copyright © 2005 rockwell automation, inc. all rights reserved. 1 power programming v2.1 kevin...

Copyright © 2005 Rockwell Automation, Inc. All rights reserved. 1

Power Programming V2.1

Kevin Miller, SYDDarryl Jacobs, Rockwell Automation

2 Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

What is Power Programming?

• Clear and consistent structure– Easy to follow program example.– Application note to guide you through a program example.

• State Model programming– Pack ML State Model as “Behavioral Model for machine”

• Standardized Tags– Pack Tags are used to provide raw efficiency data.

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What can Power Programming do for you?

• Save time• Save money• Allow you to reuse modules in future projects• Make troubleshooting easier in all machines in which you use

modular code -- no matter the customer or application• Provide a quicker return on investment


So many standards, so little time!

Business Planning & LogisticsPlant Production Scheduling,Operational Management, etc

ManufacturingOperations & Control

Dispatching Production, Detailed ProductionScheduling, Reliability Assurance, ...

BatchControl

MotionControl

ContinuousControl

Level 4

Level 3

Levels2,1,0

IEC 61131Fieldbus

Equipment Control

Intelligent Devices

ISA 88IEC 61512OPCPackML*

ISA 95

Adapted from: ISA-95.00.01-2000

Automation

ERP

MES

DiscreteControl

* PackML Model is in development


Rockwell Automation has assembled the right tools for the job

• The application engineer’s toolbox:– Functional specifications– Program structure examples– State models– Machine control templates– Axis routine module templates

We call it:Power Programming


Power Programming is:

• Integrated– Provides interoperability with plant-wide systems through Logix– Provides standard animated diagram showing the various machine states arranged in a

flow diagram

From shop floor to top floor, you and your applications down the line, will know exactly what is going on with each of your applications, no matter where you are in the plant or which application you’re looking at -- only one play book required


RA Power Programming

Machine Logic

State Logic

Notice the consistent structure, between the Machine program and the Line Program. The Machine Logic is the routine that the Hardware I/O is connected to, E-Stops and permissive. This structure was reused for line connections to individual machines.

The Same State Logic was used, there are NO differences between these routine (Except one is written in ladder and the other is a SFC for illustration of different programming techniques.


RA Power Programming


How PhaseManager fits into ISA-88 (S88) batch control model

Recipe

Procedure Formula Values

Unit Procedures

Operations

Phases

All the instructions to make a product. (For example, Tomato Soup Recipe)

SFC(s) defining the order in

which the phases run. Can be

collapsed to just a Procedure.

Lowest level of recipe control.

(Add Water)

Defines product-specific recipe values. (Use 200

gallons water)Consists of

Consist of

Consist of

Support ISA-88 Phase State Model.

RSBizWare Batch provides Batch Management for this part for complex

batches OR an SFC routine in the controller can be the entire Procedure

for a simple batch.

PhaseManager in the controller provides the state logic framework for phases and enforces the state model.


Controller Organizer View

• Phases are created and scheduled at the task level (similar to Programs)• Phase state routines are created within a phase

– Can be written in any language

Equipment Phases added in Task View

Phase Scoped Tags Folder and Control Tags are

automatically generated.

Not all States need to be implemented – only those implemented are shown

Phases can be unscheduled


Programs compared to Phases

• 1 Main Routine per program• Main is called each time task executes• Main calls other subroutines based on user

Logic• Monitor code within routine to determine

what is executing

• “- ing” routines act like main routines– Aborting, Holding, Resetting, Restarting, Running, and

Stopping

• Execution determined by phase sequencer (RSBizWare Batch or application code)

• Phase monitor tool to see which routine is executing

Program PhaseRSBizWare BatchApplication Code

Batch Sequencer


Equipment Phase Backing Tag

• A controller-scopedequipment phase backing tag is created by RSLogix 5000 automatically

• Tag’s name matches equipment phase name

– Makes code easier to read• Allows users to debug

and monitor equipmentphase’s execution

• Tag is accessible via HMIscreens

• Additionally, it provides self-documenting code by leveraging the descriptionpass-through functionality

Equipment PhaseBacking tag


Create Phase State Routine

• Phase State routines are just like “Normal” routines except:– Have a fixed name– Are executed according to the state machine rules

• State names chosen from a list of valid states:

– Restarting– Running– Holding– Resetting– Stopping– Aborting

• Just like “Normal” routines, state routines can be implemented in any available language

– Ladder Diagram– Sequential Function Chart– Function Block Diagram– Structured Text

Select equipment phase state

Select equipment phase state

language


Physical Model

Vertical Form Seal Machine

Process Cell

Unit

Equipment Module

Control Module


OEM benefits

• Scalability– Uses the same straightforward terminology no

matter the size of your machine

• Design efficiencies– Reusability

• Standardized, modular code development improves time to market– Improves design quality– Reduces errors– Uses best practices– Training costs can be focused

• allows you to easily match what customer is already using because of standardized code

• common interface minimizes customer resistance to a different brand of machine (e.g., Siemens can be migrated to A-B easily)

• Simplified maintenance– Standardized code allows allows for simplified troubleshooting – Less training required if all of the machines behave the same way


The right tools for the job

• The application engineer’s toolbox:– State models– Functional specifications– Modular code use examples– Machine program structure examples

We call it:Power Programming


Let’s take a lesson

• Observe what has taken place in batch with regard to defined standards and powerful tools to model, create, and monitor systems.

• Motion Control and Packaging is undergoing some of the same development.

• Generally the end customer needs are well defined; – Access to efficiency information. – Maintainable code or a great support contract.– Highest performance possible from the machine.– Low cost of integration of machine into facility.– A clean intuitive HMI.


Times are Changing

The packaging world has gone from (Line shaft) to (some servos) and (Integrated servo motion) machines. increased complexity of the control system required to run these machines compel technology providers to provide a more structured approach to integrating these control systems. In the end we would like to have a method available to integrate our systems with consistent tags, and data.

Cam


What RA is doing to help

• Rockwell Automation is continually pursuing and incorporating what you need to be successful

– active on industry committees to keep abreast of emerging practices and technology

– incorporating new industry technology and trends to provide the right tools

IEC 61131Fieldbus

Adapted from: ISA-95.00.01-2000

BatchControl

Levels2,1,0

Equipment Control

Intelligent DevicesAutomation

* PackML Model is in development

ContinuousControl

DiscreteControl

MotionControl

ISA 88IEC 61512OPC*PackML

– creating integrated, modular programming to provide:• A modular format• A consistent structure• State models• Consistent terminology


PackML

• Covers– Auto Mode State Model (S88

derived)– Data Definitions (Pack Tags)

• Assists – Derive efficiency information through

Pack Tags– Maintenance & Trouble Shooting

through common approach in Machine Sequence

– Consistent data format makes integration go smoother, adoption of a OEM machine is easier.


How Power Programming Helps You

• Allows you to view HMI using a machine state model


OEM benefits

• Design efficiencies– Reusability

• Modular code development improves time to market– Improves design quality, and reduces errors– Uses best practices

– Scalability • allows you to easily match what customer is already using because of standardized code• Uses the same straightforward terminology no matter the size of your machine• Common interface minimizes customer resistance to a different brand of machine (e.g., Siemens can be

migrated to A-B easily)

– Simplified maintenance• Standardized code allows allows for simplified troubleshooting • Less training required


End user benefits

• Simplified maintenance– Easier machine integration.– Quicker upgrades and on-site changes

• Less downtime – Standardization means easier troubleshooting– Lower training costs– Reduced changeover time

• Production– Greater machine interoperability– Higher efficiencies– Standardized efficiency reporting– Lower operator training costs


Rapid Application Development

Develop quickly Control Applications by reusing libraries of standard Logix program objects that contain all the data and code required to control every device in the plant floor

When you reuse code multiple times in one program:

C Programmers = InstancesAutomation Desktop =

SubsystemsISA S88 = Equipment Modules

Machine builders = Sections

Reusable code is sometimes referred to as:

C Programmers = ClassesAutomation Desktop = TemplatesISA S88 = Equipment Modules

Machine builders = Sections


Visio Version of state model

Draw ing Title:

Creation Date:

File Name:

Auto State Diagram Rev1.0

January 15, 2003

AutoStateModel.vsd

STOPPED1) System powered.2) All Axes Off (Feedback Off)3) Axes must be homed andrepositioned before running.

State=1

ABORTING1) Axes Individually commandedto stop (no coordination)2) After Stopping Axes DisableFeedback.

State=256

READY1) Starting FunctionsComplete2) Axes Geared/Cammed3) Master NOT running

State=4

STANDBY1) Machine armed forproduce conditions tocommence motion.

State=8

HELD1) Holding CommandCompleted2) Axes Remain active.

State=128

HOLDING1) Coordinated stop initiatedon master.2) All axes remain geared orcammed

State=64

ProduceCondition

sMet

ProduceCondition

sBecome

False

StartComman

d

InitializeProcessComplet

e

STARTING1) Axes faults are cleared2) Axes are enabled, Homed& moved to start positions3) Gearing/Cams initialized4) Master not Started

State=2

ABORTED1) All Axes Off (Feedback Off)2) Axes must be homed andrepositioned before running.3) Fault indications remainfor review by operator

State=512

StopProcessComplet

e

Fault

HoldingProcessComplet

e

FaultHoldCommand

FaultFault

FaultFault

Fault

STOPPING1) Stop Initiated on Master2) Once Master Stops All axescommanded to stop anddisable feedback.

State=32

StopCommand

InitializeComman

d

StopCommand

AbortingProcessComplete

StartCommand

StopCommand

From Producing

To

Sto

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StopCommand

PRODUCING1) Master Started2) All axes performing automotion3) Bars being packaged

State=16

HoldComman

d

Auto State Model Diagram

StopCommand

StopCommand

Auto Mode InitiatedBY Operator

(START AUTO)

State Transitions

Initialize CommandStart CommandStop CommandHold Command

Initialize Process CompleteStart Process CompleteStop Process CompleteHold Process CompleteProduce ConditionsFault


States and Transitions

For this state TransitionExampleLook for Example

Stopped

Stopping

Held

Holding

Aborted

Aborting

Producing

Standby

Ready

Starting

Machine powers up in stoppedstate, or from pressing the

Stop Button

1) System powered.2) All Axes Off (Feedback Off)3) Axes must be homed before running.

State=1

--> Ready--> Stopping--> Aborting

Initilaize push button transition

1) Axes faults are cleared2) Axes enabled, Homed & moved to start position.3) Gearing/Cams initialized4) Master not Started

State=2

How is this machine initalzed

1) Starting Functions Complete2) Axes Geared/Cammed3) Master NOT running

State=4

1) Machine armed for produce conditions to commence motion.

State=8

1) Coordinated stop initiated on master.2) All axes remain geared or cammed

State=64

1) Axes Individually commanded to stop (no coordination)2) After Stopping Axes Disable Feedback.

State=256

1) Master Started2) All axes performing auto motion3) Bars being packaged

State=16

1) Holding Command Completed2) Axes Remain active.

State=128

1) Stop Initiated on Master2) Once Master Stops All axes commanded to stop and disablefeedback.

State=32

Automatic transition when allaxes have completed starting

functions.

This means someone haspressed the Start button.

Making Product.

Cycle stopping and disablingthe machine.

This is a Pause or Holdcommand indicating it will cycle

stop and servos will remainactive.

A major fault has occurred,stopping functions comencing.

Machine is stopped axesdisabled.

Held with Servos Active

--> Starting

--> Standby--> Stopping--> Aborting

--> Producing--> Holding--> Stopping--> Aborting

--> Standby--> Holding--> Stopping--> Aborting

--> Stopped--> Aborting

--> Held--> Aborting

--> Standby--> Stopping--> Aborting

--> Aborted

--> Stopped

Initialize completes successfullyStop PB transition

Fault active

Start PB TransitionStop PB transition

Fault active

Produce Conditions MetHold PB transitionStop PB transition

Fault active

Produce Conditions go awayHold PB transitionStop PB transition

Fault active

Stop PB transitionFault active

Holding functions completeFault active

Start PB TransitionStop PB transition

Fault active

Fault active

Stop PB transition


Program Flow Diagram

R02Machine

Conditions

R04Auto State

Init PB pressed

R06Auto StateCommand

EM1...n (machine sections) OR

CM1...n(axis, actuator etc)

sequencecommandcomplete

R07Section

Conditions

CM1...n(axis, actuator

etc)

In our example project, we use the Start pushbutton, twice.If in the Stopped state when pressed, we consider it an st.initialize command.

If in the Ready state when pressed, we consider it a st.start command.

R02_Machine_Conditions

This routine gets status fromeach axis program, or ControlModule to validate that thecommanded state of eachrequest was reached. Thesewe call conditions, we haveissued the command and waitfor the conditions to be truebefore continuing.

R07_Section_Conditions

When in Stopped state and st.initialize the commanded state will transitioninto Starting state.

R04_Auto_State

When in Starting state there is a sequence of operations that take place;SectionCommands.Enable when All_enable_Done (meaning all axeswithin that section are emabled) the next sequence is initiatedSectionCommands.Home and so on until all required starting functions arecomplete.Then st.init_PC is returned (meaning State.Initialize Process Complete)

R06_Auto_State_Command

Note: st.xxx instructions are StateTransitions, and only used to drive the

states of the PackML State model in R04.

This example illustrates Initialization operation of this program, because it is the firstsequence that is commanded from the stopped state..

Machine.AutoState = Stopped

First time throughMachine.AutoState = Starting

When st.init_pcMachine.AutoState = Ready st.Init_pc


Pseudo Code to Program View




When in Stopped state and st.initialize the commanded state will transitioninto Starting state.

R04_Auto_State

When in Starting state there is a sequence of operations that take place;SectionCommands.Enable when All_enable_Done (meaning all axeswithin that section are emabled) the next sequence is initiatedSectionCommands.Home and so on until all required starting functions arecomplete.Then st.init_PC is returned (meaning State.Initialize Process Complete)


Note: st.xxx instructions are StateTransitions, and only used to drive the

states of the PackML State model in R04.

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How to integrate using base code


How to qualify its use

1. Clear Structure– Local tags in main program– Sub routines

• MachineConditions• AutoStateCommands, AutoState, SectionConditions

2. State Model

3. Built in data structure• UDT Pack Tags

How to know if someone is using Power Programming? If you have these three elements from our program sample you are using it.


Steps

Artistic code-Generally fast executing

-Often difficult to follow-always requires further integrations work

Power Programming-PML State Model

-Clear Structure-Best Practices-Pack Tags 2.0

Advanced Code-Cam Builder

-Higher Performance-Appnotes/Sample Code

Stepping up in technology and structure.

Take a look at where we are today and where we are heading…

Hand build one of a kind code.

State Models introduced, use of structure


A walk through Initialization

R02Machine

Conditions

R04Auto State

Init PB pressed

R06Auto StateCommand

EM1...n (machine sections) OR

CM1...n(axis, actuator etc)

sequencecommandcomplete

R07Section

Conditions

CM1...n(axis, actuator

etc)




This routine gets status fromeach axis program, orControl Moule to validatethat the commanded stateof each request wasreached. These we callconditions, we have issuedthe command and wait forthe conditions to be truebefore continuing.

R07_Section_Conditions

When in Stopped state and st.initialize the commanded state willtransition into Starting state.

R04_Auto_State

When in Starting state there is a sequence of operations that take place;SectionCommands.Enable when All_enable_Done (meaning all axeswithin that section are emabled) the next sequence is initiatedSectionCommands.Home and so on until all required starting functionsare complete.Then st.init_PC is returned (meaning State.Initialize Process Complete)


Note: any st.xxx instructions are StateTransitions, and only used to drive thestates of the PackML State model in

R04.

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From a customer

• Q The PACKML automatic mode state model provides an excellent framework or structure for organizing and developing machine control applications.

• A Consider Power Programming with Pack ML a behavioral model for a machine, or discrete process, ie. Starting= Initialize= do whatever you have to do to get ready.

• Q I am curious to know if you are aware of any OEMs or users who have adopted the PACKML automatic mode state model in there automation specifications.

• A I am aware of many of our OEM's that we have had this discussion with, and sometimes it breaks down when we get to adoption, I am working on specifying what "using Power Programming" means. I have pretty much boiled it down to 3 elements, PackML state model, State Transitions routine, Pack Tags 2.0. Beyond those basics the "artistry" of the OEM come back into play. We provide the basic structure, Model, Structure, consistent Data.

• Q Also, in your opinion, do you feel or have you seen that the PACKML automatic mode state model & PowerProgramming have lead to significant re-use of code?

• A I can speak for many of the Rockwell Applications Engineers when I tell you we use it as our "starter code". From and OEM-centric point of view, it would be wise to reuse good structure and proven code for their machines also. I have been evangelizing the benefits of code reuse for some time now, and believe the message is coming across loud and clear.

• Q Do you find that the PACKML automatic mode state model useful for rapid development of machine functional requirements? • A Sure, we have used is as the foundation of the behavior model. See the Visio file attached to the examples available at

ab.com/powerprogramming.

• Q Please let us know what your experience or knowledge is with respect to adoption of the PACKML automatic mode state model in company standards, practices or specifications.

• A Many of our customers are attempting to specify Pack ML, and we are presenting a more integrated solution with Power Programming as the 3 elements I discussed earlier, and some example code to get them going. This goes far beyond the PackML state model, and goes more into program structure.


Resources

• Power Programming Website www.ab.com/powerprogramming

• PackML OMAC Website www.packml.org

copyright © 2005 rockwell automation, inc. all rights reserved. 1 power programming v2.1 kevin...

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