General Meeting PLCopen June 1996

Transcript General Meeting PLCopen June 1996

PLCopen
Standardization in Industrial Control Programming
Welcome at this
IEC 61131-3 Tutorial
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Standardization in Industrial Control Programming
Harmonizing the way people look to
control
the future is here
Eelco van der Wal
Managing Director PLCopen
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Standardization in Industrial Control Programming
Fiction?
Imagine
*
*
*
*
you are in industrial control
working with 4 different brands of controls
using different dialects in their programming languages
strugling to match the level of your software engineers with
the electrical engineers / maintenance on the factory floor
* & seeing that your competitor does better
Why? What’s wrong ?
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Standardization in Industrial Control Programming
Out of the jungle
The current variety of problems can be
vastly reduced via standardization
... and such a standard is available
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Standardization in Industrial Control Programming
IEC 61131-3
“The best thing that happened
to industrial control”
Sugar Lantic on Automation Maillist
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Standardization in Industrial Control Programming
The 7 parts of the IEC 61131 Standard
- 1 General overview, definitions
- 2 Hardware
- 3 Programming Languages
- 4 User Guidelines
- 5 Messaging Service Specification
- 7 Fuzzy Logic
- 8 Implementation guidelines
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Standardization in Industrial Control Programming
IEC 61131-3 Programming languages /
Industrial Control Programming
The interface between the programmer and the control system
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Standardization in Industrial Control Programming
IEC 61131-3 Programming languages /
Industrial Control Programming
...with support for people
with different backgrounds
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Standardization in Industrial Control Programming
What is the Benefit of such a Standard ?
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Standardization in Industrial Control Programming
Users? Which Users?
Discrete Mnf
Process cntrl
YOU ??
System Integrator
Education
Programming
Maintenance
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Installation
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Standardization in Industrial Control Programming
Users? Which Users?
• Automobile production lines
• Water treatment plant
• Food processing and packaging machinery
• Cable manufacturing
• Semi-conductor clean room automation
• Theme-park roller coasters
• Nuclear waste treatment plant
This wide range encompass different skills
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Standardization in Industrial Control Programming
What is the Benefit of such a Standard
Reduced waste of human resources (in training,
debugging, maintenance and consultancy)
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Standardization in Industrial Control Programming
What is the Benefit of such a Standard
 Reduced waste of human resources (in
training, debugging, maintenance and
consultancy)
Creating a focus to problem solving via software re-usability
(reduced application investment and supplier dependency)
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Standardization in Industrial Control Programming
What is the Benefit of such a Standard
 Reduced waste of human resources (in
training, debugging, maintenance and
consultancy)
 Creating a focus to problem solving via
software re-usability (reduced application
investment and supplier dependency)
Reduced misunderstandings and errors
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PLCopen
Standardization in Industrial Control Programming
What is the Benefit of such a Standard
 Reduced waste of human resources (in
training, debugging, maintenance and
consultancy)
 Creating a focus to problem solving via
software re-usability (reduced application
investment and supplier dependency)
 Reduced misunderstandings and errors
Programming techniques usable in more environments
(general industrial control)
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PLCopen
Standardization in Industrial Control Programming
What is the Benefit of such a Standard
 Reduced waste of human resources (in
training, debugging, maintenance and
consultancy)
 Creating a focus to problem solving via
software re-usability (reduced application
investment and supplier dependency)
 Reduced misunderstandings and errors
 Programming techniques usable in more
environments (general industrial control)
Combining harmonously different components from different
locations, companies or countries, or projects
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PLCopen
Standardization in Industrial Control Programming
What is the Benefit of such a Standard
 Reduced waste of human resources (in
training, debugging, maintenance and
consultancy)
 Creating a focus to problem solving via
software re-usability (reduced application
investment and supplier dependency)
 Reduced misunderstandings and errors
 Programming techniques usable in more
environments (general industrial control)
 Combining harmonously different
components from different locations,
companies or countries, or projects
Increased connectivity (investment protection)
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PLCopen
Standardization in Industrial Control Programming
What is the Benefit of such a Standard
 Reduced waste of human resources (in
training, debugging, maintenance and
consultancy)
 Creating a focus to problem solving via
software re-usability (reduced application
investment and supplier dependency)
 Reduced misunderstandings and errors
 Programming techniques usable in more
environments (general industrial control)
 Combining harmonously different
components from different locations,
companies or countries, or projects
 Increased connectivity (investment
protection)
Software
Library
Function Block
"Heating"
Function
"LIMIT"
Function
"TEST"
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Function Block
"Turning"
Function Block
"Feeding"
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Standardization in Industrial Control Programming
Key quality features of IEC 61131-3
• Structured software - through use of Configuration,
Resource and Program Organization Units (POUs)
• Strong Data Typing - through languages that restrict
operations to only apply to appropriate types of data
• Execution control - through use of tasks
• Complex sequential behaviour - through Sequential
Function Charts
• Software encapsulation - through use of POUs,
structures and complex data types.
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Standardization in Industrial Control Programming
An example
Fermentation Control System
courtesy of Omron Electronics
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Standardization in Industrial Control Programming
Fermentation Process
Agitator
Feed valve
Acidic reagent
Alkali reagent
Temperature
sensor
pH sensor
Heater band
Harvest valve
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Standardization in Industrial Control Programming
Fermentation control decomposition
• MainSequence e.g. top level process steps - filling, heating, agitating,
fermenting, harvesting, cleaning.
• Valve control e.g. operating valves used to fill and empty the
fermentation vessel
• Temperature control for monitoring the temperature of the vessel
and modulating the heater.
• Agitator control for the agitator motor activated as demanded
by the main process sequence.
• pH Control for monitoring the acidity of the fermentation contents
and adding acidic or alkali reagents.
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Standardization in Industrial Control Programming
Fermentation control program
TempControl
Heat
Heat
Cool
SetPoint
TempSensor
PV
Cool
pHSensor
pHControl
AddAcid
MainSequence
Stop
Duration
Start
Temp
Stop
pH
Duration
Agitation
AddAcid
SetPoint
Start
PV
AddAlkali
AddAlkali
AgitateControl
MotorSpeed
FillState
SetPoint
MotorSpeed
PV
AgitateSpeed
ValveControl
Fill
State
Fill
ValvePositions
Harvest
Harvest
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Standardization in Industrial Control Programming
Main sequence SFC
Shows the main
process states
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S1
N
Initialisation
S2
N
Filling
S3
N
Heating
S4
N
Fermenting
S5
N
Harvesting
S6
N
Cleaning
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Standardization in Industrial Control Programming
IEC 61131-3
Overview
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Standardization in Industrial Control Programming
The IEC 61131-3 Standard
Common Elements
Programming Languages
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Standardization in Industrial Control Programming
The IEC 61131-3 Standard
Common Elements
Programming Languages
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Standardization in Industrial Control Programming
The IEC 61131-3 Programming Languages
Instruction List
LD
A
ANDN
B
ST
C
C:= A AND NOT B
Function Block Diagram
AND
A
Structured Text
Ladder Diagram
A B
C
C
-| |--|/|----------------( )
B
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Standardization in Industrial Control Programming
The IEC 61131-3 Standard
Common Elements
Programming Languages
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Standardization in Industrial Control Programming
Common Elements include :
Variables, Data Types and Declaration
Configuration, Resources and Tasks
Function, Function Blocks and Programs
Sequential Function Charts
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Standardization in Industrial Control Programming
IEC 61131-3 : Common Elements
Variables
•
Symbolic representation via labels
•
Restricted area for I/O mapping
•
Hardware independent code
What is this?
01010101 10101010
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Standardization in Industrial Control Programming
IEC 61131-3 : Common Elements
Data Types
such as:
BOOL
BYTE
INTEGER : SINT, INT, DINT, LINT
USINT, UINT, UDINT, ULINT
REAL, LREAL
DATE
TIME_OF_DAY
DATE_AND_TIME
STRING
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Standardization in Industrial Control Programming
Variable Declaration
textual representation of usage type of variable
 scope: local (or global)
 explicit parameter passing via variables (inputs or outputs)
 memory allocation
declaration can include initial values
coupled to ‘Program Organization Unit’ (Function, Function
Block or Program)
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Standardization in Industrial Control Programming
Variable Declarations
Keyword
Variable usage
VAR
Internal to organization unit
VAR_INPUT
Externally supplied, not modifiable within organization unit
VAR_OUTPUT
Supplied by organization unit to external entities
VAR_IN_OUT
Supplied by external entities. Can be modified within org. unit
VAR_EXTERNALSupplied by configuration via VAR_GLOBAL .Can be modified
within organization unit
VAR_GLOBAL
Global variable declaration
VAR_ACCESS
Access path declaration
RETAIN
Retentive variables
CONSTANT
Constant (variable cannot be modified)
AT
Location assignment
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Standardization in Industrial Control Programming
Variable Declarations : example
VAR
CONDITION_RED : BOOL;
IBOUNCE : WORD;
MYDUB : DWORD;
AWORD, BWORD, CWORD: INT;
OKAY : STRING[10] := ‘OK’;
END_VAR
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Standardization in Industrial Control Programming
IEC 61131-3 : Common Elements
Data Types&
Variables
in addition:
Your own datatypes
…
derived datatypes
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Standardization in Industrial Control Programming
Derived Datatypes
Direct derivation from elementary types, e.g.:
TYPE R : REAL ; END_TYPE
Enumerated data types, e.g.:
TYPE ANALOG_SIGNAL_TYPE : (SINGLE_ENDED,
DIFFERENTIAL) ; END_TYPE
Subrange data types, e.g.:
TYPE ANALOG_DATA : INT (-4095..4095) ; END_TYPE
Array data types, e.g.:
TYPE ANALOG_16_INPUT_DATA : ARRAY [1..16] OF
ANALOG_DATA ; END_TYPE
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Standardization in Industrial Control Programming
Your own datatype: derived datatype
TYPE
ANALOG_CHANNEL_CONFIGURATION :
STRUCT
RANGE : ANALOG_SIGNAL_RANGE ;
MIN_SCALE : ANALOG_DATA ;
MAX_SCALE : ANALOG_DATA ;
END_STRUCT ;
ANALOG_16_INPUT_CONFIGURATION :
STRUCT
SIGNAL_TYPE : ANALOG_SIGNAL_TYPE ;
FILTER_PARAMETER : SINT (0..99) ;
CHANNEL : ARRAY [1..16] OF ANALOG_CHANNEL_CONFIGURATION ;
END_STRUCT ;
END_TYPE
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Standardization in Industrial Control Programming
Your own datatype: derived datatype
TYPE
ANALOG_CHANNEL_CONFIGURATION :
STRUCT
TYPE ANALOG_DATA : INT (-4095..4095) ; END_TYPE
RANGE : ANALOG_SIGNAL_RANGE
;
MIN_SCALE : ANALOG_DATA ;
MAX_SCALE : ANALOG_DATA ;
END_STRUCT ;
ANALOG_16_INPUT_CONFIGURATION :
STRUCT
SIGNAL_TYPE : ANALOG_SIGNAL_TYPE ;
FILTER_PARAMETER : SINT (0..99) ;
CHANNEL : ARRAY [1..16] OF ANALOG_CHANNEL_CONFIGURATION ;
END_STRUCT ;
END_TYPE
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Standardization in Industrial Control Programming
Your own datatype: derived datatype
TYPE
ANALOG_CHANNEL_CONFIGURATION :
STRUCT
RANGE : ANALOG_SIGNAL_RANGE ;
MIN_SCALE : ANALOG_DATA ;
MAX_SCALE : ANALOG_DATA ;
END_STRUCT ;
ANALOG_16_INPUT_CONFIGURATION
:
TYPE ANALOG_SIGNAL_TYPE : (SINGLE_ENDED,
DIFFERENTIAL) ; END_TYPE
STRUCT
SIGNAL_TYPE : ANALOG_SIGNAL_TYPE ;
FILTER_PARAMETER : SINT (0..99) ;
CHANNEL : ARRAY [1..16] OF ANALOG_CHANNEL_CONFIGURATION ;
END_STRUCT ;
END_TYPE
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Standardization in Industrial Control Programming
Directly Represented Variables : %
Prefix
Meaning
I
Q
M
X
None
B
W
D
L
Input location
Output location
Memory location
Single bit size
Single bit size
Byte (8 bits) size
Word (16 bits) size
Double word (32 bits) size
Long (quad) word (64 bits) size
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Default data type
BOOL
BOOL
BYTE
WORD
DWORD
LWORD
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Standardization in Industrial Control Programming
IEC 61131-3 : Common Elements
COMMON ELEMENTS
a.o.
Data Types&
Variables
Configuration
Resources
Tasks
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Standardization in Industrial Control Programming
IEC 61131-3 Software Model
Configuration
Communication Function
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Standardization in Industrial Control Programming
IEC 61131-3 Software Model
Configuration
Resource
Resource
Communication Function
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Standardization in Industrial Control Programming
IEC 61131-3 Software Model
Configuration
Resource
Task
Resource
Task
Task
Task
Communication Function
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Standardization in Industrial Control Programming
IEC 61131-3 Software Model
Configuration
Resource
Resource
Task
Task
Task
Task
Program
Program
Program
Program
Execution
control path
Communication Function
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Standardization in Industrial Control Programming
IEC 61131-3 Software Model
Configuration
Resource
Resource
Task
Task
Task
Task
FB
Function
Block
Program
Program
FB
Program
FB
Program
FB
FB
Execution
control path
Access path
Communication Function
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Standardization in Industrial Control Programming
IEC 61131-3 Software Model
Configuration
Resource
Variable
access path
Resource
Task
Task
Task
Task
FB
Function
Block
Program
Program
FB
Program
FB
Program
FB
Global and direct variables
Variable
FB
Execution
control path
Access path
Communication Function
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Standardization in Industrial Control Programming
IEC 61131-3 vs conventional PLC
Configuration
Resource
Variable
access path
Resource
Task
Task
Task
Task
FB
Function
Block
Program
Program
FB
Program
FB
Program
FB
Global and direct variables
Variable
FB
Execution
control path
Access path
Communication Function
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Standardization in Industrial Control Programming
Configuration Elements
Configuration
Resources
Tasks
Global Variables
Access Paths
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Standardization in Industrial Control Programming
Configuration, Resources and
Access Paths (-Declaration)
CONFIGURATION … END_CONFIGURATION
VAR_GLOBAL … END_VAR (within CONFIGURATION)
RESOURCE … ON … END_RESOURCE
VAR_GLOBAL … END_VAR (within RESOURCE)
PERIODIC TASK
NON-PERIODIC TASK
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Standardization in Industrial Control Programming
IEC 61131-3 : Common Elements
COMMON ELEMENTS
a.o.
Data Types&
Variables
Configuration, Resources, Tasks
Programming Organization Units
* Functions
* Function Blocks
* Programs
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Standardization in Industrial Control Programming
Functions …..
* Standard functions
ADD, SQRT, SIN, COS, GT, MIN, MAX, AND, OR, etc.
* Your own defined functions:
FUNCTION SIMPLE_FUN : REAL
VAR_INPUT
A, B
: REAL;
C
: REAL := 1.0;
END_VAR
SIMPLE_FUN := A*B/C;
END FUNCTION
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Standardization in Industrial Control Programming
…. & Function Blocks
Standard Function Blocks
I NPUT OUTPUT I N_OUT EXTERNAL
FUNCTION_BLOCK
Type Local
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Standardization in Industrial Control Programming
…. & Function Blocks
Standard Function Blocks
Additional supplied
Function Blocks
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I NPUT OUTPUT I N_OUT EXTERNAL
FUNCTION_BLOCK
Type Local
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Standardization in Industrial Control Programming
…. & Function Blocks
Standard Function Blocks
Additional supplied
Function Blocks
Your own defined Function
Blocks
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I NPUT OUTPUT I N_OUT EXTERNAL
FUNCTION_BLOCK
Type Local
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Standardization in Industrial Control Programming
…. & Function Blocks
Standard Function Blocks
Additional supplied
Function Blocks
Your own defined Function
Blocks
All FBs are highly re-usable
in same program, different
programs or project
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I NPUT OUTPUT I N_OUT EXTERNAL
FUNCTION_BLOCK
Type Local
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Standardization in Industrial Control Programming
Function Block example
REAL
REAL
REAL
Hysterisis
XIN1
Q
XIN2
EPS
BOOL
Q
1
0
EPS
EPS
XIN2
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Standardization in Industrial Control Programming
Function Block example
FUNCTION_BLOCK HYSTERISIS
REAL
REAL
REAL
Hysterisis
XIN1
Q
XIN2
EPS
VAR_INPUT
XIN1, XIN2 : REAL;
BOOL
EPS : REAL;
(* Hysterisis band *)
END_VAR
VAR_OUTPUT
Q : BOOL := 0
END_VAR
IF Q THEN
Q
IF XIN1 < (XIN2-EPS) THEN
1
END_IF;
Q := 0 (* XIN1 decreasing *)
ELSIF XIN1 > (XIN2 + EPS ) THEN
0
Q := 1; (* XIN1 increasing *)
EPS
EPS
END_IF;
END_FUNCTION_BLOCK
XIN2
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Standardization in Industrial Control Programming
Programs : hierarchical design
Start : BOOL;
Emergency : BOOL;
Limit : INT;
Automation
application
INPUT
OUTPUT
IN_OUT
EXTERNAL
FUNCTION_BLOCK
PROGRAM
Type
Type
Local
Local
GLOBAL
INPUT
FUNCTION
Type
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Local
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Standardization in Industrial Control Programming
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PLCopen
Standardization in Industrial Control Programming
IEC 61131-3 : Common Elements
COMMON ELEMENTS
a.o.
Data Types
Variables
Program Organization Units
* Functions
* Function Blocks
* Programs
Configuration, Resources, Tasks
Sequential Function Chart
* Steps
* Transitions
* Actions Blocks
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Standardization in Industrial Control Programming
Sequential Function Chart, SFC
 Powerful graphical technique for
describing the sequential
behaviour of a control program
Step 1
 Used to partition a control
problem
 Shows overview, also suitable for
rapid diagnostics
N
FILL
Transition 1
Step 2
S
Empty
Transition 2
Step 3
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Standardization in Industrial Control Programming
Sequential Function Chart, SFC
 Powerful graphical technique for
describing the sequential
behaviour of a control program
Step 1
 Used to partition a control
problem
 Shows overview, also suitable for
rapid diagnostics
 The basic elements are STEPS
with ACTION BLOCKS and
TRANSITIONS
N
FILL
Transition 1
Step 2
S
Empty
Transition 2
Step 3
 Support for alternative and
parallel sequences
PLCopen 64 printed at 16-7-2015
http://www.plcopen.org
PLCopen
Standardization in Industrial Control Programming
The IEC 61131-3 Standard
Top Down
Common Elements
Programming Languages
Bottom Up
PLCopen 65 printed at 16-7-2015
http://www.plcopen.org
PLCopen
Standardization in Industrial Control Programming
IEC Programming Environments
Many of them offer:
graphical programming
screens
support for multiple
windows
mouse operation
pull-down menus
built-in hypertext help
function
software verification during
design
PLCopen 66 printed at 16-7-2015
http://www.plcopen.org
PLCopen
Standardization in Industrial Control Programming
Common Elements
Sequential Function Chart
See separate presentation
PLCopen 67 printed at 16-7-2015
http://www.plcopen.org