PLC讲义english
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可编程控制器技术讨论与未来发展摘自《可编程控制器技术讨论与未来发展》数字媒体系 08165110 多衡随着时代的发展,当今的技术也日趋完善、竞争愈演愈烈;单靠人工的操作已不能满足于目前的制造业前景,也无法保证更高质量的要求和高新技术企业的形象。
人们在生产实践中看到,自动化给人们带来了极大的便利和产品质量上的保证,同时也减轻了人员的劳动强度,减少了人员上的编制.在许多复杂的生产过程中难以实现的目标控制、整体优化、最佳决策等,熟练的操作工、技术人员或专家、管理者却能够容易判断和操作,可以获得满意的效果。
人工智能的研究目标正是利用计算机来实现、模拟这些智能行为,通过人脑与计算机协调工作,以人机结合的模式,为解决十分复杂的问题寻找最佳的途径我们在各种场合看到了继电器连接的控制,那已经是时代的过去,如今的继电器只能作为低端的基层控制模块或者简单的设备中使用到;而PLC的出现也成为了划时代的主题,通过极其稳定的硬件穿插灵活的软件控制,使得自动化走向了新的高潮。
PLC introducedThe graduation project topic is the application of PLC in the servo servo system, the PLC application and understanding of the graduate design, following the basic knowledge of PLC to make a brief introduction.The PLC can be programmed controller is the new industrial control devices based on computer technology. The PLC in the PLC draft standards issued by the International Electrotechnical Commission in 1987 made the following definition: "the PLC is a specially designed for applications in industrial environments digital computing operation of electronic devices which can be programmed memory, with to implementation of the logical, sequential operation, timing, counting and arithmetic operations, such as operating instructions in its internal storage and can be digital or analog inputs and outputs to control various types of machinery or production processes. PLC and its related peripherals should be easy and industrial control systems to form a whole, easy to extend the principle of functional design. "A.PLC features(a)High reliability, strong anti-jamming capabilityHigh reliability is the key to performance of the electrical control equipment.PLC is due to the introduction of modern LSI technology, strict production process, the internal circuit to take the advanced anti-jamming technology, with high reliability. For example, the Mitsubishi F series PLC MTBF up to 300,000 hours. Redundant CPU PLC, the average time between failures is longer. From a machine outside the circuit of the PLC, the PLC constitutes a control system, and compared to the same scale relay contactor system, electrical wiring and switch contacts have been reduced to hundreds or even thousands, the fault will be greatly reduced. In addition, PLC with a self-detection of hardware failure, failure to timely alert. In the application software, application can also be incorporated into the peripheral devices and fault diagnostic procedures, also received the fault self-diagnostic protection circuit outside the PLC system and equipment. In this way, the entire system with high reliability is also not surprising.Complete, fully functional, and applicability(b)Complete, fully functional, the applicabilityPLC development today, has formed a large, medium and small scale series products. Can be used for industrial control applications of all sizes. In addition to the logical processing functions, the modern PLC mostly data computing power can be used for a variety of digital control. In recent years the emergence of a large number of functional units of the PLC, PLC penetrated into the position control, temperature control, CNC and other industrial control. With PLC communication capability enhancement and development of human-computer interface technology, the use of PLC composed of a varietyof control systems have become very easy.(c)Easy to use, well received by engineers and technicians welcomePLC as a general-purpose industrial control computer, industrial control equipment for industrial and mining enterprises. It easy to interface, programming language is easy to be accepted for engineering and technical personnel. The ladder language graphic symbol and expression and relay circuit is very close, only a small number of switch PLC logic control instructions can easily relay circuit. Not familiar with the electronic circuit, people do not understand computer theory and assembly language using a computer to engage in industrial control to open the door.(d)System design, construction workload is small, easy to maintain, easy to transformPLC storage logic instead of wiring logic, greatly reduce the external wiring of control equipment, control system design and construction of the cycle is much shorter, while maintaining also become easily. More important is that the same device after the change the change the production process become possible. It is suitable for the occasion of many varieties, small batch production.(e)Small size, light weight, low energy consumptionUltra-Small PLC, for example, the newly produced species at the bottom of size less than 100mm, weighs less than 150g, only a few watts of power. Due to small size it is easy to load the internal machinery is the ideal control device for mechanical and electrical integration.B.The composition of the PLCPLC is divided into fixed and modular (modular) two points from the structure. Fixed PLC CPU board, I / O board, display panel, memory blocks, power, and these elements are combined into a non-removable as a whole. Modular PLC CPU module, I / O modules, memory, power supply modules, backplane or rack, these modules can be combined according to certain rules configuration.(a)The composition of the CPUCPU is the core of the PLC, since the role of the nerve center, at least one CPU in each PLC, the PLC system program, the functions entrusted to the reception and storage of user programs and data collected from field input devices sent a scanned stateor data, and deposit shall be required to register, at the same time, the diagnostic power and the working status of the PLC internal circuitry and programming process in syntax errors. Into operation from the user program memory, one by one read command, the corresponding control signal analysis and then according to the mandate of instruction, to command the control circuit.CPU is the main contact between the computing device, controller, register, and to implement them, control and status bus, a CPU unit also includes a peripheral chips, bus interface, and related circuit. Memory is mainly used for storing programs and data is an integral unit in PLC.User opinion, unnecessarily detailed analysis of the internal circuitry of the CPU, but on the part of the working mechanism should have sufficient understanding. The CPU controller controls the CPU to read instructions, which explain the instructions and execute instructions. However, the pace of work is controlled by the oscillation signal. The arithmetic unit is used for digital or logic operation under the command of the controller. Register to participate in operations, and store intermediate results of operations, it is under the command of the controller.CPU speed and memory capacity are important parameters in the PLC, they determine the pace of work of the PLC, IO number and software capacity, thus limiting the size of the control.(b)I / O modulesThe interface of the PLC and the electrical circuit is completed by the input and output portion (I / O). I / O modules with integrated PLC's I / O circuit, the input registers reflect the state of the input signal, output point to reflect the state of the output latch. The input module electrical signals into a digital signal into a PLC system, the output module is the opposite. I / O module is divided into the digital input (DI), digital output (DO), analog input (AI), analog output (AO).The I / O are classified as follows:Switch: the voltage level points, 220VAC, 110VAC, 24VDC, points by way of isolation and separation of relays and transistor isolation.Analog: Signal type, current-(4-20mA, 0-20mA), voltage type (0-10V,0-5V,-10-10V), etc., precision points, 12bit, 14bit, 16bit.In addition to these general-purpose IO, there are special IO module, such as thermal resistance, thermocouple, pulse module.I / O points to determine the module specification and quantity, I / O modules can be more or less, but the maximum number of the ability of the CPU can manage the basic configuration, that is, by the largest number of floor or rack slot limit.(c)Power supply modulePLC power supply IC for the PLC module supplies power to operate. At the same time, some of the input circuit to provide 24V power supply. Power input type: AC power (220VAC or 110VAC), DC power supply (usually24VDC).C. Working principlePut into operation when the programmable logic controller, the course of their work is generally divided into three stages, that is, the input sample, the user program execution and output refresh three stages. Completion of the three stages is called a scan cycle. During the entire operation, the CPU of the programmable logic controller scan speed, repeat the above three stages. (a)Input sampling phaseThe input sampling stage, the programmable logic controller in order toscan read into the state of all input and data, and deposit them with the corresponding unit in the I / O image area. Transferred to the user program execution and output refresh period after the end of the input samp le. In both phases, even if the input state and data changes, the state and data of the corresponding unit in the I / O image area will not change. Therefore, if the input pulse signal, the signal of the pulse width must be greater than one scan cycle, in order to ensure that in any case, the input can be read into the.(b)User program execution stageIn the user program execution stage, programmable logic controllers are always followed by a top-down order to scan the user program (ladder). Scan each one ladder, and always scan by the contact of the ladder left of the control of line, and first left and right first and then the order of logical operations on the control circuit by the contact form , then the logical result of the operation, refresh the logic of the coil system RAM storage area corresponding state; or refresh the state of the output coil corresponding bits in the I / O image area; or determine whether to perform the ladder the provisions of the special function instruction.That is, during user program execution, only the input status and data points in the I / O image area does not change, the output point and soft devices in the I / O image area or system RAM storage areastatus and data are likely to change, but came in above the ladder program execution results will be ranked below those who used these coils or data ladder work; the contrary, the row below the ladder, thethe status of logic coils to be refreshed or the data can only be to the next scan cycle can be ranked on top of the program work.If you use the I / O instruction immediately you can directly access the I / O points in the process of program execution. That the use of I / O instruction, the input process image register values are not updated, the program directly from the I / O module value, the output process image register is immediately updated, this immediately enter some difference.(c)Output refresh periodWhen the scan the user program after the end of the programmable logic controller to enter the output refresh period. During this time, the CPU in accordance with the I / O image area corresponding to the state and data refresh all of the output latch circuit driven by the output circuit corresponding peripherals. At this time, is the real output of the programmable logic controller.D.PLC applicationsAt present, the PLC at home and abroad has been widely used in iron and steel, petroleum, chemicals, electricity, building materials, machinery manufacturing, automobile, textile, transportation, environmental protection and cultural entertainment industry, usage can be broadly divided into the following categories.(a)Switch logic controlThis is the PLC basic, wide range of applications, which replaces thetraditional relay circuit, logic control, sequential control, both for the control of a single device, can also be used for multi-group control and automated assembly line.Such as injection molding machines, printing presses, stapler machine, combined machine tools, grinding machines, packaging production lines, electroplating lines and so on.(b)Analog ControlIn the industrial production process, there are many continuous variables, such as temperature, pressure, flow, level and speed are analog. To make the programmable controller to handle analog, analog (Analog) and Digital (Digital) A / D conversion and D / A conversion. PLC manufacturers are supporting the production of A / D and D / A converter module, the programmable controller for analog control.(c)Motion ControlPLC can be used in a circular motion or linear motion control.From the configuration of the control mechanism, early used directly in the switch I / O modules to connect the position sensors and actuators, is now generally use a dedicated motion control module. Drive a single or multi-axis position of the stepper motor or servo motor control module. The world on all major PLC manufacturers products almost every motion control functions, widely used in a variety of machinery, machine tools, robots, elevators and other occasions. (d)Process controlProcess control refers to the closed-loop control of temperature, pressure, flow analog. As an industrial control computer, the PLC can prepare a variety of control algorithm, the complete closed-loop control. PID regulation is a general closed-loop control system using more regulation. And medium-sized PLC have PID modules, and many small PLC also has this feature module. PID processing is generally run a dedicated PID subroutine. Process control in metallurgy, chemical industry, heat treatment, boiler control and so on a very wide range of applications.(e)Data processingModern PLC math (including matrix operations, functions, operation, logic operation), data transfer, data conversion, sorting, look-up table, bit operation functions, you can complete the data collection, analysis and processing.These data can be compared with the reference value stored in memory to complete the control operation can also use the communication functions to other intelligent devices, or print them tabulation. The data processing is generally used for large-scale control systems, flexible manufacturing systems such as unmanned control; can be used for process control systems, such as papermaking, metallurgy, food industry, some large-scale control system.(f)Communications and networkingPLC communication with the communication between PLC and communication between the PLC and other intelligent devices.With the development of computer control, factory automation, network development,the PLC manufacturers have attached great importance to the PLC communication function, have launched their own network systems. The newly produced PLC communication interface, communication is very convenient. E. History of the development(a)OriginGeneral Motors in 1968 to replace the relay control device requirements;In 1969, Digital Equipment Corporation developed the first programmable logic controller PDP-14, successful trial in the U.S. GM's production line, using procedural means for the first time used in electrical control, which is the first generationprogrammable logic controllers, said Programmable, is recognized as the world's first PLC.In 1969, the United States developed the world's first PDP-14;In 1971, Japan developed the first DCS-8;In 1973, Germany developed the first PLC;In 1974, the Chinese developed the first PLC.(b)DevelopingThe microprocessor in the early 1970s. Will soon be introduced into the programmable logic controller, programmable logic controller to increase the computing, data transmission and processing and other functions, the real computer features of industrial control devices. Programmable logic controller is the product of combining conventional control concepts of computer technology and relay. Development of personal computers, in order to facilitate and reflect the features of the programmable controller, programmable logic controllers be called the Programmable Logic Controller (PLC).The late 1970s, the programmable logic controller into the practical stage of development, computer technology has the full introduction of the programmable controller, a leap to make it function. Higher operating speed, ultra-compact size, the more reliable industrial anti-jamming design, analog computing, the PID function and the high cost laid in modern industry.The early 1980s, the programmable logic controller has been widely used in the advanced industrial countries. Production of programmable controllers on the country in the world is increasing, production is rising. This indicates that the programmable controller has entered a mature stage.1980s to the mid-1990s, the fastest-growing period of the programmable logic controller, the annual growth rate has been maintained at 30 to 40 percent. During this period, the PLC in the processing capacity of analog, digital computing power, man-machine interface capabilities and network capabilities have been greatly improved, programmable logic controllers gradually into the field of process control in the field of process control is replaced in some applications dominance of the DCS system.The late 20th century, the development characteristics of the programmable logic controller is more responsive to the needs of modern industry. This period the development of mainframes and super-minicomputer,the birth of a variety of special function units, the production of a variety of man-machine interface unit, communication unit, so that the application of programmable logic controllers, industrial control equipment supporting easier.。
PLC IntroductionProgrammable controller is the first in the late 1960s in the United States, then called Plc programmable logic controller (Programmable Logic Controller) is used to replace relays. For the implementation of the logical judgment, timing, sequence number, and other control functions. The concept is presented Plc General Motors Corporation. Plc and the basic design is the computer functional improvements, flexible, generic and other advantages and relay control system simple and easy to operate, such as the advantages of cheap prices combined controller hardware is standard and overall. According to the practical application of target software in order to control the content of the user procedures memory controller, the controller and connecting the accused convenient target.In the mid-1970s, the Plc has been widely used as a central processing unit microprocessor, import export module and the external circuits are used, large-scale integrated circuits even when the Plc is no longer the only logical (IC) judgment functions also have data processing, PID conditioning and data communications functions. International Electro technical Commission (IEC) standards promulgated programmable controller for programmable controller draft made the following definition : programmable controller is a digital electronic computers operating system, specifically for applications in the industrial design environment. It used programmable memory, used to implement logic in their internal storage operations, sequence control, timing, counting and arithmetic operations, such as operating instructions, and through digital and analog input and output, the control of various types of machinery or production processes. Programmable controller and related peripherals, and industrial control systems easily linked to form a whole, to expand its functional design. Programmable controller for the user, is a non-contact equipment, the procedures can be changed to change production processes. The programmable controller has become a powerful tool for factory automation, widely popular replication. Programmable controller is user-oriented industries dedicated control computer, with many distinctive features.First, high reliability, anti-interference capability;Second,programming visual, simple;Third, adaptability good;Fourth functional improvements, strong functional interface1.Design Theory DevelopmentToday, the primary focus of most design research is based on mechanical or electrical products. One of the by-products of this proposed research is to enhance our fundamental understanding of design theory and methodology by extending it to the field of engineering systems design.A system design theory for large-scale and complex system is not yet fully developed. Particularly, the question of how to simplify a complicated or complex design task has not been tackled in a scientific way. Furthermore, building a bridge between design theory and the latest epistemological outcomes of formal representations in computer sciences and operations research, such as discrete event system modeling, can advance future development in engineering design.2.Application in Logical Hardware DesignFrom a logical perspective, PLC software design is similar to the hardware design of integrated circuits. Modern VLSI designs are extremely complex with several million parts and a product development time of 3 years [Whitney, 1996]. The design process is normally separated into a component design and a system design stage. At component design stage, single functions are designed and verified. At system design stage, components are aggregated and the whole system behavior and functionality is tested through simulation. In general, a complete verification is impossible. Hence, a systematic approach as exemplified for the PLC program design may impact the logical hardware design.Programming languagesHigher level PLC programming languages have been around for some time, but lately their popularity has been mushrooming. As Raymond Lavelle, vice president and general manager, Siemens Energy and Automation. Inc, Programmable Controls Division, points out :”As programmable controls are being used for more and more sophisticated operations, languages other than ladder logic become more practical, efficient, and powerful. For example, it's very difficult to write a trigonometric function using ladder logic. ”Languages gaining acceptance include Boolean, control system flowcharting, and such function chart languages as Graphtec and its variations. And these’s incre asing interest in languages like C and BASIC.PLCs in process controlThus far, PLCs have not been used extensively for continuous process control. Will this continue? ”The feeling that I’ve gotten,” says Ken Jeannette, manager, product planning, Series One and Series Six products, at GE Frame North America, "is that PLCs will be used in the process industry but not necessarily for process control.”Several vendors-obviously betting that the opposite will happen-have introduced PLCs optimized for process applications. Rich Ryan ,manager, commercial marketing, Allen-Bradley Programmable Controls Div, cites PLCs’ increasing use in such industries as food, chemicals, and petroleum. Ryan feel there are two types of applications in which they’re appropriate.”One, "he says, "is where the size of the process control system that's being automated doesn’t justify DCS[distributed control systems].With the starting price tags of those products being relatively high, a programmable controller makes sense for small, low loop count applications. The seconds where you have to integrate the loop closely with the sequential logic. Batch controller sere prime examples, where the sequence and maintaining the process variable are intertwined so closely that the benefits of having a programmable controller to do the sequential logic outweighs some of the disadvantages of not having a distributed control system.”Bill Barkovtz, president of Triconex, predicts that "all future controllers that come out in the process control system business will embrace a lot more PLC technology and a lot more PLC functionality than they ever did before.”Communications and MAPCommunications are vital to an individual automation cell and to the automated factory as a whole. We've heard a lot about MAP in the last few years, and a lot of companies have jumped on the band wagon. Many, however were disappointed when a fully-defined and completed MAP specification didn’t appear immediately. Says Larry Kumara:”Right now , MAP is still a moving target for the manufacturers specification that is not final. Presently, for example, people are introducing products to meet the MAP 2.1standard.Yet 2.1-based products will be obsolete when the new standard for MAP,3.0is introduced.”Because of this, many PLC vendors are holding off on full MAP implementations. Omron, for example , has an ongoing MAP-compatibilityprogram, but Frank Newborn, vice president of Omron’s Industrial Division, reports that because of the lack of a firm definition, Omron's PLCs don't yet talk to MAP.Since it’s unlikely that an individual PLC would talk to broadband MAP anyway, makers are concentrating n proprietary networks. According to Sal Provanzano, users fear that if they do get on board and vendors withdraw from MAP, they ‘ll pulse width modulation control system be the ones left holding a communications structure that’s not supported.。