plcopen standardization in industrial control programming plcopen 1 printed at 6/4/2015 plcopen p.o....

PLCopenStandardization in Industrial Control Programming

PLCopen 1 printed at 04/18/23 PLCopen P.O. Box 2015, NL 5300 CA Zaltbommel

PROGRAMACIÓN DE PLCs



EL PLC Y EL DIAGRAMA LADDER

The ladder diagram has and continues to be the traditional way of representing electrical sequences of operations. These diagrams represent the interconnection of field devices in such a way that the activation, or turningON, of one device will turn ON another device according to a predetermined sequence of events.



EL LADDER PROGRAM



Ejemplo de Direccionamiento

L1 L2PB1 LS1 FS2 SOL6

ELEMENTO

PB1

LS1

FS2

SOL6

| | ( )| | | |I:1/1 I:1/2 O:3/1I:1/3

DIRECCIÓN

L1 L2

I:1/1

I:1/2

I:1/3

O:3/1



IEC 61131-3 Software:

changing the world of industrial automation

-the status, the structuring tools, the

activities and the libraries



the future is here

IEC 61131-3

Harmonizing the way people look to control



Fiction?Imagine

• you are in industrial control working with 4 different brands of controls using different dialects in their programming languages

• struggling to match the level of your software engineers with the electrical engineers / maintenance on the factory floor & seeing that your competitor does better

Why? What’s wrong ?



Out of the jungle

The current variety of problems can be vastly reduced via standardization

... and such a standard is available



IEC 61131-3

“The best thing that happened to industrial control”



The 5 parts of the IEC 61131 Standard

- 1 General overview, definitions IS

- 2 Hardware IS

- 3 Programming Languages IS

- 4 User Guidelines

- 5 Messaging Service Specification

IS = International Standard



IEC 61131-3 Programming languages /Industrial Control Programming

The interface between the programmer and the control system



IEC 61131-3 Programming languages /Industrial Control Programming

...with support for people with different backgrounds



The IEC 61131-3 Standard

Common Elements

Programming Languages



IEC 61131-3 : Common ElementsVariables & Data Types

What is this?

01010101 10101010

Historically

• Reference to a physical memory location

• Reference to a physical Input



IEC 61131-3 : Common ElementsVariables & Data types

Temperature_Sensor_1 : Integer

• Symbolic representation via labels

• Restricted area for I/O mapping

• Hardware independent code

• Higher transparency & readability

• Less errors



IEC 61131-3 : Common Elements

Software Model

• Configuration

• Resources

• Tasks



IEC 61131-3 Software ModelConfiguration

Communication Function



IEC 61131-3 Software ModelConfiguration


Resource Resource



IEC 61131-3 Software Model

Task Task Task Task

Resource Resource

Configuration





Execution control path

Task

Program Program

Task

Program

Task

Program

Task

Resource Resource

Configuration





Global and direct variables

Access path


Variable access path

FBTask

Program Program

FB FB

Task

Program

Task

Program

FB FB

Task

Resource Resource

Configuration


Function Block

Variable



IEC 61131-3 vs conventional PLC

Global and direct variables

Access path


Variable access path

FBTask

Program Program

FB FB

Task

Program

Task

Program

FB FB

Task

Resource Resource

Configuration


Function Block

Variable



Conventional PLC vs IEC 61131-3

Task 1

Program

Task

Resource

Read inputs

Do Calculations

Set Outputs

Endless Loop:

Task 2

Task 3

Task 4

Time based

Events based

Events based

Time based



Common Elements: Tasks

IEC 61131-3

EmbeddedPLCs

PC basedControl

SoftLogic

Drives

LON nodes

DCS



Common Elements : Tasks & Datatypes

RPM =2000Windows CE 3.0

IEC 61131-3 tasks

SCADA & HMI tasks

I/O Communication tasks

OPC

Multi –functional Operator Panel

I/O Communication bus



IEC 61131-3 : Common ElementsCOMMON ELEMENTS

a.o.

Data Types & Variables

Configuration, Resources, Tasks

Programming Organization Units

* Functions

* Function Blocks

* Programs



Functions …..

* Standard functions

ADD, SQRT, SIN, COS, GT, MIN, MAX, AND, OR, etc.

* Your own defined functions: FUNCTION SIMPLE_FUN : REAL

VAR_INPUTA, B : REAL;C : REAL := 1.0;

END_VARSIMPLE_FUN := A*B/C;END FUNCTION



…. & Function Blocks Standard Function Blocks

FUNCTION_BLOCK

I NPUT OUTPUT I N_OUT EXTERNAL

LocalType

Hysterisis

QXIN1

XIN2

EPS

BOOLREAL

REAL

REAL



…. & Function Blocks Standard Function Blocks Additional supplied

Function BlocksFUNCTION_BLOCK


LocalType

Hysterisis

QXIN1

XIN2

EPS

BOOLREAL

REAL

REAL




Function Blocks Your own defined Function

Blocks

FUNCTION_BLOCK


LocalType

Hysterisis

QXIN1

XIN2

EPS

BOOLREAL

REAL

REAL




Function Blocks Your own defined Function

Blocks All FBs are highly re-usable

in same program, different programs or project

FUNCTION_BLOCK


LocalType

Hysterisis

QXIN1

XIN2

EPS

BOOLREAL

REAL

REAL



Function Block exampleHysterisis

QXIN1

XIN2

EPS

BOOLREAL

REAL

REAL

1

EPSEPS

0

XIN2

Q



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



Programs : hierarchical design

Automation

application

Start : BOOL;

Emergency : BOOL;

Limit : INT;

PROGRAM

GLOBAL

LocalType

FUNCTION

INPUT

LocalType

FUNCTION_BLOCK

INPUT OUTPUT IN_OUT EXTERNAL

LocalType



Advantages POU’s

Create own Function Block Libraries (per application area)

FBs are tested and documented

Make libraries (world wide) accessable

Re-use as much as possible

Change programming to creating networks of FBs

Save 40% on next project



IEC 61131-3 : Common ElementsCOMMON ELEMENTS

a.o.Data Types VariablesProgram Organization Units

* Functions* Function Blocks* Programs

Configuration, Resources, Tasks

Sequential Function Chart* Steps* Transitions* Actions Blocks



Sequential Function Chart, SFC Powerful graphical technique for

describing the sequential behavior of a control program

Used to partition a control problem

Shows overview, also suitable for rapid diagnostics

Step 1 N FILL

Step 3

Step 2 S Empty

Transition 1

Transition 2



Sequential Function Chart, SFC Powerful graphical technique for

describing the sequential behaviour of a control program

Used to partition a control problem

Shows overview, also suitable for rapid diagnostics

The basic elements are STEPS with ACTION BLOCKS and TRANSITIONS

Support for alternative and parallel sequences

Step 1 N FILL

Step 3

Step 2 S Empty

Transition 1

Transition 2



SFC : alternative sequences

Step 1 N FILL

Step 3

Step 2 b S Empty

Transition 1b

Transition 2b

Step 2 a S Empty

Transition 1a

Transition 2a




Common Elements




The IEC 61131-3 Programming Languages

Instruction List Structured Text

Function Block Diagram Ladder Diagram

C:= A AND NOT B

A B C

-| |--|/|----------------( )

LD A

ANDN B

ST C

AND

A C

B



Ladder Diagram (LD) Standardized, rationalized set of relay

ladder programming symbols Based on well-known North american

style of programming, resembling US-type of electrical drawing standard

A B C

-| |--|/|----------------( )



Instruction List (IL)

Single Accumulator based execution model Based upon the German ‘Anweisungsliste’, AWL One operation such as storing a value in the

accumulator register, is allowed per line

LD A

ANDN B

ST C



Structured Text (ST) High level language, block structured Syntax resembles PASCAL Complex statements and nested instructions possible Support for

Iteration loops (REPEAT-UNTIL; WHILE-DO) Conditional execution (IF-THEN-ELSE; CASE) Functions (SQRT(), SIN())

C:= A AND NOT B



Function Block Diagram (FBD) Graphical language, widely used in Europe Allows program elements which appear as blocks to be

"wired" together in a form analogous to a circuit diagram Used in many applications that involve the flow of

information or data between control components

AND

A C

B

chemistry




Common Elements


Top Down

Bottom Up



IEC Programming EnvironmentsMany of them offer: graphical programming

screens support for multiple

windows mouse operation pull-down menus built-in hypertext help

function software verification during

design



What is the Benefit of such a Standard ?



Users? Which Users?

Education

InstallationMaintenance

Programming

Process cntrl

Discrete Mnf

System Integrator YOU ??



Users? Which Users?

• Automobile production lines

• Water treatment plant

• Food processing and packaging machinery

• Cable manufacturing

• Semi-conductor clean room automation

• Theme-park roller coasters

• Nuclear waste treatment plant

This wide range encompass different skills



What is the Benefit of such a Standard Reduced waste of human resources (in training,

debugging, maintenance and consultancy)



What is the Benefit of such a Standard Reduced waste of human resources (in

training, debugging, maintenance and consultancy)

Creating a focus to problem solving via software re-usability (reduced application investment and supplier dependency)






Reduced misunderstandings and errors






Reduced misunderstandings and errors

Programming techniques usable in more environments (general industrial control)






Reduced misunderstandings and errors Programming techniques usable in more

environments (general industrial control)

Combining harmoniously different components from differentlocations, companies or countries, or projects







environments (general industrial control) Combining harmoniously different

components from different locations, companies or countries, or projects

Increased connectivity (investment protection)







environments (general industrial control) Combining harmoniously different

components from different locations, companies or countries, or projects

Increased connectivity (investment protection)

Function "LIMIT"

Function "TEST"

Function Block"Turning"

Function Block"Feeding"

Function Block"Heating"

SoftwareLibrary



Advantages for Educational level

IEC 61131-3 programming courses are:

Supplier independent Product independent Better matching theory with praxis Based on up-to-date programming techniques and structural

thinking



1993:

IEC 61131-3 is reality

as a paper standard

and now…...



.. the Chicken and Egg problem

Users vs.

see the benefits of the standard but need products to fulfill their needs

Suppliers

uncertainty about its effect strategic choice high investment (SW + HW) uncertain on ROI



The Association PLCopen

Standardization in Industrial Control Programming

What does PLCopen want and do

and how does it effect you



PLCopen Mission

We want to be the leading association resolving topics related to

control programming to support the use of

international standards in this field.



Strategical aspects

All voting members are equal: one member = one vote

PLCopen is focused towards independent services, not products

Focus towards users’ awareness

Commitment of user and supplier members



Programming in its environment

Database Tools Visualization / HMI Project designTools

DocumentationTools

ProgrammingTools

Debugging Tools

Networking Tools ConfigurationTools

Simulation Tools



Organisation

TECHNICAL PROMOTIONAL

COMMITTEES

BOM, MD & General MeetingBOM, MD & General Meeting

TC1TC1 TC3TC3 TC4TC4 TC5TC5 PC2PC2 PC3PC3TC2TC2 PC4PC4PC1PC1

PLCopenStandardization in Industrial Control programming



TC1: Standards

IEC 61131-3 is enhanced with Corrigendum & Amendments Development of joint PLCopen position for IEC Communication of information from IEC to PLCopen Improvement proposals Focused to upcoming update: beginning 2001



TC2: Functions

Definition of Function Block libraries Function block calling conventions … for example: Motion Control Profile: the integration of

different technologies



TC3 : The Essence of Compliancewithout testing there is no standard

The IEC 61131 standard only gives basic rules for compliance Certification gives guidance for users towards real IEC 61131-

3 programming systems (e.g. PLCopen certified list shows compliant products)



TC3: PLCopen Compliance Levels

ApplicationProgram

FB

Variable

CodeBody

FB

Variable

CodeBody

FB

Variable

CodeBody

ApplicationProgram

FB

Variable

CodeBody

FB

Variable

CodeBody

FB

Variable

CodeBody

Full Compliance LevelPortability of applications

Portability Level &X-Reusability Level

Portability of Function (Block) libraries

Base LevelPortability of minimal systems



Compliancy:Results and Status (Oct. ‘00)

Accreditation installed: two institutes accredited Base Level definition ready for IL, ST and SFC. LD and FBD

in progress Test software ready for IL, ST and SFC. FBD and LD in

preparation 22 software packages certified (see website for status)



Compliancy: Results



TC4: Communication

Communications interfaces Interfaces to add-on packages Application interchange format Mapping of Profibus has been done Mapping of CANopen under construction



TC5: Safe software guidelines

Support for safe programming techniques Focus to IEC 61508 “Functional Safety of Safety Related

systems” Guidelines for the use of the IEC standard Function Blocks can be certified Basis for easier commissioning



General Promotion

PC1: General Promotion PC3: Promotion North America PC4: Promotion Japan



PC2: Common training program

The effect of training is often underestimated Standardization can be very useful and provide a better

interface between study and reality PC2 defined common basics for training.. .. for instance: a IEC 61131-3 training guideline is published Training facilities fulfilling basic requirements can be

certified and listed / referenced to (see website for listing)



PLCopen as a World-wide association

> 100 members (Oct. 2000)

from 21 countries all over the world

Suppliers, institutes and users

See newsletter / website for up-to-date list



PLCopen as a World-wide association

Office in Japan

Main Office in Europe

Office in North America



PLCopenEelco van der Wal

P.O. Box 2015

NL 5300 CA Zaltbommel

Netherlands

Tel: 31-418-541139Fax: 31-418-516336

www.plcopen.orgemail: [email protected]



PLCopen N.A.Jeremy Pollard

Barrie, Ontario, Canada

email: [email protected]

www.plcopen.org



PLCopen JapanYoshio Jamaguchi san3rd Floor, 3-61-8, WadaSuginami-kuTokyo 166, Japan

Tel: (+81) 3 3315 0194

Fax: (+81) 3 3315 0192

www.plcopen.orgemail: [email protected]



The association PLCopen

Together we can make it happen:

Standardization in Industrial Control Programming

plcopen standardization in industrial control programming plcopen 1 printed at 6/4/2015 plcopen p.o....

Documents

plcopen standardization

industrial control slide

ca zaltbommel slide

ca zaltbommel iec

ca zaltbommel ejemplo

ca zaltbommel programacin

ca zaltbommel fiction

programming languagesis