Automating Manufacturing Systems with PLCs.pdf



Taken from Preface: Designing software for control systems is difficult. Experienced controls engineers have learned many techniques that allow them to solve problems. This book was written to present methods for designing controls software using Programmable Logic Controllers (PLCs). It is my personal hope that by employing the knowledge in the book that you will be able to quickly write controls programs that work as expected (and avoid having to learn by costly mistakes.)

This book has been designed for students with some knowledge of technology, including limited electricity, who wish to learn the discipline of practical control system design on commonly used hardware. To this end the book will use the Allen Bradley ControlLogix processors to allow depth. Although the chapters will focus on specific hardware, the techniques are portable to other PLCs. Whenever possible the IEC 61131 programming standards will be used to help in the use of other PLCs.

Copyright (c) 1993-2008 Hugh Jack (jackh@gvsu.edu).

Contents:

  • PROGRAMMABLE LOGIC CONTROLLERS
    • INTRODUCTION
    • A CASE STUDY
    • SUMMARY
    • PRACTICE PROBLEMS
    • PRACTICE PROBLEM SOLUTIONS
    • ASSIGNMENT PROBLEMS
  • PLC HARDWARE
    • INTRODUCTION
    • INPUTS AND OUTPUTS
    • RELAYS
    • A CASE STUDY
    • ELECTRICAL WIRING DIAGRAMS
    • SUMMARY
    • PRACTICE PROBLEMS
    • PRACTICE PROBLEM SOLUTIONS
    • ASSIGNMENT PROBLEMS
  • LOGICAL SENSORS
    • INTRODUCTION
    • SENSOR WIRING
    • PRESENCE DETECTION
    • SUMMARY
    • PRACTICE PROBLEMS
    • PRACTICE PROBLEM SOLUTIONS
    • ASSIGNMENT PROBLEMS
  • LOGICAL ACTUATORS
    • INTRODUCTION
    • SOLENOIDS
    • VALVES
    • CYLINDERS
    • HYDRAULICS
    • PNEUMATICS
    • MOTORS
    • OTHERS
    • SUMMARY
    • PRACTICE PROBLEMS
    • PRACTICE PROBLEM SOLUTIONS
    • ASSIGNMENT PROBLEMS
  • BOOLEAN LOGIC DESIGN
    • INTRODUCTION
    • BOOLEAN ALGEBRA
    • LOGIC DESIGN
    • COMMON LOGIC FORMS
    • SIMPLE DESIGN CASES
    • SUMMARY
    • PRACTICE PROBLEMS
    • PRACTICE PROBLEM SOLUTIONS
    • ASSIGNMENT PROBLEMS
  • KARNAUGH MAPS
    • INTRODUCTION
    • SUMMARY
    • PRACTICE PROBLEMS
    • PRACTICE PROBLEM SOLUTIONS
    • ASSIGNMENT PROBLEMS
  • PLC OPERATION
    • INTRODUCTION
    • OPERATION SEQUENCE
    • PLC STATUS
    • MEMORY TYPES
    • SOFTWARE BASED PLCS
    • SUMMARY
    • PRACTICE PROBLEMS
    • PRACTICE PROBLEM SOLUTIONS
    • ASSIGNMENT PROBLEMS
  • LATCHES, TIMERS, COUNTERS AND MORE
    • INTRODUCTION
    • LATCHES
    • TIMERS
    • COUNTERS
    • MASTER CONTROL RELAYS (MCRs)
    • INTERNAL BITS
    • DESIGN CASES
    • SUMMARY
    • PRACTICE PROBLEMS
    • PRACTICE PROBLEM SOLUTIONS
    • ASSIGNMENT PROBLEMS
  • STRUCTURED LOGIC DESIGN
    • INTRODUCTION
    • PROCESS SEQUENCE BITS
    • TIMING DIAGRAMS
    • DESIGN CASES
    • SUMMARY
    • PRACTICE PROBLEMS
    • PRACTICE PROBLEM SOLUTIONS
    • ASSIGNMENT PROBLEMS
  • FLOWCHART BASED DESIGN
    • INTRODUCTION
    • BLOCK LOGIC
    • SEQUENCE BITS
    • SUMMARY
    • PRACTICE PROBLEMS
    • PRACTICE PROBLEM SOLUTIONS
    • ASSIGNMENT PROBLEMS
  • STATE BASED DESIGN
    • INTRODUCTION
    • SUMMARY
    • PRACTICE PROBLEMS
    • PRACTICE PROBLEM SOLUTIONS
    • ASSIGNMENT PROBLEMS
  • NUMBERS AND DATA
    • INTRODUCTION
    • NUMERICAL VALUES
    • DATA CHARACTERIZATION
    • SUMMARY
    • PRACTICE PROBLEMS
    • PRACTICE PROBLEM SOLUTIONS
    • ASSIGNMENT PROBLEMS
  • PLC MEMORY
    • INTRODUCTION
    • PROGRAM VS VARIABLE MEMORY
    • PROGRAMS
    • VARIABLES (TAGS)
    • SUMMARY
    • PRACTICE PROBLEMS
    • PRACTICE PROBLEM SOLUTIONS
    • ASSIGNMENT PROBLEMS
  • LADDER LOGIC FUNCTIONS
    • INTRODUCTION
    • DATA HANDLING
    • LOGICAL FUNCTIONS
    • DESIGN CASES
    • SUMMARY
    • PRACTICE PROBLEMS
    • PRACTICE PROBLEM SOLUTIONS
    • ASSIGNMENT PROBLEMS
  • ADVANCED LADDER LOGIC FUNCTIONS
    • INTRODUCTION
    • LIST FUNCTIONS
    • PROGRAM CONTROL
    • INPUT AND OUTPUT FUNCTIONS
    • DESIGN TECHNIQUES
    • DESIGN CASES
    • SUMMARY
    • PRACTICE PROBLEMS
    • PRACTICE PROBLEM SOLUTIONS
    • ASSIGNMENT PROBLEMS
  • OPEN CONTROLLERS
    • INTRODUCTION
    • IEC 61131
    • OPEN ARCHITECTURE CONTROLLERS
    • SUMMARY
    • PRACTICE PROBLEMS
    • PRACTICE PROBLEM SOLUTIONS
    • ASSIGNMENT PROBLEMS
  • INSTRUCTION LIST PROGRAMMING
    • INTRODUCTION
    • THE IEC 61131 VERSION
    • THE ALLEN-BRADLEY VERSION
    • SUMMARY
    • PRACTICE PROBLEMS
    • PRACTICE PROBLEM SOLUTIONS
    • ASSIGNMENT PROBLEMS
  • STRUCTURED TEXT PROGRAMMING
    • INTRODUCTION
    • THE LANGUAGE
    • AN EXAMPLE
    • SUMMARY
    • PRACTICE PROBLEMS
    • PRACTICE PROBLEM SOLUTIONS
    • ASSIGNMENT PROBLEMS
  • SEQUENTIAL FUNCTION CHARTS
    • INTRODUCTION
    • A COMPARISON OF METHODS
    • SUMMARY
    • PRACTICE PROBLEMS
    • PRACTICE PROBLEM SOLUTIONS
    • ASSIGNMENT PROBLEMS
  • FUNCTION BLOCK PROGRAMMING
    • INTRODUCTION
    • CREATING FUNCTION BLOCKS
    • DESIGN CASE
    • SUMMARY
    • PRACTICE PROBLEMS
    • PRACTICE PROBLEM SOLUTIONS
    • ASSIGNMENT PROBLEMS
  • ANALOG INPUTS AND OUTPUTS
    • INTRODUCTION
    • ANALOG INPUTS
    • ANALOG OUTPUTS
    • DESIGN CASES
    • SUMMARY
    • PRACTICE PROBLEMS
    • PRACTICE PROBLEM SOLUTIONS
    • ASSIGNMENT PROBLEMS
  • CONTINUOUS SENSORS
    • INTRODUCTION
    • INDUSTRIAL SENSORS
    • INPUT ISSUES
    • SENSOR GLOSSARY
    • SUMMARY
    • REFERENCES
    • PRACTICE PROBLEMS
    • PRACTICE PROBLEM SOLUTIONS
    • ASSIGNMENT PROBLEMS
  • CONTINUOUS ACTUATORS
    • INTRODUCTION
    • ELECTRIC MOTORS
    • HYDRAULICS
    • OTHER SYSTEMS
    • SUMMARY
    • PRACTICE PROBLEMS
    • PRACTICE PROBLEM SOLUTIONS
    • ASSIGNMENT PROBLEMS
  • CONTINUOUS CONTROL
    • INTRODUCTION
    • CONTROL OF LOGICAL ACTUATOR SYSTEMS
    • CONTROL OF CONTINUOUS ACTUATOR SYSTEMS
    • DESIGN CASES
    • SUMMARY
    • PRACTICE PROBLEMS
    • PRACTICE PROBLEM SOLUTIONS
    • ASSIGNMENT PROBLEMS
  • FUZZY LOGIC
    • INTRODUCTION
    • COMMERCIAL CONTROLLERS
    • REFERENCES
    • SUMMARY
    • PRACTICE PROBLEMS
    • PRACTICE PROBLEM SOLUTIONS
    • ASSIGNMENT PROBLEMS
  • SERIAL COMMUNICATION
    • INTRODUCTION
    • SERIAL COMMUNICATIONS
    • PARALLEL COMMUNICATIONS
    • DESIGN CASES
    • SUMMARY
    • PRACTICE PROBLEMS
    • PRACTICE PROBLEM SOLUTIONS
    • ASSIGNMENT PROBLEMS
  • NETWORKING
    • INTRODUCTION
    • NETWORK STANDARDS
    • 6 Sercos
    • PROPRIETARY NETWORKS
    • NETWORK COMPARISONS
    • DESIGN CASES
    • SUMMARY
    • PRACTICE PROBLEMS
    • PRACTICE PROBLEM SOLUTIONS
    • ASSIGNMENT PROBLEMS
  • INTERNET
    • INTRODUCTION
    • DESIGN CASES
    • SUMMARY
    • PRACTICE PROBLEMS
    • PRACTICE PROBLEM SOLUTIONS
    • ASSIGNMENT PROBLEMS
  • HUMAN MACHINE INTERFACES (HMI)
    • INTRODUCTION
    • HMI/MMI DESIGN
    • DESIGN CASES
    • SUMMARY
    • PRACTICE PROBLEMS
    • PRACTICE PROBLEM SOLUTIONS
    • ASSIGNMENT PROBLEMS
  • ELECTRICAL DESIGN AND CONSTRUCTION
    • INTRODUCTION
    • ELECTRICAL WIRING DIAGRAMS
    • FAIL-SAFE DESIGN
    • SAFETY RULES SUMMARY
    • REFERENCES
    • SUMMARY
    • PRACTICE PROBLEMS
    • PRACTICE PROBLEM SOLUTIONS
    • ASSIGNMENT PROBLEMS
  • SOFTWARE ENGINEERING
    • INTRODUCTION
    • DEBUGGING
    • PROCESS MODELLING
    • PROGRAMMING FOR LARGE SYSTEMS
    • DOCUMENTATION
    • COMMISIONING
    • SAFETY
    • LEAN MANUFACTURING
    • REFERENCES
    • SUMMARY
    • PRACTICE PROBLEMS
    • PRACTICE PROBLEM SOLUTIONS
    • ASSIGNMENT PROBLEMS
  • SELECTING A PLC
    • INTRODUCTION
    • SPECIAL I/O MODULES
    • SUMMARY
    • PRACTICE PROBLEMS
    • PRACTICE PROBLEM SOLUTIONS
    • ASSIGNMENT PROBLEMS
  • FUNCTION REFERENCE
    • FUNCTION DESCRIPTIONS
    • DATA TYPES
  • PLC REFERENCES
    • SUPPLIERS
    • PROFESSIONAL INTEREST GROUPS
    • PLC/DISCRETE CONTROL REFERENCES
  • GNU Free Documentation License

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