automation process by using plc omron with...

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 : ...........................................................

iii

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

iv

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.

2

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.

5

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.

6

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:

7

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:

9

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.



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.



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.



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.



Able to shows the

timer or counter flag

directly.

Only apply for

timer and counter

completion flag

[14] .

RD From DM0000 to

DM6655.


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.



freely. CQM1H-CPU61

[15] .

Not available in

CQM1H-CPU21

PLC.

RJ From AR0000 to AR0027.


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.

automation process by using plc omron with...

Documents