Automation Software · 2020. 5. 5. · Automation Software 5 One of the key points is to write it...

TECHNOLOGY REPORT

AutomationSoftware

TABLE OF CONTENTSHow to document a PLC program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Automation, AI and the IIoT help to advance industry . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

HMI software makes the user experience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

AD INDEXBeckhoff Automation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Siemens Energy & Automation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Wind River . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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So, you have a PLC, and you need to program it to run an automated machine . If you want to be a programming hack, just sit down and start writing the ladder logic and debug it . While you may understand your methods, others won’t, at least not quick-ly . So, if you want to do it like the big integrators do, there are some things to focus on to

ensure efficient development of PLC-based control systems .

There is more to it than just writing the PLC program . The architecture of the program must

first be defined, and, once written, it will need to be debugged, tested and accepted, often

by different individuals . Outside of the program itself, this documentation includes a ma-

chine controls programming specification and acceptance documents .

When spearheading the control software design effort, there should be a strong emphasis

on creating software that is documented, organized, structured and reusable . This emphasis

helps to ensure efficient development of PLC-based control systems .

Many senior controls engineers will focus on the step sequence that controls the repeatable

automatic sequence of the machine . In my column on how to write a PLC step sequence

program (www .controldesign .com/stepsequence), I suggested it’s best practice to “define

a machine’s control modes, main cycles and sequence steps before a program is written, or

you’ll just write scatter code and confuse others .”



How to document a PLC programDocumentation for PLC programs exists externally and internally in several forms, so don’t forget the specification and tag names

By Dave Perkon, technical editor



One of the key points is to write it down .

Documenting the program before it is

written, as a programming specification,

not only helps program development, the

documentation can then be edited into an

acceptance testing document . It also helps

the understanding of the control system

over the 10-plus years it will be in opera-

tion for the other guy’s benefit . After the

program has been running for five years

and edits are needed due to manufactured

product changes, the controls program-

ming specification for the machine should

help ensure program logic added is consis-

tent with the original program .

Automatic, manual and step cycles control-

ling manageable-sized, logical sequences

is a must . An overall machine cycle often

helps to synchronize individual station or

equipment sequences, such as pick up part,

place part and index conveyor .

There is much more to the documentation

beyond the machine operation modes,

machine cycle control and the machine

sequences themselves . Outside of the

sequence, it is important to document the

hardware and software (firmware and ver-

sion) used to create the program, as well,

that information is especially important

five years from now, so make sure it is

updated, as-built .

Inside the program, there is much docu-

mentation, as well . Many controllers are now

capable of storing and displaying the rung

and device descriptions . The days of lost

documentation are past . However, there

are ways to make the program more read-

able, and that should be documented both

outside and inside a program, as well .

Reading down tag names or descriptions

on the coils in the rungs of the ladder logic

should read like a machine sequence of

operation . While there are many parts to a

PLC program that needs to be written, if the

auto cycle sequence—the part that repeats

every machine cycle—isn’t clearly written,

it’s likely an example of how to confuse the

next guy who looks at it .

There is much more to writing a best-case

example of a PLC program, and that in-

cludes defining how to create self-docu-

menting memory, programs and functions .

In the past, the PLC memory was fixed . The

manufacturer controlled variable naming

and often limited the number of variables .

Inputs (I), Outputs (O), Bits (B), Integers (I),

Floating point (F) and String (S) variable

names all started with an identifying letter,

for example I:0/1, O:1/0, B3:0/15 . The type

of variable is indicated in the name, but not

the function . In this case, a description is

added to define the variable function, such

as “System air pressure ok .”

With most newer PLCs and PACs, tag-

based variable naming is used . The con-

tacts, coils, timers and counters can be



self-defining, and how it is done should be

documented to be consistent .

And careful variable naming will help with

the auto complete function that groups

variables together when selecting them

from a drop-down list during program

development .

For example, in a system with three sta-

tions, the variable name local to each sta-

tion can start with S100, S200 and S300 .

These prefixes can make it easy to copy

and paste programs and then search and

replace the prefix, as needed . It’s a form

of reusable code . Another example is a

robot that has multiple pick-and-place

motions that set a “busy” local bit when

each motion is in cycle . It may be helpful

to have the word, “busy,” in the first part

of the variable name . In this case, the auto-

complete feature displays all the busy bits

together, (for example, b_BusyR1PickNest1,

b_BusyR1PickNest2, b_BusyR1PlaceTest1,

b_BusyR1MoveToClear) . In this case the b_

indicates the variable type is a bit . Some

choose not to use these variable type iden-

tifiers, and it’s documented .

Alternatively, the prefix vlb_ could be used

to indicate variable local bit and vpb_ to

indicate a variable program (global) bit . The

point is variable naming should be defined

so others can understand the naming con-

vention used . And, no matter the naming

convention, if the variable tag name is not

self-defining, add a descriptor, such as “Ro-

bot 1 is busy picking from nest 1,” and there

are many other examples . These self-defin-

ing names or descriptors or both are for the

next guy . Be a courteous programmer and

document things .

These self-defining names or descriptors or both are for the next guy .

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Automation software comes in different clothing and performs different tasks . It could be a programming integrated development environment (IDE) such as RSLogix5000 or CodeSys 3 .x, or a SCADA application created in Inductive Auto-mation’s Ignition . It all comes in different flavors and colors .

Artificial intelligence (AI) is the new kid on the block and is coming on very strong in certain

sandboxes .

Machine learning applications are not new, but the methods used are . Is AI ready for prime

time? It’s sure getting there .

Sharmeer Mirza, who is a senior research engineer at PepsiCo, recently gave a talk on how

they are using AI and machine learning to create a better potato chip . It is based on sensing

the texture of the chip without harming the little fellow .

The premise is to bounce a laser off the chip and correlate the returning sound(s) to texture

creating a quality check for the product .

If this sounds like adaptive process control (APC), I would say you are right . But using end

product statistics along with APC to create a better chip may be considered novel .



Automation, AI and the IIoT help to advance industrySoftware enables adaptability and flexibility

By Jeremy Pollard, CET



Machine learning extends into various

industries such as biology, blood systems,

neural networks and the like . Most would

argue that to be AI you have to use an algo-

rithm, but in this early stage in AI machine

learning the jury may still be out .

Adaptive learning may be the automation

software that leap frogs us into true AI

applications .

Also we need to remember that the control

engineering discipline has yet to catch up to

the AI learning curve .

My good friend Dick Morley, father of the

PLC, told me many times that point-of-sale

manufacturing will come to a Home Depot

near you . There are already many instances

of mobile manufacturing, such as pizzas and

kitchen cabinets .

But what about a machine that can cre-

ate a single unit of Product X and then a

single unit of Product Y? That’s adaptabil-

ity and flexibility .

CNC machines of current day with an au-

tomatic tool changer isn’t AI but is adap-

tive based on its g-code and m-code . A 3D

printer can also be considered an adaptive

machine, but then most printers are .

Single-use devices such as a rotary phone,

as we know, are dead in the water . Can

multi-function be described as adaptive?

B&R Automation, along with Control De-

sign, wrote a white paper on adaptive sys-

tems instead of having dedicated machine

designs . Hmm, one might say!

Automation software wears many hats as

suggested . So what member of the soft-

ware community allows for a batch-of-one

mentality?

John Kowal, B&R director of business de-

velopment, suggests that each product can

be individually manufactured as ordered,

like McDonald’s . You order your product; it

gets made and delivered . No finished goods

inventory control required . In this day and

age of trends and fads, investment in manu-

facturing can be made knowing that the

new-age production machines will be re-

purposed after the fad wanes in popularity .

Kowal makes an interesting observation,

something he calls, “digital native .” This

is where a majority of youth have grown

up with the digital age of mobility, access

and information everywhere . They expect

things and, along with the McDonald’s

mentality, want it now; manufacturing

must adapt to keep the masses connected

to the buying process .

IIoT is not legacy, but it will have to in-

tegrate with legacy somewhere . This will

take both hardware and automation soft-

ware, perhaps yet to be developed, but it

will come .



Inductive Automation’s Ignition is a prime

example of how flexible an HMI/SCADA

system can be, as well as supporting the

new paradigm . The way it integrates new

technology and not have things such as

MQTT as a bolt-on lends itself to the tasks

at hand such as cloud data easily .

The Industrial Internet Consortium (IIC)

was created to foster the development and

adoption of interconnected devices and

machines along with the people who de-

velop and use the technology and software .

The IIC runs an IT/OT task group, which has

proclaimed that our new age of network-

ing with devices is not about having these

two work independently, but to create the

culture that allows them to work together

to solve the issues that will invariably raise

their ugly heads with the new order .

It comes down to standards . There are

many bodies that are developing certain

standards, and there will be many compa-

nies who will engage these standards in

order to gain market share and to do the

right things .

Make no mistake, it will be the software that

will drive the integration and sense of com-

munity in our future world .

IIoT is not legacy, but it will have to integrate with legacy somewhere .

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Human-machine-interface (HMI) software has come a long way over my 32-year automation career . I have developed many simple HMI applications using a DOS-based operating system and experienced its rise with the introduction of Windows decades ago and the open systems of today . But it’s not the hardware I remember; it’s the

HMI software .

For me, my HMI experience didn’t start with a monochrome display; I started designing

operator-interface panels full of illuminated pushbuttons requiring that holes be drilled and

each device be wired . There would be 25 or more of these devices controlling the machine

cycle and manual functions . Every motion had an illuminated pushbutton controlling the

motion and displaying its status with a light .

A one- or two-line text display was a luxury, but imagine programming a hundred or more

alphanumeric status and fault messages and controlling them via ladder-diagram program-

ming to display what’s important, especially when many needed to be displayed at the

same time . It wasn’t easy; it was time-consuming and there was never enough information .

The graphic world of Windows certainly helped to simplify HMI software development in

the early days . However, electronic help documents within the program were OK at best,

but the user did receive a large stack of printed manuals to help guide the way . Today,


HMI software makes the user experienceWhile the hardware chosen for a human-machine interface makes the HMI software choice easy, it’s always the software that makes the application shine

By Dave Perkon, contributing editor




the availability of online-help multime-

dia is important, but some HMI software

suppliers do it much better than others .

Take the time to view the available online

training documentation and videos from

beginner level to advanced . It may likely

be a differentiator when selecting an HMI

software package .

The multimedia training is impressive with

some HMI software . And it gets even better .

The HMI software of today goes well be-

yond the software capabilities of the past .

A single HMI can connect to multiple PLCs

monitoring and controlling them all . Some

act as a gateway tying multiple PLCs to-

gether, sharing data between each . While it

isn’t really for real-time control, it can pass

informational data back and forth such as

status, batch and lot numbers, and other

non-time-critical data .

It’s the higher-end HMI software packages

that really expand the user experience and

makes the connections . And, by connec-

tion, I mean connecting to everything on

the factory floor and everything above it, as

well including data historian, ERP and the

cloud . The resulting HMI and SCADA enable

viewing industrial applications on desktops,

high-definition TVs, tablets and mobile de-

vices . And it’s all integrated in a single de-

velopment environment, the HMI software .

The right HMI software allows use of de-

velopment tools, component libraries and

database integration to quickly create just

about any industrial HMI application need-

ed . Pick the right software and the Industrial

Internet of Things (IIoT) is literally at your

fingertips—but a PC and Ethernet connec-

tions will be needed .

These applications range from a simple

HMI or overall equipment efficiency dis-

plays to centralized data acquisition, device

monitoring and control, and enterprise-level

analytics . If it’s in the requirements, the

programmer’s mind or noted as a future re-

quirement, some HMI software can do it, so

be sure to take the time to find an easy-to-

use platform with the features that fit well

with the IIoT .

Often, more than one developer is involved

with an HMI development project . HMI

software that allows multiple programmers

or even an unlimited number to work with

the software at the same time is an advan-

tage . Other software packages charge for

individual licenses to do the same work, but,

clearly, having a single software platform

that can bring together as many program-

mers as needed along with the data and

systems needed to create multiple industrial

applications is the better choice .

The HMI software may come with every-

thing needed to create the application,

but the future demands more . And don’t

think the software is for a single HMI . It

can be scalable for many HMI displays,



and software modules can be added and

developed without impacting existing ap-

plications . And it is all designed to work

seamlessly with them .

Take the time to look at the capabilities

of today’s HMI software . It can create just

about any industrial automation solution

needed whether it’s just a local machine

display, a plant SCADA system, connecting

to the IIoT, tracking operations using MES

or beyond . HMI software can do it, or it can

likely be expanded as needed . Adding the

connections, reports, charts and tables for a

clear view of the machine, process, system

or facility has never been easier .

It’s the higher-end HMI software packages that really expand the user experience

and makes the connections .

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