History of Industrial - welcome to CTS Engineering Ltd. [Read-Only].pdf · Programming Less...
Transcript of History of Industrial - welcome to CTS Engineering Ltd. [Read-Only].pdf · Programming Less...
History of Industrial Control
PC or PLC ?PC or PLC ?
1990 -
PLCsPLCs
1970 - 1995
Relays & ContactsRelays & Contacts
1950 - 1975
- Hard-wired Electrical Circuits
- Microprocessor Based- Proprietary Hardware- Electrical Circuit Programs
- Open Hardware Platforms- Integrated Software- Graphical Programming
Less Expensive, Easier to Use, Higher Productivity
Why MX Computer Control?
Best in class PC based control software.
Mitsubishi and Steeplechase, two leaders in their fields.
A proven real-time operating system.
Best in class intelligent distributed input / output devices.
An objective supplier.
Why MX Computer Control?
Faster design cycles.
MX Computer Control.
Features specifically for discrete automation.
Reduce machine downtime.
Future-proofing your factory .
Complete, integrated solution.
50% reduction in downtime and installation time.
Operator level diagnostics.
Hard real-time control.
Go from this...
PLCOperator Station
I/O Modules
Programming PC
Computer RoomCell Control PLC
testing widgets
32 passed
0 failed
…to this!
I/O Modules
Computer Room
testing widgetstesting widgets
32 passed32 passed
0 failed0 failed
Five rules of PC-based control..
Provide deterministic real-time performance(Hard real-time control)Same or better determinism than a PLC.
Control must always have the highest priority.
Windows tasks must not interrupt control tasks.
Five rules of PC-based control..
Survive failure of NT.
PC must not lose control if Windows or NT fails.
Control must be informed of OS failure (NT), allowing:∗ Continued execution of control program, or∗ Orderly I/O shutdown.
Five rules of PC-based control..
Provide protection from Windows applications and drivers.
Bad OS drivers (kernel mode drivers) can write data anywhere, including the I/O table.
Five rules of PC-based control..
Survive a hard disk failure.
Hard disk has the lowest MTBF.
The control engine loaded and protected in memory.
Five rules of PC-based control..
Use robust, reliable real-time kernel.
Installed base.
History in ‘mission critical’ applications.
InIn ConCon troltrol OO
Disk ServicingDisk Servicing
utut
MouseMouse
Real-TimeTasks
NT DPC
User Tasks User Tasks
Windows NT Priority
Non-Deterministic Scan Times
Soft Logic processing
Hard real-time processing
InIn ControlControl OutOut
DiskDisk User TasksUser Tasks
InIn ControlControl
Deterministic, Repeatable Scan Times (1 to 500 ms)
Real-Time OS Priority
All windows processing
Logic control
MxCCControl
Designer
MxCCControl
DesignerMxCCHMI
MxCCHMI
Excel,SPC,
Data Logging
Excel,SPC,
Data Logging
OtherWindows
Applications
OtherWindows
Applications
WindowsWindows
Real-time OS approach
Real Time PLC Control EngineReal Time PLC Control Engine Watch DogTimer
I/O Drivers ...I/O Drivers ...
Hard Real Time OSFirewall
Windows
RTOS
Not all vendors meet THE 5
vital rules of PC-based controlMake sure the solution meets your needs.
Deterministic real-time performance.
Protection against other applications and drivers.
Control must survive Windows crash.
Control must survive hard-disk crash.
Robustness - history and installed base.
MXCC flowchart programmingIntuitive and self documenting.
Cuts design cycles 50-70%.
Powerful diagnostic capability.
Flow chart programming
Basic Constructs:
• Actions
• Decisions
• Comments
• Flows
• Connectors
• Start/Stop
sub_prog.flo
I/O
Advanced Constructs:
• Sub-Programs
• I/O Specific Calls
• Parallel Branch & Merge
• PID Support PID
Flowchart enhanced ladder logic
a = (b + c / d) *2;
Message = “Station 1 Faulted”;
speed > setpoint *0.75
- Actions, decisions, and diagnostic messages.
Insert flowchart blocks directly in ladder logic.
Decision
Action
Combined flowchart/ladder
Both ladder and flowcharts execute together.Combine them with flowchart enhanced ladder.
Using a diagnostic wizard
Replaces standard ‘decision’ element where diagnostic logic would be added.
Loops back on itself for a given condition.
Using a diagnostic wizard
Fill in the decision criteria.Fill in the time-out fault period.Fill-in any fault logic conditions.Diagnostic wizard does the rest.
The tags referenced in the selected element are shown in the Instant Watch.
This is the element contents.List of tags in the element
Here are the tag values
If no element is selected, all tags referenced in the flowchart are shown.
Instant watch
Double click on a tag name to bring up a Local Force Window
The Local Force Window allows you to change internals or force I/O’s
Toggle and force
Reduce down time
With legacy PLC systems:
Most machine faults are mechanical.
Ladder logic makes it difficult to incorporate diagnostics.Operators don’t understand PLC ladder logic.
With MXCC:
Most maintenance calls are electrical because :
Empower the operator with on-line diagnostics.Graphically visually describe the fault and recovery.
Graphical Operator InterfaceWindows based MMI.Draw your operator screens.Direct access to MXCC data.
MXCC MMI FeaturesDirect access to MXCC run-time data.
MXCC tag browser.
Pre-built panel instruments.
Graphic animation.- Colour, fill, size, position, rotate, visibility.
Real-time trending.- Trend charts, bar charts, X-Y plots.
Powerful command language.- Sounds, execute applications, files, HMI screen displays.
Import .PCX and .ADE files.
Factory floor connectivity
I/O
MxCC
I/O
Office ClientPC
TCP/IP - Ethernet
MxCC
PC data from factory floor to office.
Production statistics.
Current machine status.
Downtime analysis.
Remote programming
MxCC #1 MxCC #2 MxCC #3
MxCC on a remote PC
Ethernet
Designer runs here
These stations have MxCC Runtime. They also run WinNT applications
MXCC - Single tag database
ControlDesignerControl
Designer MxCC MMIMxCC MMI DDEServerDDE
ServerReal-TimeSimulation
Real-TimeSimulation
Client-Server
Network
Client-Server
Network
Common Tag Database& I/O Configuration
Common Tag Database& I/O Configuration
Real-Time Control EngineReal-Time Control Engine
MX ComputerControl
A70BDE-ABFI/O Scanner Interface Card
A Series Expansion Rack
Uses standard and Special I/O Modules
Rack based I/O
Drivers:Mitsubishi A-Series AB Remote I/O Data Highway +
Datalogic Devicenet Fast DDE
GE-Fanuc Genius Generic I/O Honeywell SDS
Interbus-S (Full Slot) Interbus-S (Half Slot) MEI DSP
Modicon S908 Optomux Profibus
PID Loop - Floating RS-232/422 - Serial Port PAMUX
Industrial I/O support
Real-time simulationUse flowcharts to simulate response.
Verify your design.
Re-use your designRe-useable program modules - subprograms.
Re-useable HMI components - dynamos.
More benefitsDDE server.
Data express DLL toolkit.
PID control options.
Motion control options.
Database import/export.
HMI flexibility.
Station Faulted?
Display"Station 1 Faulted"
Station 1 FaultedStation 1 Faulted
On-line diagnosticsDiagnose faults directly in the flow chart.
Display fault and corrective action to operator.
Query operator for responses.