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i
AUTOMATION PROCESS BY USING PLC
OMRON WITH PC CUSTOMIZED SIMULATOR
Teh Tze Keong
Bachelor of Mechatronics Engineering July 2012
ii
“ I hereby declare that I have read through this report entitle “Automation Process by
Using PLC OMRON with PC Customized Simulator” and found that it has comply the
partial fulfillment for awarding the degree of Bachelor of Mechatronic Engineering”.
Signature : .......................................................
Supervisor‟s Name : EN. SHAHRUDIN BIN ZAKARIA
Date : ...........................................................
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AUTOMATION PROCESS BY USING PLC OMRON WITH
PC CUSTOMIZED SIMULATOR
TEH TZE KEONG
A report submitted in partial fulfillment of the requirements for the degree
of Bachelor of Mechatronics Engineering
Faculty of Electrical Engineering
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
JUNE 2012
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I declare that this report entitle “Automation Process by Using PLC OMRON with PC
Customized Simulator” is the result of my own research except as cited in the references.
The report has not been accepted for any degree and is not concurrently submitted in
candidature of any other degree.
Signature : ..............................
Name : TEH TZE KEONG
Date : 8 JUNE 2012
v
ACKNOWLEDGEMENT
First and foremost, I would like to express my greatest gratefulness and sincere
thanks to my supervisor, Mr. Shahrudin Bin Zakaria, for his valuable helps and guidance in
the portion of supervision of this final year project. In truth, he gave me precious advices
during my dilemma in doing this final year project through this period of time.
In addition, I would like to thanks Sophic Automation Sdn. Bhd. PLC senior
programmer, Tan Khaik Koon, without him, I would not be able to get an overall idea on
how pass data to data memory, he had offer me a great help in this final year project.
Furthermore, I would like to give my appreciation to Sophic Automation Sdn. Bhd.
Software senior programmer, Yeoh Yow Yih for teaching me in Microsoft Visual Basic
2008 programming. Without his support and patient, I would not be able to write coding in
Visual Basic in such short period.
Last but not least, the appreciation gives to the lab technician, Siti Fatimah Binti
Kamarudin, due to her cooperation by letting me to make use of PLC in PLC laboratory.
Without her, I would not be able to access OMRON PLC CQM1H-CPU21 in PLC
laboratory. My fellow friends should be also recognized for their support, my sincere
appreciation to those who had provided me brilliant idea and assistance during my final
year project. Unfortunately, it is impossible to list all of my friends in this restricted space.
I am thankful to my family members.
Once again, I thank all people above for their tolerance and endeavors.
vi
ABSTRACT
Programmable Logic Controller (PLC) is a common process controller used in the
industry area. But, most of the engineer and technician do not have any single knowledge
about PLC, thus, this is very dangerous for those who running the maintenance process
sine they do not know what is the PLC input or output, I/O status, as an example, motor
and actuator as output, while electrical current as input. This project mainly describe about
how to enable the engineer or technician to read and understand the Programmable Logical
Controller (PLC) I/O status. This can be done by using host link communication method.
In order to achieve host link communication, an interface for PC and PLC is needed, which
is also known as protocol of communication. The system is mainly using PC as simulator
to read the data from CQM1H-CPU21 PLC and show the status of the I/O on the PC
simulator created by Microsoft Visual Basic 2008, and this will let the end use to monitor
the status of the automation machine easier, safer and also reduce the operating cost of
company for long term. The test result is expected to be providing stable communication
between PC and PLC and the status of I/O devices are expected shown on the screen of PC
simulator created by Microsoft Visual Basic 2008 according to the setting timer from
1milisecond to 1second gap.
vii
ABSTRAK
Programmable Logic Controller (PLC) adalah salah satu jenis alat kawalan yang
biasa digunakan di dalam kawasan industri. Namun demikian, kebanyakan jurutera atau
juruteknik tidak sedar tentang ilmu PLC. Justeru, fenomena ini adalah sangat
membahayakan mereka yang menjalankan penyelenggaraan tanpa mengira jurutera
ataupun juruteknik yang menjalankan tugas. Hal ini disebabkan oleh mereka tidak sedar
tentang status input dan juga ouput, contohnya motor dan silinder sebagai output, dan arus
elektrik sebagai input. Projek ini menerangkan tentang komunikasi antara OMRON PLC
(CQM1H-CPU21) dan PC melalui Microsoft Visua Basic 2008. Komunikasi jenis ini
mempunyai harga pasaran yang tinggi dalam bidang industry. Sistem ini akan mengunakan
PC sebagai simulator untuk membaca I/O status dalam PLC dan mempamerkan status
tersebut dalam simulator yang direka mengunakan Microsoft Visual Basic 2008. Dengan
ini, penguna mesin dapat meihat status I/O mesin mereka melalui PC simulator dengan
lebih mudah dan selamat. Hasil projek ini adalah dijangka dapat menyediakan komunikasi
yang stabil antara PC dan PLC serta mengurangkan kos operasi untuk jangka masa yang
panjang, status I/O juga dijangka dapat ditunjukkan di dalam PC simulator yang direka
melalui Microsoft Visual Basic 2008 dengan kadar yang segera.
viii
TABLE OF CONTENTS
DECLARATION………………………………………………………………….............iii
ACKNOWLEDGEMENT ............................................................................................... v
ABSTRACT .................................................................................................................... vi
ABSTRAK ......................................................................................................................vii
TABLE OF CONTENTS ............................................................................................. viii
LISTS OF TABLES ......................................................................................................... x
LIST OF FIGURES ........................................................................................................ xi
LIST OF ABBREVIATIONS ........................................................................................xii
CHAPTER I INTRODUCTION ..................................................................................... 1
1.1 Introduction .............................................................................................................. 1
1.2 Problem Statement ................................................................................................... 3
1.3 Objectives ................................................................................................................ 3
1.4 Project Scope ........................................................................................................... 4
CHAPTER 2 LITERATURE REVIEW ......................................................................... 5
2.1 Introduction .............................................................................................................. 5
2.2 Types of Interface..................................................................................................... 6
2.3 Types of Connection ................................................................................................ 8
2.4 Type of header ......................................................................................................... 9
2.5 Software Tools ....................................................................................................... 11
2.5 Literature Review Summary ................................................................................... 14
CHAPTER 3 METHODOLOGY .................................................................................. 15
3.1 Overall Design ....................................................................................................... 15
ix
3.2 Software Design ..................................................................................................... 17
3.4 Gantt Chart ............................................................................................................. 19
3.5 K-chart ................................................................................................................... 19
3.6 Study and Research ................................................................................................ 22
CHAPTER 4 RESULT AND ANALYSIS............................................24_Toc326875988
4.1 CQM1H-CPU21 Graphical User Interface (GUI) Data Read Accuracy................... 24
4.2 CQM1H-CPU21 Graphical User Interface (GUI) Data Read Stability .................... 28
4.3 Hardware Repeatability .......................................................................................... 30
4.4 Industrial Survey .................................................................................................... 32
CHAPTER 5 DISCUSSION .......................................................................................... 34
CHAPTER 6 CONCLUSION AND RECOMMENDATION ...................................... 37
6.1 Conclusion ............................................................................................................. 37
6.2 Recommendation.................................................................................................... 38
REFERENCES .............................................................................................................. 39
APPENDICES ................................................................................................................ 50
x
LISTS OF TABLES
Table 2.1: Touch Screen VS Laptop/Desktop ..................................................................... 7
Table 2.2: Comparison of Types of Connections ................................................................ 9
Table 2.3: Comparison of Header Code for Read Purpose ................................................ 10
Table 2.4: Command Line Interface VS Graphical User Interface .................................... 11
Table 3.1: Gantt Chart ...................................................................................................... 20
Table 3.2: Definition of Accuracy .................................................................................... 27
Table 4.1: Definition of accuracy ..................................... Error! Bookmark not defined.7
Table 4.2: Actuator trigger according to length of wood ................................................. 300
Table 4.3: Survey questions ............................................................................................. 32
xi
LIST OF FIGURES
Figure 3.1: Overall Project Flow Chart ............................................................................. 16
Figure 3.2: Software Design Flow Chart .......................................................................... 18
Figure 3.3: K-Chart .......................................................................................................... 21
Figure 3.4: Command and Response Format .................................................................... 22
Figure 4.1: CQM1H-CPU21 Graphical User Interface ..................................................... 25
Figure 4.2: CQM1H-CPU21 Graphical User Interface after Connection Establish ............ 26
Figure 4.3: Graph of Accuracy versus Number of Experiment .......................................... 27
Figure 4.4: Graph of Connection Stability versus Time .................................................... 29
Figure 4.5: Hardware outlook ........................................................................................... 30
Figure 4.6: Success/Fail versus length of material ............................................................ 31
Figure 4.7: Survey feedback ............................................................................................. 33
xii
LIST OF ABBREVIATIONS
PLC - Programmable Logical Controller
I/O - Input or output
LED - Light emitting Diode
PC - Personal Computer
API - Application Programming Interface
GUI - Graphical User Interface
CLI - Command Line Interface
1
CHAPTER I
INTRODUCTION
This chapter explains the traditional Programmable Logical Controller (PLC) status
monitoring system compared with the proposal system.
1.1 Introduction
Programmable Logical Controller (PLC) is one of the famous automation process
controller used all over the world. It is mainly apply in control of machinery on factory
assembly line, quality control line or light fixtures for more economy operational cost.
Programmable Logical Controller (PLC) is famous because of its flexibility and user
friendly ladder diagram programming language.
Programmable Logical Controller (PLC) was invented during the rise of automotive
manufacturing trend in America. During the period without the invention of Programmable
Logical Controller (PLC) in America, whenever the production model change, the control
panel must had been re-wired in order to change the sequence of automation process. After
the introduction of Programmable Logical Controller (PLC), the re-wiring process is not
necessary anymore; this is because the Programmable Logical Controller (PLC) had been
adopted into automotive industry when software revisions replace the modification of
hardware.
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By the way, Programmable Logical Controller (PLC) is not as perfect as we think,
it is good at flexibility for automation process control and other applications, but, the
monitoring of it is limited to those people who know how to use and program the
Programmable Logical Controller only. In order to monitor how much data or the counter‟s
value, the user will need to enter the Programmable Logical Controller (PLC) ladder
diagram to view the data they need. In addition, every different kind of Programmable
Logical Controller got their own custom ladder diagram programming language, although
the flow to program is almost the same, the end user still unable to learn every kind of
language for it except for those expertises.
From the above paragraph, it is clear that if want to know the status or data of
automation process, will need to hire someone who able to access and read Programmable
Logical Controller (PLC) ladder diagram just to obtain the data we want from
Programmable Logical Controller (PLC), and this phenomena is really waste of human
resources. Thus, the implementation of PC base simulator is require to show the data of
Programmable Logical Controller (PLC) on the screen of PC without need any access into
the Programmable Logical Controller (PLC).
Every kind of Programmable Logical Controller (PLC) only can be communicate
with PC software such as Microsoft Visual Studio, Microsoft Visual Basic, MATLAB, and
etc. through their own unique protocol. Some examples of Programming Logical
Controller (PLC) are Omron, Keyence, Panasonic, Mitsubishi, Allen Bradley,
Telemechanique, Hitachi, and etc.. But, in this project, I only was going to do the PC
simulator for the OMRON Programmable Logical Controller (PLC) CQM1H-CPU21.
3
1.2 Problem Statement
From the internship period, I had observe that a lot of factories engineer or
technician still do not have any idea on their device status such as sensor, actuator, motor
and sort of automation devices. This had make hard for engineer or technician who going
to run maintenance and also in the process of monitoring machine status such as the motor
status, or the output counts; this is because not everyone know how to monitor the status of
Programmable Logical Controller (PLC) ladder diagram, or directly from the LED
indicator on the Programmable Logical Controller (PLC). From this project, the low cost
monitoring system will be developed and able to reduce operation cost of the factory for
long term planning and able to prevent put engineer or technician into great danger while
operate or running maintenance on the machine.
1.3 Objectives
The objectives of this project are:
i) To design a PC simulator that able to monitor the Omron CQM1H-CPU21 PLC
current I/O status.
ii) To apply the knowledge of Microsoft Visual Basic 2008 Programming in
automation monitoring process that controlled by Omron CQM1H-CPU21 PLC.
iii) To design and develop a low cost PC simulator that able to monitor the Omron
CQM1H-CPU21 PLC current I/O status.
iv) To develop a prototype of simple automation process to show the function of
PC simulator.
4
1.4 Project Scope
This project will focus primarily on the software design (types of programming
language) and hardware design to monitor the Omron CQM1H-CPU21 PLC I/O status
directly on the screen of PC via PC simulator that designed by Microsoft Visual Basic
2008.
a) Software part:
1. To program a PC simulator by using Microsoft Visual Basic 2008.
2. To read I/O status from Omron CQM1H-CPU21 PLC only, not include write
data into PLC.
3. The PC simulator only can be used with Omron CQM1H-CPU21 PLC only.
4. The PC simulator must connect to Omron CQM1H-CPU21 PLC by using
RS232 cable.
b) Hardware Part
1. The automation process to be designed possesses not more than 10 I/O on
Omron CQM1H-CPU21 PLC.
2. The PC which equip with PC simulator must be connected to PC by using
RS232 cable and the wiring connection must be refer to Omron
CQM1H-CPU21 Operational Manual.
3. The total cost of the hardware must not more than RM500.
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CHAPTER 2
LITERATURE REVIEW
2.1 Introduction
PC simulator is one of the methods to connect the Programmable Logical
Connector (PLC) and monitor the Programmable Logical Controller (PLC) status. This
type of application is fairy important and possess high demand in the industry area,
especially for those do not have knowledge on Programmable Logical Controller (PLC).
As we know that, the Inputs and outputs of Programmable Logical Controller (PLC) are
form by various kinds of dangerous equipments, such as motor, actuator, driller, sensor,
even 240V electric supply is count as input.
Thus, with this system, it can prevent that some engineers or technicians who not
equip with Programmable Logical Controller being injured or hurt by the inputs or outputs
of Programmable Logical controller (PLC) while they are going to run a maintenance on
the machine. In addition, with this project, it is able to reduce the production operation cost
monthly by reduce the human resources needed in that particular area.
Thus, it is very appealing to design and implement a low cost real time machine
monitoring system in future, providing an instant Programmable Logical Controller (PLC)
I/O status and also some information that required by user when the automation process is
on the running mode.
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2.2 Types of Interface
There are many methods to illustrate the data of Programmable Logical Controller
(PLC) to user through pre-determine interface path. The available interfaces are monitor
screen of laptop or desktop and touch screen.
Among these two types of screen, the price of touch screen will be higher compare
to monitor screen of laptop or desktop. In addition, user need to purchase additional touch
screen in order to use it as interface, but the user still need a laptop or desktop to program it.
Furthermore, touch screen size normally is smaller than laptop or desktop monitor screen.
In order to be able using touch screen as interface, the user need to learn the way to
program and design the touch screen interface[1], while if just use laptop or desktop screen,
user just need to learn Microsoft Visual Basic 2008 language. For touch screen, user can
just change the input data on the screen by touching it, but if want to change the sequences
of automation process, a laptop or desktop still needed, whereby if using the screen of
laptop or desktop as interface, both sequence and input data change can be done easily in
the laptop or desktop.
In addition, the ladder diagram in CQM1H-CPU21 PLC is different for touch
screen interface and normal interface created by Microsoft Visual Basic 2008. This is
because touch screen is only used to display, while, means in the PLC ladder diagram, need
to set program, that is transmit (TXD), so that the PLC will send the data from PLC to
touch screen automatically [2] . Whereby, the simulator created by the Microsoft Visual
Basic 2008 will just use data read function to read the value or data in normal ladder
diagram.
From the above comparison, it is obvious that touch screen will consume more
budget compare to the normal laptop or desktop screen. Thus, as the budget is the biggest
concern, so, the interface I choose here is by using laptop screen. Table of summary for
comparison of both type of interface is in Table 2.1:
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Table 2.1: Touch Screen VS Laptop/Desktop
Topic Touch Screen Laptop/Desktop Screen
Ease Need learn particular touch
screen programming language in
its custom software.
Need do additional programming
in PLC for data transmit (TXD)
[2] .
Just need to do Microsoft Visual
Basic 2008 programming
interface.
Flexibility User could direct change input
data for automation process by
just touch the screen, but need
connect to laptop or desktop in
case want change sequence of
process.
User able to change input data
or sequence of automation
process directly in laptop or
desktop.
Multitasking Touch screen do not provide
multitasking ability.
Laptop or desktop have
windows that enable a user to
easily view, control, and
manipulate multiple things at
once.
Cost Need purchase touch screen as
interface, while also need laptop
or desktop as programming
tools.
Just use laptop or desktop to
program and display.
8
2.3 Types of Connection
There are few types of connection available for the CQM1H-CPU21 Programmable
Logical Controller; they are host link connection which using RS232C cable, DeviceNet,
Controller Link, and Ethernet.
Among these four types of connection, RS232C provide lowest budget option,
followed by Ehternet, DeviceNet and Controller Link. This is because we can just simply
purchase the RS232C connector, also known as 9 pin D-sub connector and make own cable
by following the OMRON operational manual under wiring section [3-5] . The function of
RS232C connection is almost the same compare with Ethernet, DeviceNet, and Controller
Link connection.
From the data transmit aspect, DeviceNet and Controller Link connection possesses
better solution, this is because they no need any additional program in order to show their
data on the screen. This can be done by just purchase DeviceNet cable and Controller Link
unit with installed software, and then the data can be seen without any extra interface
needed. Method to operate the DeviceNet can be obtain in its manual[6] .Whereby,
Controller Link Unit is another additional plug in for CQM1H-CPU21 Programmable
Logical Controller, this Controller Link Unit are used to transmit data in big quantity, but it
still need an software interface created by user [7] . For Ethernet connection, it can conduct
function as excellent as Control Link Unit, but we need to purchase OMRON FINS
Ethernet Communication Interface API, the price of this will cost $395.00 (U.S. Dollar)
[8] . And this is over my range of budget for this project.
From the above comparison, it is obvious that connection type of RS232C will
provide more economical solution, since the budget is biggest concern in this project, so, at
this part, I will choose RS232C host link communication as connection type between
CQM1H-CPU21 PLC and my laptop. Table 2.2 shows the specifications of each type
connections:
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Table 2.2: Comparison of Types of Connections
Topic RS232C DeviceNet Ethernet Controller Link
Unit
Ease Need to build
own cable
[3] .
Able to
purchase in
whole set.
Able
purchase in
whole set.
Able to purchase
in whole set.
Cost Cheapest
since can
custom made
according to
operational
manual [3] .
Expensive,
need
purchase
software and
DeviceNet
controller
card.
Expensive,
need
purchase
cable from
detailer.
Expensive, need
purchase
software and
Controller Link
Unit controller
card.
2.4 Type of header
In the CQM1H-CPU21 Programmable Logical Controller, there are total 38 type of
header code. But in this project only use 1 type of header code in this project to read the
data from the CQM1H-CPU21 Programmable Logical Controller.
Since in this project only do for read data from CQM1H-CPU21 Programmable
Logical Controller, thus, I will only choose from 8 types of memory read header codes
which are IR/SR area read (RR), LR area read (RL), HR area read (RH), PV read (RC), TC
status read (RG), DM area read (RD), EM area read (RE), and AR area read (RJ) [9] .
These 8 types of header codes possess different application field, such as RD is using to
read data memory area which is from DM0000 to DM 6559 [10]. For IR/SR area read (RR),
it is read only the IR and SR which means this header code able to read from IR016 to
10
IR243 and from SR244 to SR251. Table 2.3 shows the comparison between these 8 types
of header codes, and their application field [9]:
Table 2.3: Comparison of Header Code for Read Purpose
Header
Codes
Application Memory Area Advantages Limitations
RR From IR0000 to IR0255.
Total of 256 available
storing memory [11].
Direct information
from I/O status.
Value depends on
IR/SR [11] .
RL From LR0000 to LR0063.
Total of 64 available
storing memory [12].
Sharing memory area
when connect
CQM1H-CPU21
with other types of
PLCs.
Only used to share
data between
CQM1H-CPU21
and other PLCs
[12] .
RH From HR0000 to HR0099.
Total of 100 available
storing memory [13].
Data store even after
the power of
CQM1H-CPU21 is
turn off.
Cannot use as reset
input for Keep (11)
[13] .
RC From PV0000 to PV0511.
Total of 512 available
storing memory [14].
Able to read the
current values of
timer and counter.
Only apply for
timer and counter
present values (PV)
[14] .
RG From TC0000 to TC0512.
Total of 512 available
storing memory [14].
Able to shows the
timer or counter flag
directly.
Only apply for
timer and counter
completion flag
[14] .
RD From DM0000 to
DM6655.
Total of 6656 available
storing memory[10].
Able to manipulate
value through Ladder
diagram
programming.
Need additional
rung /step in ladder
diagram to set data
of data memory
area.
RE From EM0000 to Able to be used Only apply in
11
EM6143.
Total of 6144 available
storing memory [15].
freely. CQM1H-CPU61
[15] .
Not available in
CQM1H-CPU21
PLC.
RJ From AR0000 to AR0027.
Total of 28 available
storing memory[16].
Serve as CQM1H-
CPU21 PLC internal
setting memory area.
Only used for
setting purpose.
2.5 Software Tools
Software tool is one of the most powerful PC based path to design whatever
applications we want. There are some common in use software tools such as Microsoft
Visual studio, MATLAB, C Sharp, Perl and so on. Software tools are mainly divided into
2 main types that are Command Line Interface software and Graphical User Interface. Both
kinds of interfacing software got their own strength, but also got their shortage when
compare to each other. Comparison of Command Line Interface (CLI) with Graphical User
Interface (GUI) can be seen as in the Table 2.4 below [17, 18] :
Table 2.4: Command Line Interface VS Graphical User Interface
Topic Command Line Interface (CLI) Graphical User Interface (GUI)
Ease Need to get familiar and
memorized in order to operate
the command.
Difficult for beginner to navigate
and operate a command line
interface.
Fast tools for expertise.
May have some difficulties for
beginner to learn.
Control technique includes
using of mouse to control.
Easier to pick up this interface
compare to Command Line
Interface
Control User has much control of their User often needs to do some
12
file system, for example, they
could move a file just by 1 line
command.
specify tasks may need to resort
to a command line to complete
a particular task.
Appearance The appearance of Command
Line Interface does not change
usually.
Graphical User Interface tends
to change often, especially with
every new released version.
This lead to wasting user time.
Multitasking Command Line Interface did not
offer the same ease and ability to
view multiple things at once on
the same screen.
There does have terminals
within desktop environment,
example GNOME allow
multitasking.
Graphical User Interface users
have windows that enable a user
to easily view, control, and
manipulate multiple things at
once.
Speed Command Line user only needs
to use keyboard to navigate
command line interface and
often need only few lines to
perform a task.
An advance command line
interface user is mostly able to
get something done much faster
than advanced Graphical User
interface user.
Graphical user Interface may be
easier to be used because of the
mouse.
But, using a ,mouse or keyboard
to navigate your operating
system for many things is going
to be much slower compare to
someone who work in
command line interface
environment.
Resources Command Line Interface only
used up little bit of computer
resources.
There is no graphical layer
needed to be installing to enable
functionality of command line
interface.
A Graphical User Interface will
require more system resources
in order to load its elements
such as icons, fonts and so on.
Furthermore, video drivers,
mouse drivers, and other drivers
need to be load will take
additional resources.
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