Transcript Standardization in Industrial Control Programming

PLCopen for efficiency in automation
IEC 61131.3 the Industrial Programming Standard
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PLCopen - IEC 61131 - 3
Overview
“There are three classes of people: those who see.
Those who see when they are shown.
Those who do not see.”
Leonardo da Vinci (Italian draftsman, Painter, Sculptor, Architect and Engineer
whose genius epitomized the Renaissance humanist ideal. 1452-1519)
"Any sufficiently advanced technology is indistinguishable from magic.“
Arthur Charles Clarke
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The goal of this presentation is to provide the attendees with
information and a review of the IEC 61131-3 control system
automation software standard which is an open (nonpropriety) based standard applicable to the implementation
of a PLC Open system including the application of Field Bus
technology. The attendees will gain knowledge involving the
IEC 61131-3 software standard utilizing RTU/PLC/DCS.
IEC = International Electro-technical Commission
A World organization that prepares and publishes international standards
for all electrical and electronic related technologies
Founded in 1906 * Over 50 participating countries * Different levels of membership
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What is the IEC 61131 standard ?
IEC 61131 is an international standard for
programmable controllers consisting of 5
parts:
 Part 1: General information
 Part 2: Equipment characteristics
 Part 3: Programming languages
 Part 4: User guidelines
 Part 5: Communication
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IEC 61131 and PLC Open – Mission
PLC Open is a vendor and product
independent world-wide organization
that brings greater value to users of
Industrial Control Systems through
the pursuit of the IEC 61131-3
software development standard
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Goals of IEC 61131.3 and PLC Open

PLC Open Certification and compliance testing
 Definition of several levels of IEC 61131-3 compliance
(Base Level, Portability Level, Full compliance Level)
 Establish strict test procedures
 Establish certification tests at independent test institutes
Ultimate
Goal: Portability of PLC programs
Program once run on any hardware platform
not hardware specific or dependent
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Table of contents
 Advantages of IEC61131-3 for programmers
 History and international standards 1970 to 1995
 7 parts of the IEC 61131 standard
 IEC 61131-3 software models
 the 5 languages of the IEC 61131-3
 FBs (Function blocks) and POUs (Programmable Organizational Units)
 IEC data types, standard functions and standard function blocks
 PLCopen certification
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Table of contents - continued
 PLCopen compliance levels
 PLCopen training logo
 PLCopen address
"Concern for man himself and his fate must always form the chief interest of all
technical endeavors, concern for the great unsolved problems of the organization of
labor and the distribution of goods--in order that the creations of our mind shall be a
blessing and not a curse to mankind.
Never forget this in the midst of your diagrams and equations." Albert Einstein
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Advantages of IEC 61131-3
 International accepted standard
• Step by step all suppliers will support it
• Uniform structures, languages, and the way of handling
 It saves you time
•
•
•
•
•
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Unique software model and data/ type concept
You only have to learn it once for different controller types
Reduced misunderstandings and errors
Standard functions and function blocks
Reusability of tested software
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Advantages of IEC 61131-3
 Supports safety and quality programming
• Easy and comfortable structuring
• Data typing prohibits programming errors
 Provides the best language for each problem
•
•
•
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•
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Consistent specifications of 5 languages
Two textual and two graphical languages
One structuring language, providing an overview
Availability of high level language
Possibility to mix different languages
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IEC 61131.3 the Industrial Programming Standard
International Language Standardization
NEMA Programmable Controllers Committee formed (USA)
GRAFCET (France)
DIN 40719, Function Charts (Germany)
NEMA ICS-3-304, Programmable Controllers (USA)
IEC SC65A/WG6 formed
DIN 19 239, Programmable Controller (Germany)
IEC 65A(Sec)38, Programmable Controllers
MIL-STD-1815 Ada (USA)
IEC SC65A(Sec)49, PC Languages
IEC SC65A(Sec)67
IEC 848, Function Charts
IEC 64A(Sec)90
IEC 1131-3
Type 3 report
recommendation
IEC 61131-3
name change
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Source: Dr. J. Christensen
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The 7 Parts of The IEC 61131 Standard
 Part 1
General overview, definitions
IS
 Part 2
Hardware
IS
 Part 3
Programming Languages
IS
 Part 4
User Guidelines
IS
 Part 5
Communication
IS
 Part 7
Fuzzy Logic
IS
 Part 8
Technical Report
IS = International Standard
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IEC 61131 - Part 1 - General Overview
 Definitions and glossary of terms used in the standard
 List of related / referenced IEC standards
 Principal functional characteristics of programmable
controller systems
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IEC 61131 - Part 2 - Hardware
 Electrical, mechanical and functional requirements for
Programmable Controllers and associated peripherals
 Service, storage and transportation conditions
 Information to be supplied by manufacturer
 Test methods and procedures for verification of compliance
of programmable controllers and associated peripherals
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IEC 61131 - Part 3 - Programming
Languages
 Software-, communication- and programming-model
 Definition of five interlinked programming languages
 Syntax and semantics of two textual and two graphical
languages: Instruction List (IL), Structured Text (ST), Ladder
Diagram (LD) and Function Block Diagram (FBD)
 Sequential Function Chart (SFC) for program structuring
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IEC 61131 - Part 4 User Guidelines
Assists the user in:
 Utilizing the other parts of the programmable controller
standard
 Specifying the requirements for applications
 Selecting and implementing systems
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IEC 61131 - Part 5 Communication
 Based on MMS (Manufacturing Message Specifications)
(still in progress)
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IEC 61131 - Part 7 Fuzzy Logic
 Provides the definition of fuzzy control sets
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IEC 61131 - Part 8 Technical Report
 Provides guidelines for the application and implementation
of programming languages for programmable controller
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IEC 61131-3 Software Model
Configuration A
Resource L
Task1
Program P1
Resource L
Task2
Task3
Program P2
Program P3
FB1
FB3
FB2
Task4
Program P4
FB4
global and direct addressed variables
access paths
Task association
Access path association
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OB1
Operating System
FB
FC
FB
Other
OBs
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FC
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FB
FC
OB - Organization Block
FC - Function
FB - Function Block
Memory
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Definition of Software Model Terms
 Configuration
A language element corresponding to a programmable controller system
 Resource
A language element corresponding to a signal processing function and its humanmachine interface and sensor actuator functions, like a CPU in your system
 Task
An execution control element providing for periodic or triggered execution of a group
of associated program organization units
 Program
Highest level program organization unit, several in - and outputs possible, can call
FBs and Functions
 FB
Program organization unit Function Block, several in - and outputs possible, can call
other FBs and Functions
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The Common Elements
• Character set
(English.........)
• Data types
(BOOL, WORD, INTEGER.................)
• Variables
(VAR, VAR_input, VAR_output..........)
• POUs, Program Organisation Units
(Function, Function Block...)
• SFC Elements
(Steps, Transitions.................................)
• Configuration elements:
(Tasks)
• Basis for software re-use
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IEC 61131-3 Elementary Data Types
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No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
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Keyword
Data Type
Information at
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Bits
BOOL
SINT
INT
DINT
LINT
USINT
Boolean
Short integer
Integer
Double integer
Long integer
Unsigned short integer
1
8
16
32
64
8
UINT
UDINT
ULINT
REAL
LREAL
TIME
DATE
TIME_OF_DAY
or TOD
DATE_AND_TIME
or DT
STRING
BYTE
WORD
DWORD
LWORD
Unsigned integer
Unsigned double integer
Unsigned long integer
Real numbers
Long reals
Duration
Date (only)
Time of day (only)
16
32
64
32
64
Date and time of day
Character string
Bit string of length 8
Bit string of length 16
Bit string of length 32
Bit string of length 64
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8
16
32
64
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Directly represented variables – Hardware Addressable Inputs and Outputs
The identifier of a directly represented variable always begins with "%" character.
Below are the naming conventions of a directly represented variable for a channel of a single board. "s" is
the slot number of the board. "c" is the number of the channel.
%IXs.c
free channel of a Boolean input
%IDs.c
free channel of an integer input
%ISs.c
free channel of a message input
%QXs.c free channel of a Boolean output
%QDs.c free channel of an integer output
%QSs.c free channel of a message output
Below are the naming conventions of a directly represented variable for a channel of a complex equipment.
"s" is the slot number of the equipment. "b" is the index of the single board within the complex equipment.
"c" is the number of the channel.
%IXs.b.c
%IDs.b.c
%ISs.b.c
%QXs.b.c
%QDs.b.c
%QSs.b.c
free channel of a Boolean input
free channel of an integer input
free channel of a message input
free channel of a Boolean output
free channel of an integer output
free channel of a message output
Below are examples:
%QX1.6 is the 6th channel of the board #1 (Boolean output)
%ID2.1.7 is the 7th channel of the board #1 in the equipment #2 (integer input)
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The 5 Languages of IEC 61131-3
Instruction List
LD
A
ANDN
B
ST
C
Structured Text
C:= A AND NOT B
AND
A B
C
Step 2
Ladder Diagram
N
FILL
C
S
Empty
Transition 2
-| |--|/|----------------( )
Step 3
B
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Step 1
Transition 1
Function Block Diagram
A
Sequential Function Chart
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Ladder Diagram (LD)
 Standardized, rationalized set of relay ladder programming
symbols
 Based on well-known US-style of programming, resembling
electrical drawing standard
A B
C
-| |--|/|----------------( )
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Ladder Diagram (LD)
Ladder Diagram (LD) is a graphic representation of Boolean equations,
combining contacts (input arguments) with coils (output results). The LD
language enables the description of tests and modifications of Boolean
data by placing graphic symbols into the program chart. LD graphic
symbols are organized within the chart exactly as an electric contact
diagram. LD diagrams are connected on the left side and on the right side
to vertical power rails.
A and not B equals C
-| |--|/|----------------( )
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Instruction List (IL)
 Single Accumulator based execution model
 Based upon the German ‘Anweisungsliste’, AWL
 Only one operation such as storing a value in the
accumulator register, is allowed per line
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LD
A
ANDN
B
ST
C
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Instruction List (IL)
Instruction List, or IL is a low level language. It is highly effective
for smaller applications or for optimizing parts of an
application. Instructions always relate to the current result (or
IL register).
The processor indicates the operation that must be made
between the current value and the operand. The result of the
operation is stored again in the current result.
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LD
IX1
(* push button *)
ANDN
MX5
(* command is not forbidden *)
ST
QX2
(* start motor *)
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Structured Text (ST)




High level language, block structured
Syntax resembles PASCAL
Complex statements and nested instructions possible
Support for
• Iteration loops (REPEAT-UNTIL; WHILE-DO)
• Conditional execution (IF-THEN-ELSE; CASE)
• Functions (SQRT(), SIN())
C:= A AND NOT B
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High level language, Syntaxed structured
 Syntax resembles traditional programming code
such as C++, JAVA, PASCAL
 Complex statements and nested instructions possible
 Support for



Iteration loops (REPEAT-UNTIL; WHILE-DO)
Conditional execution (IF-THEN-ELSE; CASE)
Advanced Math Functions (SQRT(), SIN())
Applications with complex calculations and data
processing examples would involve two phase
flow calculations, gas calculations, etc.
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C:= A AND NOT B
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Function Block Diagram (FBD)
 Graphical language, widely used in Europe
 Allows program elements which appear as blocks to be
"wired" together in a form analogous to a circuit diagram
 Used in many applications that involve the flow of
information or data between control components
AND
A
C
B
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Graphical language, widely used in Distributed
Control Systems (DCS) and Analog intensive
control systems
 Allows program elements which appear as
blocks (Function Blocks) to be connected
together in a form analogous to a circuit
diagram
 Most applications apply to analog control
 Used in many applications that involve the flow
of information or data between control
component
 Examples include PID and analog scaling
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AND
A
C
B
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Sequential Function Chart (SFC)
 Graphical language which provides a
diagrammatic representation of program
sequences --> flowchart
 Based on the French Grafcet (IEC 848)
 Main structure and suitable for rapid diagnostics
 The basic elements are steps with action blocks
and transitions
 Steps consist of a piece of program that is
carried out until a condition specified in the
transition is met
 Programming of complex tasks by dividing in
smaller parts
 Each element can be programmed in any of the
IEC- languages such as LD or ST or IL or FB mix
or match any of the languages
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Step 1
N
FILL
Transition 1
Step 2
S
Empty
Transition 2
Step 3
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Technological programming language for
Sequential
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Step 1
describing

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Action 1
Action 2
Transition
Structured program draft

Description of the process with steps
and transitions
 Clear, easy to understand by the process,
production and operations staff

Step 2
Action 1
Application examples





Presses and Packaging technology
Production lines
Process technology (start up – shutdown)
OEM equipment machinery technology
Rotating Machinery e.g. compressors, pumps
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Transition
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POU = Program Organization Unit
POU’s enable re-use of software from macro level (Programs)
to micro level (FB and Functions).
A POU consists of a header (variable declaration) and the
body (instructions).
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POU Type
Replicated as:
Comments
Program
Function Block
Program instance
FB instance
Function
Function
Main program
Subroutine with own
memory, several in and outputs possible
Subroutine without
memory
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IEC 61131-3 Standard Datatypes






Bit string types
(BOOL, BYTE, WORD, DWORD, LWORD)
Integer types
(SINT, INT, DINT, LINT)
Unsigned integer types (USINT, UINT, UDINT, ULINT)
Real types
(REAL, LREAL)
Time types
(TIME, DATE, TIME_OF_DAY, DATE_AND_TIME)
Character types
(STRING)
Vendor and user defined data types are possible
• Direct derived, sub range, enumeration
• Array, structure
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IEC 61131-3 Standard Functions
 Bit string functions
 Numerical functions
(AND, OR, XOR, NOT, SHL, SHR, ROL, ROR)




(e.g. USINT_TO_DINT, BOOL_TO_BYTE)
Type conversions
Selection functions
Comparison functions
String functions
(ADD, SUB, MUL, DIV, MOD, EXPT, ABS,
SQRT, LN, LOG, EXP, SIN, COS, TAN, ASIN,
ACOS, ATAN)
(SEL, MIN, MAX, LIMIT, MUX)
(GT, GE, EQ, LT, LE, NE)
(LEN, LEFT, RIGHT, MID, CONCAT,
INSERT, DELETE, REPLACE, FIND)
Vendor and user defined functions are possible
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IEC 61131-3 Standard Function Blocks




Bitable
Edge detection
Counters
Timers
(SR, RS, SEMA)
(R_TRIG, F_TRIG)
(CTU, CTD, CTUD)
(TP, TON, TOF, RTC)
Vendor and user defined function blocks are possible
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PLCopen
Mission
We want to be the leading association
resolving topics related to
control programming
to support the use of
international standards in this field.
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PLCopen was founded on June 15, 1992 in Giessen, Germany.
Target was to promote IEC 61131-3, inform customers and give
more weight to the IEC 61131-3 standard.
PLCopen
Standardization in Industrial
Control programming
TC6
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The Essence of Compliance
without testing there is no standard
 The IEC 61131 standard gives rules for compliancy
 Certification gives guidance for users towards real IEC
61131-3 programming systems (e.g. PLCopen certified list
shows compliant products)
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PLCopen Compliance Level
To take away the confusion, PLCopen....
 .... has defined 2 levels of compliance with a defined set
of features
 .... has defined an accreditation procedure
 .... has accredited test institutes
 .... developed test software, shared amongst members
 .... has defined a certification procedure
 .... and has members with certified products
This assures compliance now, and in the future.
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PLCopen Compliance Levels
Application
Program
FB
Variable
Code
Body
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Conformity Level &
Reusability Level
Re-usability of Function (Block)
libraries
FB
FB
Variable
Variable
Code
Code
Body
Body
Base Level
Portability of minimal systems
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Application
Program
FB
Variable
Code
Body
FB
FB
Variable
Variable
Code
Code
Body
Body
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Compliance
Certified products
can use these logo’s
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PLCopen Training Logo
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PLCopen
www.plcopen.org
P.O. Box 2015
NL 5300 CA Zaltbommel
The Netherlands
Tel: +31-418-541139
Fax: +31-418-516336
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