plcopen: changing the world of industrial automation...
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PLCopenfor efficiency in automation
Page 1 printed at 9/14/2011 www.PLCopen.org
PLCopen:
changing the world of industrial automation
Overview of the current activitiesand working groups
Eelco van der Wal
Managing Director PLCopen
PLCopenfor efficiency in automation
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PLCopen tagline
PLCopenfor efficiency in automation
Why and How
PLCopenfor efficiency in automation
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Percentage of Software development costs in
production systems (source: McKinsey)
0%
20%
40%
60%
80%
100%
1970 1980 1990 2000
Mechanic Electric Software
PLCopenfor efficiency in automation
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Managing Complexity
100 – 10,000 – 1mio – 100mio Lines of Code
PLCopenfor efficiency in automation
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A hierarchy of abstraction
PLCopenfor efficiency in automation
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Abstraction via Function Blocks
MC_MoveAbsolute
AXIS_REF Axis Axis AXIS_REFBOOL Execute Done
BOOLREAL Position
BOOLREAL Velocity CommandAborted
WORDREAL Acceleration
BOOL
REAL Deceleration
REAL Jerk
MC_DIRECTION Direction
Error
ErrorID
ContinuousUpdate
BufferMode
Busy
Active
BOOL
MC_BUFFER_MODE
BOOL
BOOL
PLCopenfor efficiency in automation
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Function Block exampleFUNCTION_BLOCK HYSTERISIS
VAR_INPUT
XIN1, XIN2 : REAL;
EPS : REAL; (* Hysterisis band *)
END_VAR
VAR_OUTPUT
Q : BOOL := 0
END_VAR
IF Q THEN
IF XIN1 < (XIN2-EPS) THEN
Q := 0 (* XIN1 decreasing *)
END_IF;
ELSIF XIN1 > (XIN2 + EPS ) THEN
Q := 1; (* XIN1 increasing *)
END_IF;
END_FUNCTION_BLOCK
Hysterisis
QXIN1
XIN2
EPS
BOOLREAL
REAL
REAL
1
EPSEPS
0
XIN2
Q
PLCopenfor efficiency in automation
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Information hiding via Function Blocks
MC_MoveAbsolute
AXIS_REF Axis Axis AXIS_REFBOOL Execute Done
BOOLREAL Position
BOOLREAL Velocity CommandAborted
WORDREAL Acceleration
BOOL
REAL Deceleration
REAL Jerk
MC_DIRECTION Direction
Error
ErrorID
ContinuousUpdate
BufferMode
Busy
Active
BOOL
MC_BUFFER_MODE
BOOL
BOOL
PLCopenfor efficiency in automation
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Axis_Ref with 1 FB
FBAxis1
Axis_Ref
Structure
I/F
Task
Manager
DriveConver-
sion
Time or event driven
PLCopenfor efficiency in automation
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Axis_Ref with 2 FBs
FB1Axis1
Axis_Ref
Structure
I/F Drive
Task
Manager
Conver-
sion
Time or event driven
FB2
PLCopenfor efficiency in automation
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HW Independence via Function Blocks
Software View
InputsName
Outputs
Hardware View
I/F Sercos Drive Motor
E
Drive Motor
E
PWM
I/F
Encapsulation / Information Hiding
PLCopenfor efficiency in automation
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Encapsulation: Webcutting
Synchronization of web
feeding & rotating cutter
PLCopenfor efficiency in automation
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Mechatronic solutions
Mechanical
solution.
Control
solution
PLCopenfor efficiency in automation
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Decomposition and Reuse
PROGRAM
GLOBAL
LocalType
Automation
application
FUNCTION
INPUT
LocalType
FUNCTION_BLOCK
INPUT OUTPUT IN_OUT EXTERNAL
LocalType
PLCopenfor efficiency in automation
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Sequential Function Chart, SFC
Step 1 N FILL
Step 3
Step 2 S Empty
Transition 1
Transition 2
N Initialisation S1
N FillingS2
N HeatingS3
N FermentingS4
N HarvestingS5
N CleaningS6
PLCopenfor efficiency in automation
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Time-to-Market
via flexibility in equipment and process
Asset utilizationminimal finished good inventory
Flexibility in Manufacturingprocess followed by packaging to provide end product
Overall Equipment Effectiveness, OEE
PLCopenfor efficiency in automation
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Mapping OMAC State Diagram to SFC
PLCopenfor efficiency in automation
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PLCopenfor efficiency in automation
How?
PLCopenfor efficiency in automation
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2011
PLCopenfor efficiency in automation
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PLCopen as a World-wide association
Office in Japan
Main Office in Europe
Office in North America Office in China
PLCopenfor efficiency in automation
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Organization
TECHNICAL PROMOTIONAL
COMMITTEES
PLCopenStandardization in Industrial Control programming
TC1 TC2 TC3 TC4 TC5 TC6 PC1 PC2 PC3 PC4 PC5
General Meeting, BOM, MD
PLCopenfor efficiency in automation
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IEC 61131-3
Harmonizing the way people look to control
TC1 Standards:the basis
PLCopenfor efficiency in automation
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IEC 61131 PartsProject Title Valid till
61131- 1, Ed 2.0 General information, 2003-05 2013
61131- 2, Ed 3.0 Equipment requirements and tests, 2007-07 2012
61131- 3, Ed 3.0 Programming languages (Currently CDV - Committee Draft for Voting) 2012+5
61131- 4, Ed 2.0 User guidelines (TR), 2004-07 2010
61131- 5, Ed 1.0 Communications, 2000-11 2013
61131- 6, Ed 1.0 Functional safety for PLC (Currently CDV - Committee Draft for Voting) 2012+5
61131- 7, Ed 1.0 Fuzzy control programming, 2000-08 2013
61131- 8, Ed 2.0 Guidelines applic. & implem. progr. languages (TR), 2003-09 2008
61131- 9, Ed 1.0Single-drop digital communication interface for small sensors
and actuators (SDCI) aka “IO-Link” (Currently CD - Committee Draft)
2012+5
PLCopenfor efficiency in automation
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Why include Object Orientation in the 3rd edition?
Main reason:
To link better to the scared resources
of engineers in the future
We’d better adapt to them
then vice versa
PLCopenfor efficiency in automation
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IEC 61131-3
Harmonizing the way people look to control
and PLCopen extends this basis
PLCopenfor efficiency in automation
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TC2
Functions and Function Blocks
-
Harmonization of libraries
of reusable components
-
Example: Motion Control
PLCopenfor efficiency in automation
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PLCopen Motion Control :
The merge of Logic and Motion
IEC 61131-3
PLCopen
Logic Motion Control
PLCopenfor efficiency in automation
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Status PLCopen Motion Control Part 1 – Function Blocks for Motion Control
Part 2 – Extensions
Part 3 – User Guidelines
Part 4 – Coordinated Motion
Part 5 – Homing procedures
Part 6 – Fluid Power
Over 27 companies certified with over 36
products (check website for full list)
PLCopenfor efficiency in automation
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Current PLCopen Motion Control Releases
Merge of Part 1 and Part 2 – Motion Control 2.0
Release of Part 5 – Homing
Update of Part 3 – User Guidelines
Part 6 – Extension for Fluid Power
PLCopenfor efficiency in automation
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The next step:
Adding Safety (TC5)
(at machine level)
IEC 61131-3
PLCopen
Logic Motion ControlSafety
PLCopenfor efficiency in automation
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Reasons to merge – a changing environment
Too many dialects, too many standards, including IEC 61508
and IEC 62061;
Additional governmental requirements increasing the liability
issues;
No independent training material
Trend to software solutions
Too much done by machine builder themself
Growing market expected
PLCopenfor efficiency in automation
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Reasons to merge – a changing environment
The tendency to move from one motor (master axis) to
multiple axes, driven by mechatronic solutions;
The availability and acceptance of digital networks with
safety functionality built-in;
The inherent move from hardwired safety functionalities to
software solutions;
The increasing importance of safety related issues regarding
personnel and machines.
PLCopenfor efficiency in automation
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TC5 - Safety : New initiative
Focused to material presses used for metal
forming
Extensions for Presses will be published as Part 5
MC_PathGearInMaster for press application
Axis
Execute
Axis
Done
MC_MoveAbsolute
Press Motion(Single Axis Motion)
Position
Velocity Active
CommandAborted
Jerk
Direction
Busy
Buffermode
Acceleration
Deceleration Error
ErrorID
AxisGroup
MasterAxis
AxisGroup
MasterAxisMC_PathGearInMaster
Robot Motion(Axis Group Motion)
Execute
RatioNumerator
Active
CommandAborted
Jerk
RatioDenominator
InGear
CoordSystem
Acceleration
Deceleration Error
ErrorID
Buffermode
Busy
Robot1 Robot2
PLCopenfor efficiency in automation
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PLCopen
Combining Logic, Motion and Safety
Providing Structuring, Decomposition,
Reuse and less training
PLCopenfor efficiency in automation
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TC3 - Benchmarking
A benchmark is a reproducible, portable test to
measure the performance of a given system in
comparison to other systems
PLCopenfor efficiency in automation
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TC3 - Benchmarking
There are two main objectives to use a
benchmark:
1. To estimate the performance of the PLC in
your own application
2. To compare the performance of the PLC with
other PLCs and find out the specific strength
and weakness of a given system
PLCopenfor efficiency in automation
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Benchmarking (TC3)
Two different sets of benchmarks defined:
1. 5 different types of applications, which
are typical for the usage of a PLC.
2. Measures each language feature of the
IEC 61131-3 separately
PLCopenfor efficiency in automation
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Communication (TC4)
PLCopenfor efficiency in automation
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TC4 Communication
OPC UA specifies HOW
PLCopen specifies WHAT
PLCopenfor efficiency in automation
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OPC-UABaseVariableType
OPC UA Part 5
OPC-UA DI
Examples
IEC 61131-3 OPC-UA
CtrlProgramType
BaseObject Type
OPC UA Part 5
CPU_A100
CtrlTaskType
Main
nInput
CtrlResourceType
CtrlFunctionBlockType
CtrlConfigurationType
PLC_Z345 FB_MotorControler
FB_MotorControler:
MotorControler1fOutput
bLocal
bLocalMain
CPU_A100:
CPU1
CtrlProgramOrganizationUnitType
DeviceType
TopologyElement
Type
Configurable
ObjectType
ConfigurableComponentsType:
Resources
ConfigurableComponentsType:
Resources
FB_MotorControler:
MotorControler2
CPU_A100:
CPU2
Priority
BlockType
PLCopenfor efficiency in automation
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TC6 – XML
Opening up the development environments
by specifying XML formats for IEC 61131-3
PLCopenfor efficiency in automation
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XML (TC6)
Development
tool
Other
Development
tool
Other
Development
tool
Producer of
graphical and
logical
information
Consumer of
graphical and
logical
information
XML
XML
XML
XML
PLCopenfor efficiency in automation
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PLCopenfor efficiency in automation
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PLCopenfor efficiency in automation
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The link to other simulation tools
MatLab / Simulink
Calculate / simulate complex behaviors
like a 80 synchronized motors in one
packaging machine
or like the control of windmills
PLCopenfor efficiency in automation
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PC2 - Training
Important to create sufficient human
resources capable to create and innovate
PLCopenfor efficiency in automation
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Overview
PLCopenfor efficiency in automation
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More Information...and to download the specifications (f.o.c)
www.plcopen.org
Free-of-Charge electronic Newsletter ‘PLCopening’ (in English)
email: [email protected]
PLCopenfor efficiency in automation
Page 49 printed at 9/14/2011 www.PLCopen.org
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