC system nowadays. It’s the one system that keeps everything running perfectly, smoothly, and fast. The PLC system is often used by industry and plantation. Without it, the economy won’t grow very high and fast because everything will be slow. Can anyone imagine what it will be like when there’s no PLC system at all? Industry will be running on manual method. Nothing can grow very powerful and fast without the suitable PLC system.

About PLC System
PLC system is the major key in the technology and world development. PLC or Programmable Logic Controller is the system that makes machineries work automatically. It incorporates three basic features of input, process, and output where everything has to go along well and harmoniously. The input or data should go along with the suitable operation or process in order to produce the intended result or output. It’s a quite complicated process to make all machineries become automatic. This system is responsible for all the growth in industry, manufacturing process, and even entertainment. Without such system, amusement rides or movie making process can’t be done. That’s why PLC system is very important and needed by all kinds of industry.

Everything inside the PLC System
The PLC system is quite complicated. It requires special computers, special programs, special language and even special design. The special computers are needed because the computers will be located inside harsh industry environment. The computers should be strong and resistant to almost everything: starting from dust, liquid, moisture, shake, vibration, and bump. It’s impossible to store the PLC configuration inside regular computer because the computers aren’t designed to be used inside harsh environment. The PLC language basically uses the ladder logic. But when the industry requires more comprehensive and complicated process, the system can be designed with several languages so that it can do several different tasks. It’s important to have reliable and skilled PLC experts that can handle everything, including making the design. Each automation process is unique and different from one another. It’s the experts’ job to make sure that the program can run well and won’t experience any issues. When business people want to make sure that their PLC system to work well, they should also hire professional and qualified PLC experts.

Without PLC system, it’s impossible for us to reach this point of development. Everyone knows that this system is needed. They also know that this system is important for everyone and every industry. What would people do now if there’ no such thing as PLC system to help them?

Development of PLC Core Application

A first restraint in development of application is that specification, design and activities of coding will be geographically far-away from each other. In sequence to follow the development and validate that the transitions between the phases are possible, a minimum of formal documentation will be necessary. A second restraint is that one system I&C of plant may control some components which have been acquired individually. The strategy to address this issue is explained in the PCDH.

The lifecycle planned addresses the core application software development of every PLC in a whole system of plant system I&C. Some systems of plant system I&C will be very large and will execute some high level functions. The one plant system I& development C can be crashed in some life cycles. Generally, a developer of PLC is in charge of one (or some) high-level function, spread on one or some PLCs. It is recommended that one life-cycle is involves one high level function activity, and consequently one PLC developer activity. The life cycle is nothing more than the special steps pursued in a normal life cycle of software engineering. The only innovation here is in the adding of a stage of integrated validation testing.

As the design detailed of the plant system I&C will be finished as the software development initiates, a documents full set will be accessible, crashed in 9 deliverables as identified in the PCDH. These deliverables will comprise the architecture of I&C hardware, an analysis of functional, an Inputs/Outputs list, etc.

Requirements Specification
Software specifications are fully covered during the design phase of I&C. They will be mostly covered in the analysis of functional, but other inputs for example state machines and philosophy of control will also be applied.

Design Specification
Two phases in the Software Design are considered: a design of architectural and a design of detailed. The design of architectural will be also involved by the analysis of functional, as it will identify the major action blocks inside the core application. It is not necessary that the blocks of peripheral are defined, as they will all be built up base on templates or will be produced automatically. The design of detailed contains of defining how all the functions will be executed. The following information should be offered for each controller at this stage:
• The each programming block naming and numbering: FB,DB,OB,FC,
• The section of core application for full program structure of each OB.
• Any detailed network, hardware, configuration or project used.

Unit Testing and Coding of PLC for Plant System I&C

Unit testing and Coding will be executed concurrently. It has been established that unit testing radically improves the robustness and reliability of the code generated. This means that each FC and FB must be tested autonomously. The architecture standard makes this simpler, as the core application has no straight external interface. So any block programmed interface in the core application can be substituted by a variable in sequence to imitate the behavior of the interface. Unit testing doesn’t need a official document. Though, if too many errors are detected during the validation phases, a test of official unit document may be asked by IO.

Simulated Validation Testing
The standard is to have a simulation test carried out before the test with the system associated. There are some reasons:
• The actual system does not constant must be associated/ready for activities of testing. Their life cycles can be desynchronized until link.
• As many functional problems as possible tracking before linking to the actual system. The software will be more established at the connection time, so fewer time will be lost in troubleshooting of software during testing the system.
• It will be probable to test the I&C in its integrality level when the systems have been acquired individually when the I&C is created of few controllers.
• If simulation is accessible, corrective and adaptive maintenance will be probable without having the connected of system.

This phase is possible, as it might not make many senses for systems of small plant. For systems of large plant with a lot of controllers, simulation will involve only low functionality level. The complex algorithms of development with multiple couplings is too time consuming and does not value added. Nevertheless, it is severely suggested. The simulator development and the control units development will be completed by different people. Therefore different understandings of how the system control should run will be brought face to face at an early project phase. The simulator will be linked to the controllers throughout the network field. It will read or write the variables of joint DB identified in the layer of controller simulation. These variables will substitute the real I/Os controller. There is no specification so far relating to the technology to be used for the simulator development, but the simulator will be sent to IO after FAT.

Integrated Validation Testing
This test will be performed during FAT and will be created with the connected of real system. Since some components may not be on hand during this phase, the strategy will be applied.

Input/Output Wrapper of PLC

The aim of this layer is to straight apply the addressing area of Siemens data block at the lowest level. This has 2 benefits:
• It is probable to put the information in subsystems and systems hierarchically.
• All the variables can be done with just one easy block.
Complicated interfaces like positioning modules of FM453 and CP441 serial communications modules will also be applied in this layer. There is a connection between the health monitoring function and this layer. All the variables distributed by the wrapper will be transferred to the system of health monitoring. The system of health monitoring transfers these variables to the interface of CODAC. The point is to have raw values of CODAC accessible on a system screen for debugging purposes.

Interface Switch
Linking a process simulator to the controller provides the following possibilities:
• The software validation without being associated to the process
• Modification of the software and be capable to test these adaptations on a different platform, before loading on the real control unit during incorporation and commissioning.
The switch of interface purely switches the signal variables origin between the simulator and real process. The interface switch control will be a configuration variable of CODAC. This command must have some security connected with it in the sense that it cannot be utilized during process.

Engineering Limits
It is required to set limits reflecting the actuator limit or the physical process articulated in engineering format for numerical outputs. The output of PLC may be incorrect if these limits are went over. The limits will be set by variables of configuration.

FBS Wrapper
This block just transmits the variables of signal presented in a naming convention of PBS to a naming convention of FBS. Numerical and digital signal variables are separated because the layers above are different.
Conversion will be necessary for the majority of the numerical signal variables. This conversion can be quadratic, linear, or of superior orders. All the parameters of conversion will be provided by configuration variables of CODAC.

Standardization
The idea is to homogenize the core application of PLC code as much as possible. The same devices type should be controlled with the same function of PLC. In fact, the same devices type will be wired with different logic. For instance, a valve: some valves limit switches will be wired with positive logic, 24VDC – position reached, and some with negative logic, 0VDC – position reached, even as control of the valve is similar. The standardization block function would be to process the reversal necessary for all discrete signals, in order to show a standard signal interface for the different devices types to the core application of PLC.

Knowing more about PLC

There are some automation tools available in the market; PLC automation tool is one of the most popular among them. So what makes this automation tool so special, before deciding on using this automation tool, it will be better if we know more about this automation tool. Automation has become so popular so that there are many industries that start using this automation concept to create more efficient, effective and precision during production. For those who spend a lot of time and money, choosing automation concept can be a good solution; the reason is because automation is better compared with other conventional methods due to its effectiveness. PLC automation tool has become a choice for many industries when it comes to automation tools.

The benefit of using PLC automation
Most of you may have known some various forms PLC, although you have known about this automation tool, some of you may have no idea on using this automation tool. It is quite reasonable if you don’t know on how to use this automation tool. This automation tool is a system using some logic procedures to produce decision and outcomes. There are many industries who have used this automation tool due to its effectiveness, using this PLC automation is not only useful in terms of productivity and cost, you will also have the opportunity to create a better system.

Start learning PLC automation for a better job with good salary
If you have realized the importance of using PLC automation in the industry, then start learning about this automation tool can be a good decision. When you want to learn about this automation tool, it is important that you will have strong determination. Learning about this automation tool will make you to study regularly. By learning about this automation tool, you will also increase your chance for getting hired by many companies. A job in this automation field is quite promising, for those who have knowledge in this automation field, they can have a secured job with good salary. By learning PLC automation, you can create better chances for a more promising job with good salary.

If you have realized the importance of learning PLC automation, the next step you need to do is to find a training center where you can learn about this PLC. When finding a training center, India can be a good place where you can start learning about this automation tool, the reason is because India is famous for its PLC training centers.

Main Specifications AS-Interface of TWIDO PLC

The following provides the major specifications of the bus of AS-Interface V2:
Specifications:

1. Slave Addressing: every slave linked to the bus AS-Interface have to have an address between 1 and 31, escorted by "bank" /A or "bank" /B for extensive addressing. The slaves distributed from the factory have the address 0. Addresses are programmed via a specialized terminal of addressing.

2. Slaves Identification: All slave devices associated to the bus of AS-Interface are recognized by:
• A code of ID identity that specifies the slave type such as sensor, extended slave, etc.
• A code of I/O that confirms distribution of input/output.
• A code of ID2 that specifies the slave internal functionalities,
• A code of ID1 that specifies an additional identity of slave,

3. Slaves and inputs/outputs maximum number
A bus of AS-Interface can support a maximum on the same bus of:
• 31 slaves with standard settings of address; with addresses from 1 to 31,
• 62 slaves with extensive settings of address; every slave can have a maximum of 4 inputs and/or 3 outputs, the addresses are from 1 A/B to 31A/B.

4. AS-Interface Bus Topology and Maximum Length
The AS-Interface bus topology is flexible. It can be completely adapted to gather the user’s requires. The total length of all the branches of the bus has to not go over 100 meters without a repeater.

5. The Cycle Time of AS-Interface Bus
This is the cycle time between the module of master and slave. The system of AS-Interface always transfers information, which is the same length to every slave on the bus. The cycle time of AS-Interface depends on the active slaves number that connected to the bus. The scan time t stands for the time of exchange between a master and n active slaves. So, for:
• The active slaves up to 19, t = 3ms
• The active slaves 20 to 31 t = (1+n) * 0.156ms. This means that for 31 extensive address setting slaves constructed in /A, + 31 extensive address setting slaves constructwd in /B. the time of scan will be 10 ms.
Maximum cycle time:
• For 31 standard or extensive address setting slaves, maximum 5 ms
• For 62 extensive address setting slaves, maximum 10 ms.

6. Flexibility and Reliability
The process transmission utilized guarantees dependable operation. The master observes the data sent and the line supply voltage. It notices transmission errors as well as failures on slave, and transmits the information to the PLC. The slave exchange or connection of a new slave during operations does not disturb communications with the other slaves.

Hardware Config PLC STEP7

When building an application of PLC STEP7, the first step is to make the Project of S7 and configure the hardware. This article gives the rules to be practical when choosing parameters. The rules below show the exclusions.

1. CPU Configuration
• Straight away a CPU is put in a Rack, the first parameter required is the address of IP on the network. This interface is linked to the PON. The CODAC controls the plan of IP address on the PON and will supply the information. There is not require to construct a network. It will be needed when PLCs are interrelated in the plant system.
• Double-Click the hardware config on the CPU and select the tab of “General”. In the text field of “Comment”, initiate the PLC PBS number, the cubicle PBS and location.
• Select the tab of “Cycle/Clock Memory”. Check “Clock Memory” and bring in “100” in the field of “Memory Byte”.
• Select the tab of Startup. Check “Cold Restart” for Startup following Power On.
• Double-Click on filed of X5-PN:IO of the CPU. Select the tab of “time-of-Day Synchronization. Check “Enable Time of Day synchro in NTP Mode”. Bring in 2 NTP Servers Address.
• Write down 60 in “Update Interval”.

CP Configuration
Immediately a CP is put in the Rack, the first parameter applied for is the network IP Address. This network is the network of Profinet, actually divided from the PON. The address default can be left as it is. There is not require to have a particular IP Address Plan. Build a New Network in Subnet, with default parameters. Click the right button- on the “X1 PN-IO”, field of the CP and choose “insert PROFINET IO System”.

Configuration of Remote IO Rack
While installing a rack of remote IO in the network of Profinet the only parameter to identify is the name. This name is vital because it is used by the network communications of Profinet. In the Rack of the “Comment” text field, the PBS location and number of the cubicle should be stated. The default addresses recommended by STEP 7 will be implemented when inserting the IO boards in the racks. It is essential to follow this rule because according to the type of boards Step 7 selects specific areas of Input/Output.

The boards in the racks of remote IO have to be placed in the following order:
1. Boards of Digital input
2. Boards of Digital output
3. Boards of Analog input:
3.1. Boards of thermocouple input
3.2. 0..10V, 4-20mA, etc.
3.3. Boards of RTD input
4. Boards of Analog output

Hardware Configuration and Standard PLC Software Structure

The first step is to make an appropriate of configuration hardware. The 2nd step is to import the SPSS. There are 2 choices: import the source file or incorporate the binaries directly in the project. The files stated below can be faced on the Mini-CODAC at the following file:
/opt/codac-/step7/STL
/opt/codac-/step7/STEP7
Where is release-dependent.

Hardware Configuration
Subsequent to a project of STEP7 is made, the PLC hardware can be identified with following stages.
1. For S7-300 PLC, add a Simatic 300 Station, for S7-400 PLC add a Simatic 400 Station.
2. Edit the hardware using HwConfig which is unlocked by double-clicking the button on the Hardware. Add a rack and put the rack with suitable CPU and power supply. Refer to the catalog of PLC for suitable references. Another CPUs can be employed as long as they have an interface of Ethernet and they able to operate Open IE Communication. However, CPUs not comprised in the catalog will not be supported by CODAC.
3. Using NetPro identify the addresses of IP of the CP modules and CPU in the rack. The addresses of IP have to be same as earlier configured in the CPU.
4. The configuration of hardware should be stored and compiled either in NetPro or HwConfig. After the configuration of hardware is collected it is reproduced as system data in the folder of CPU | S7 Program | Blocks in the Simatic Station.

Import from external source files of the Standard PLC Software Structure
1. Construct the hardware of PLC.
2. Open Libraries | Standard Libraries | Communication Blocks in the Simatic Manager, and drag-and-drop UDT65 (TCON_PAR), FB65 (TCON), FB63 (TSEND), FB64 (TRECV), and FB66 (TDISCON) in the folder of CPU | S7 Program | Blocks.
3. Select the symbol of table and import StandardSoftwareStructure.sdf and store it. It is required to save the table symbol at this step to be able to collect the source of STL in consequent step.
4. Insert the source of external from the file of StandardSWStructure.AWL in the folder of CPU | S7 Program | Sources and collect. The compilation should not provide any errors if stages 2 and 3 are executed correctly.
5. Insert the file of StandardSWStructure400.AWL in the folder of CPU | S7 Program | Sources and compile to carry out the specific initialization of S7-400 for S7-400 CPU. Insert the file of StandardSWStructure300.AW" in the folder of CPU | S7 Program | Sources and compile to carry out the specific initialization of S7-300 for S7-300 CPU.

Knowing More About PLC Automation

When it comes to PLC automation, you will realize that automation has become quite popular due to its effectiveness. If you are interested in joining in automation field, there are some factors you need to know before entering in automation field. You should know that in the future, the concept of automation will become more popular, and it will be better if you can gain the benefit due to its popularity. There are many benefits you can get when the industry start using automation, the most important thing you realize is that it will be really helpful in term of productivity. When you realize the importance of using automation, there are some automation tools available to choose such as PLC and SCADA, you can consider using PLC automation as this automation tool is quite popular and has been used by many industries.

The importance of using PLC automation
Using PLC automation means that you will get many benefits in terms productivity, cost and quality. What makes automation become so popular is due to its effectiveness when used in production process. By using automation, you will create more efficient process and it will also increase the quality and precision. For those who consider using automation system, they have made a good decision. There are many industries that start using automation by using automation; it will also save a lot of time compared if the industry uses conventional system. When using automation, there is no need to rebuild the production lines, because this PLC automation will automatically do it for you.

PLC automation training – where to find
As described earlier, there are some different automation tools available in the market, but you consider using PLC automation as this automation is quite popular and known to be the best automation tool. The fact is that there are many companies who need someone with major knowledge in this automation field. In the future, people with skill in this automation field will be needed by many companies. Realizing about this fact, those who want to enter in this automation field, they should join in some PLC automation training classes.

By joining in PLC automation training, you will be taught on how to use the best automation concept. For those who want to join in the plc training, there are some plc training centers where they can learn about this automation process. India is one of the most famous places where there are many students that learn about PLC automation.

General Requirements of PLC Applications at ITER

- Flexibility
• All interfaces might be not accessible during integration and commissioning. The application should permit some signals to be required, or the missing interface partial simulation.
- Maintainability
• Adequate system information should be supplied.
• The application of PLC should be integrated a way that changes have only local impact.
- Ability to be tested
• PLC functions for unit testing should simple.
• The software of control systems should be tested separately from the system. The idea is to check the system of control when it is linked to a simulator rather than the system. The designer of plant system must identify beforehand which controllers must be tested together.
- Readability
• Every transformation of information should be simple to track.

The principle is to have a universal architecture for functions inside all the PLCs arranged on the project. According to the particular application of PLC, all the blocks might not be showed. For instance:
• A “Master Controller”, in the architecture of I&C will not have any hardware interface of Input/Output but will have many interfaces with other PLCs in the manufacturing system.
• Interfaces with fast controller will possibly be very extraordinary and may use the interface of CODAC, as Fast Controllers are operation EPICS and are accordingly linked to Channel Access.

Excluding for the core application of PLC, the structure internal of all other blocks will be typical for all PLCs organized on the project. Only the structure and volume of the data calculated in these blocks will be dissimilar. As far as possible, these blocks will be produced automatically, using the arrangement database as input. The interface of CODAC will be fully produced by the package of SDD. Additional production activities will be based on these structures. The regulation loops and state charts of the process will be realized. Only process programming should be establish here. The core application of PLC will implement the functions of control. Its functionality will be exaggerated by all the interfaces. All the treatment or programming not directly involving the process is carried out in the peripheral blocks such as, interfaces, system monitoring.

The core application of PLC will use the variables of configuration which is transferred by the Interface of CODAC as the key inputs from operation. Some variable of configuration for instances:
- requests ON/OFF
- requests OPEN/CLOSE,
- request HIGH VACUUM/ROUGHING/VENTING,
- Temperature set point
- Current set point,

CODAC PLC Interface Good Practice

The interface of CODAC development is very important that variables of configuration are not overwritten in the core application. There is no variable read back, so if one of these variables is adapted in the PLC, the connected EPICS PV will be misaligned. A variable of configuration have not to be measured as a simple setting for an output of PLC. It is obviously identified in the requirements for the design conceptual of the PLC, that outputs of PLC are handled by the core application. Straight writing from CODAC to the outputs is prohibited.

The device is managed by the control loop, consequently the control value issued by the control loop must be transferred to CODAC as a variable of state, not as a variable of configuration. If the mode of “open loop” is realized, then the input of user must be implemented as a divide configuration variable.

Process Function Standard Structure
The organization conceptual of a control function has three major parts: control logic and the control loop, state management, and interlocks. - The part of state management is stand for by a Petri Net or a GRAFCET. The state management will be controlled by exchanges with the process inputs and the CODAC. State management never starts the process outputs straightly. The part of interlocks and control logic mostly manages the control function of digital process outputs. It is controlled by the process inputs and the state management. The standard is that the actuator command is written only at one place in the code, in sequence to create the code easier to read and maintain. A diagram of logic gathers:
• All process conditions needed to make sure that the actuator is technically ready.
• The conditions of state.

- The control loop controls the continuous process outputs. It is controlled by the state management and the continuous process inputs. It is very frequently necessary to modify the control loop configuration according to the operational state, e.g. change the inhibit the integral action, set point, open the loop, etc..

The control function implementation is also standardized. Every function of control will be executed in one control block created of the three parts explained above:
- Interlocks and control logic
- Control loop
- State management
The block of control can be an FC or an FB, base on if it is a unique case or multiple cases. The three parts can be realized in the same control block or in dedicated ones – regarding on the function complexity.

CODAC Interface in PLC Core Application

The core application of PLC will calculate the configuration variables of CODAC and the inputs of hardware and produce the outputs in order to achieve the requested of configuration. The changeable of state report the effective state of the process. The major principle is that it is always probable to have a simple comparison in CODAC between the configuration or state of the process that was asked for and the actual state. Mutual data are state variables generated by other plant systems and transferred by core system of CODAC. Crosswise wired connects between plant systems are strictly not allowed. Information transmission of between plant systems will employ the mutual data link.

The CODAC interface main function is to run the communication PLC side with CODAC, which is built up in an EPICS environment. The communication CODAC side is controlled by a specific driver in the PSH. This communication decays in 4 categories, as represented:
• Simple commands
• Configuration variables
• Collaborative data
• State variables
In 2 the link “8” demonstrates another use of these variables: offer configuration to the I/O interface of hardware. Mostly, it will give parameters conversion from physical to engineering units, inhibits and forcing values, it will also influence the mode of simulation. The variables of state are used to transfer the process state:
• Straight from the I/O interface of hardware. This direct link is needed as the core applications of CODAC use these variables without involve computing in the core application of PLC. It is significant to note that these variables are in units of engineering, and they can also can be simulated or forced.
• From the calculated variables issued by the core application of PLC.
• From the monitoring of system.

Simple controls are variables command to “TRUE” during one cycle in the PLC. These simple commands are utilized in the cases where it is not essential to remember the action related to this command, as is the case for variables of configuration.

The data collaboration is state variables transferred between plant system I&Cs. A strong necessity of the PCDH is that no oblique physical link is permitted between plant system I&Cs. Any such link has to be in the form software of a link between 2 PLCs from the 2 different plant system I&Cs. This mutual data will be state variables with the “Collaborative Data” specific classification.

PLC Interface CODAC Configurations

Forcing
During incorporation, commissioning and sometimes during maintenance, it is normal that the engineers will desire to force some variables of the signal to a definite value, because the associated signal is not linked, missing, is not equipped or has failed. It is better to get this fact into account in the design of software, so that this “uneven” behavior will be prohibited. The goal is to keep away from dangerous “temporary-permanent” observes like forcing a signal with the PLC hardwired modifications, strapping of relays, hardcoded modifications, etc. This layer of the forcing must be developed and in particular:
• Some signals can’t be forced at any time as this could be destructive.
• The unit of control may not be able to achieve an operational state as long as variables signal are forced.
• Reducing this feature of forcing.
All permanent and runtime parameters will be provided by the CODAC configuration variables.
This interface attends to communications between the PLCs of a same manufacturing system I&C, for the case where a functional interface is needed. The protocol of Siemens to be used will be identified later in the document. There are 3 different cases from a conceptual point of view:
• A link of the master/slave where the master PLC is transferring the commands e.g. Boolean or numerical, to a slave PLC.
• A link of point-to-point where 2 PLCs are switching over states. This transmission of the state can be I/O of another PLC.
• A communication of multipoint where a PLC is issuing states to a group of PLCs. In an architecture of master/slave, the coordinator of master transfers orders to the slaves. A paradigm of communication must be defined for these orders. Every case will be implemented with the most suitable technology of Siemens.

The Monitoring of System
A job will be committed to the system monitoring of PLC: the following parameters will be examined:
• The operating mode, such as, RUN/STOP
• Memory:
- To load memory assigned within the range: 0..100%
- To work memory assigned within the range: 0..100%
- Retentive within the range: 0..100%
Scan cycles:
• Longest
• Shortest
• Average
• Standard deviation
- CPU Time including date and hour
- Configured
- Communication
- Connections accessible for max numbers
- The number of connections employed

I/Os:
- The status of board
- The raw value of every signal
Alive counter.

Everything about Programmable Logic Controller

Programmable Logic Controller or PLC is an automation system that is usually used in industry, manufacturing process, or even entertainment. It’s the program that enables the machine to do all the work on their own. Sure, human labor may still be needed to supervise and monitors the work process. But everything usually moves on its own. That’s why Programmable Logic Controller program is very important and vital in the working industry.

About Programmable Logic Controller
Programmable Logic Controller was first invented in the 1968 by Bedford Associates. At that time, the automotive industry was overwhelmed with the growing needs for automotive products. The human labor couldn’t compete with the time limit and restriction. That’s why the automotive industry needs a great and helpful program that can help them deal with manufacturing process. Bedford Associates won the right to create the system and since then the company has started and developed PLC system. They started to realize the importance of having reliable automation programs and they know all industry will need this kind of program. It’s true that since then, the development of PLC system is quite fast and remarkable. All kinds of industrial and heavy manufacturing processing require the handy help of Programmable Logic Controller system.

The Usage of Programmable Logic Controller System
The Programmable Logic Controller was first used in automotive industry only. But as time passes by, other industries start to see the benefits of using this system. They don’t need to push the human labor to work on their limit. The human labor can be used to monitor and supervise the process only. Now, most industrial businesses are using this system to help them work faster. This system even reaches out to entertainment and enjoyment area where most amusement rides are using the automation program. Without the program, it’s impossible for entertainment industry to reach this successful point. Sometimes, this kind of program and system are also used within movie industry. The Programmable Logic Controller system has definitely changed the way industry works and also the economic element of the world.

Without Programmable Logic Controller, it’s impossible to reach this kind of success and development. Everything would be slow because everything will be done manually and by hand. People can’t possibly compete with the fast and precision of machinery system. People should be able to take care of everything that’s related to the PLC system because it’s the one thing that enables them to earn a living. Everyone knows how important it is to have reliable Programmable Logic Controller for their business.

Network and Operator Interface of EPICS PLC

Network
The Ethernet of Redundant gigabit with fiber optics connected like as a "star" initiating from the CCR (central control room) to every accelerator such as 50-GeV PS, 3-GeV RCS and Linac, and the facility of experimental is the control network backbone. The star like the optical fiber cables of 100baseFX expand to network switches over the facility from every the station of backbone. The majority of the network end joins for instance IOCs are 100baseTX. Some of the nodes in a high EMI noise levels for example close to high powered pulsed power supplies or klystrons should be 100baseFX. They are going to use the connections of Ethernet in stead of other area buses. As a result the total number of IP addresses needed for the control system could simply go beyond a few thousands. For that reason it is impossible to apply a space of global IP address. As an alternative they are going to exploit a space of Class B private IP address and use a router to communicate to outside of the network.

They have not figured out how the network should be separated into subnets. The channel access (CA) of EPICS protocol needs the network broadcast. As a result all nodes of EPICS should be in one subnet. Nodes for diagnostic purpose should be in the right place to a different subnet because they have to be free from the subnet of EPICS. Such diagnostic nodes comprise a port of communication for a traffic watcher, of course, it should have also a port in the subnet of EPICS to search out network traffic and an IOC’s CPU console such as RS232c throughout a terminal server. Those two kinds of nodes are in general close each other in space, and consequently it is better to realize the technique of virtual-LAN to decrease cabling and network switches number.

Operator interface
They will use one of the requirements of EPICS OPI tools for the operation of EPICS, but not specific yet which one should be applied. Also there are two options; (1) the applications of OPI work directly on a PC Linux or (2) the applications of OPI work on an X-client machine with a PC with X-server or an Xterminal. The first option is good for traffic network but not good for applications of maintaining. The later is just opposed. Another operator interface type is required which is associated to the some issues.

Design of the Control System of PLC Driver

Right now, only VMEs under the operating system vxWorks can be employed as an IOC of EPICS. There are a lot of modules VME are offered commercially for processing analogue signals and normal digital. The drivers of EPICS are already offered for many modules. For that reason, it doesn’t need to worry about devices which need only the signals. Though, there are a lot of devices which require special handlings. PLCs are reliable and cheap in a sense that they remain operation under any trouble in networking or computers, and thus it is preferable to employ PLCs for some serious devices for example an ion-source. How PLCs create communication with IOCs is one of the problems that have to establish early. The answers are as follows;
• Using Ethernet TCP/IP. Along with PLCs offered commercially, presently only PLC of FA-M3 by Yokogawa support the protocols of data transfers we needed.
• Allocate an ID (identification number) to every PLC. It is hazardous to rely only on the address of IP. Check the ID to ensure you are communicating with a suitable PLC before any communication with a PLC and at any data transmit to a PLC.
• No entity commands for action. Only transfer data from/to PLC memory is supported. Any operation of device should be done while contents of memory in a limited address range.
• No straight write to memory of PLC. An IOC transfers 3-word data such as a content, an ID, and a memory address) to the PLC memory communication area. After that, a PLC ladder program transfers the content to a proper address after checking its ID.

The PLC EPICS driver prototype has been written and effectively used for the operation of ion-source, even though all the rules stated above are not fully applied yet in the prototype driver. Waveform digitizers choice is another vital issue that has to think for device control. Its driver of EPICS has been finished and tested partially. Since the network of Ethernet runs over the area, then chose Ethernet for digital data connection avoiding another field buses type so that all of the communication of data is united. By doing so, we can trace back all data throughout network which will considerably help us for diagnostics of operation. Also it lessens the stock items number which may decrease the operational cost. It is developing an interface board of Ethernet which will be employed primarily in the quadrupole magnets power supplies at the DTL to achieve the unified Ethernet connections.