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HandlingMachiningAssemblyControl

PneumaticsElectronicsMechanicsSensoricsSoftware

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ControlElectronics

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IPC recipe book

Blue Digeston Automation

Blue Digest on Automation

© 2004 by Festo AG & Co.Ruiter Strasse 82D-73734 EsslingenFederal Republic of GermanyTel. (0711) 347-0Fax. (0711) 347-2155

All texts, representations, illustrations and drawings included in this book are theintellectual property of Festo AG & Co., and are protected by copyright law. All rightsreserved, including translation rights. No part of this publication may be reproduced ortransmitted in any form or by any means, electronic, mechanical, photocopying orotherwise, without the prior written permission of Festo AG & Co.

A few years ago it was still a topic of discussion as to whether industrial PCs andprogrammable logic controllers were in competition with each other or werecomplementary. Today, both systems have their place and are used as a matter ofcourse.

The focus of discussion and development has now shifted towards network technologyinstead. Decentralized automation technology is once again the hot topic inautomation. The Ethernet network – an age-old fixture in the PC world but entirely newin the field of automation – has made decentralized automation manageable. The useof fieldbusses for decentralizing the input/output level has led to experts in automationtechnology becoming familiar with the terminology and techniques of networking andserial data transmission. This knowledge is now being combined with the experienceof the network engineers. As a result, integrating automation technology into thenetworks used in manufacturing and administration is at last becoming so easy that thetechnology can be put to widespread use.

For almost two decades now, Beck IPC GmbH, a subsidiary of Festo AG & Co, hasbeen developing industrial control technology based on PC technology. In order tomake the grade, every new development has had to meet certain requirements. Eachone must be:

_ small and maintenance-free, to allow smaller control cabinets to be used_ PC-based, to enable users to respond flexibly to widely differing demands_ modular and/or part of a complete family of hardware and software_ programmable as a PC or a PLC_ network-capable with Ethernet

This book describes examples of applications using the controllers from Beck andFesto. We trust you enjoy browsing and reading through the book, and hope that thedescriptions might give you some ideas for new solutions of your own.

Wetzlar, October 15, 2000Bernhard [email protected]://www.beck-ipc.comhttp://www.festo.com

Preface

Preface..............................................................................................................................5

Control and handling technology ..............................................................................9

The Boxer opens cardboard boxes..................................................................................10From a handling device to a gateway..............................................................................12Fully automatic welding in giant containers....................................................................14Feeding, checking and sorting small parts with the Checkbox ......................................16Making beautiful clothes in Denmark ..............................................................................18Storing grain .....................................................................................................................20Controlling mobile road tarring machines ........................................................................21Sending electronic devices from the clean room for testing ...........................................22Manufacture of MKP-SI capacitors ..................................................................................24Production of spray cans .................................................................................................26Sawing up thick tree trunks..............................................................................................28Controlling at random.......................................................................................................30Excursion: Programming with FST...............................................................................32

Networking and remote maintenance ......................................................................35

Pad printing on a network................................................................................................36Securing pedestrian precincts .........................................................................................38Recording process data and arranging for essential repairs ...........................................40Data backup on the network.............................................................................................42Modernisation of a high-bay warehouse ..........................................................................44Calling the emergency repair service ..............................................................................45Calling the machine .........................................................................................................46Control and operation via the Internet ..............................................................................47Excursion: Programming in line with IEC 6 1131-3 with MULTIPROG........................48

Measurement technology, data processing and quality assurance..................51

Collecting and processing environmental data ...............................................................52Observation of historical buildings and structures..........................................................54Compressed-air filling station for tyres ............................................................................56Automated soil examination ............................................................................................57Testing Tipptronic system modules................................................................................58Testing Checkbox modules.............................................................................................60Monitoring welding data ...................................................................................................62Optimisation of a gas-fired power station ........................................................................63Quality assurance in cylinder manufacture.....................................................................64Acquisition of measured data and controlling an aerialin a measuring balloon.....................................................................................................65Examination of rubber compounds ..................................................................................66Testing CAN valves.........................................................................................................68Measuring soot content in the air.....................................................................................70Monitoring a radio station's high-frequency band ............................................................71Excursion: Programming in C/C++................................................................................72

Contents

Process control systems, lab. technology and hydr. engineering...................73

Water treatment ................................................................................................................74Ensuring cleanliness in cheese production ....................................................................79Statistical process control in the manufacture of thermocylinders .................................80Data acquisition in sewage treatment plants...................................................................81Controlling a biological trickling filter scrubber ...............................................................82Determining the cell state of microorganisms ................................................................84Filling up with liquefied natural gas.................................................................................86Providing for clean water..................................................................................................88

Edutainment and simulation.......................................................................................91

Discoveries on the high seas ..........................................................................................92Keepers in the wild...........................................................................................................94Learning to use modern automation technology..............................................................95

Applications with the IPC@CHIP ................................................................................97

Ethernet - CAN gateway ...................................................................................................98Controlling with the IPC@CHIP........................................................................................99Learning with the IPC@CHIP .........................................................................................100Monitoring with the IPC@CHIP ......................................................................................101Excursion: Hardware ...................................................................................................102

Index..............................................................................................................................105

Control and handling technology 9

It is certainly a pleasure to fold open a cardboard box and lovingly to pack it withcarefully chosen Christmas presents for someone close to your heart.

It is hard, tiring work to open not one cardboard box butseveral hundred a day so that they can be filled with goods. This is where acombination of mechanical systems and control technology is called for. This is wherepneumatic components are used for the drive units, in conjunction with small, fast-acting controllers.

Starting from "little" tasks such as these right through to assembly stations, they arestill out there today: systems and installations which need control technology, usingBoolean algebra, AND and OR, steps for organising the working sequence – all thishelps get the job done. Even if public discussion tends more to focus on the networks,the operating philosophy and many other things, there are still millions of relaysswitching motors on and off, and millions of valves letting cylinders travel back andforth.

The modular system of the IPC PS1 with its multiplicity of different input and outputmodules and the modules for controlling stepping motors, servoelectric andservopneumatic axes is ideally suited to mastering these tasks. And the minicontrollers of the Front End Controller family feel most at home in small-scaleapplications, where there is always call for fast and flexible automation technology thatboosts productivity.

In this section you will find a number of examples in which the main focus is on controltechnology. Enjoy your read.

Control and handlingtechnology

10 Control and handling technology

As explained in the introduction to this section, folding open hundreds of cardboardboxes is laborious and tedious work. All the same, every day more and more boxeshave to be opened, taped, filled, closed, addressed … Mail-order business is growing –and every time an order is placed, a new box is needed.

Automating a task like this calls for a great deal of know-how. Because althoughcardboard boxes are sturdy, they are certainly not stiff. The box gives way, moves, isnever precisely the same size, and appears in an infinite number of variants. With theaid of a sophisticated mechanical system in conjunction with pneumatic drives andvacuum suction devices, boxes of different sizes and different strengths can be openedand set up automatically, and the base taped ready for the box to be filled.

The Boxer from the Rembrandt Packaging company inHolland is one such device that assembles not just one but hundreds of cardboardboxes a day, and also tapes up the base. The boxes can then be filled, sealed anddispatched.

As easy as it may sound to "open a cardboard box", the solution is equally elaborateand complex. This is because a system has to be constructed that is very cost-effective (cardboard boxes should of course cost nothing – they are "only" thepackaging) yet at the same time highly flexible. Depending on the products beingpacked, the boxes have to be larger or smaller, thicker or thinner walled, stiffer or morepliable. Not only that, no-one really has space for a Boxer, so the machine must becompact and offer very flexible installation options – for operation from the left or theright, or any other variant you care to think of. Rembrandt has therefore constructed theBoxer from individual modules which can be assembled to suit the customer's specificrequirements.

Cooperation between Festo and Rembrandt has helped to make the Boxer flexible andfast in production. Festo in Holland manufactures the entire control cabinet with the

The Boxer openscardboard boxes


controller, valve terminals and all connecting cables and connection tubes. The cablesand tubes are supplied by Festo ready cut to the correct length. The controller is fullyprogrammed and tested. When the control cabinet is delivered, the assembly team atRembrandt needs just another two hours to place the Boxer at the company's disposal,ready installed and tested. The only thing that is faster is assembling the cardboardboxes with the Boxer ...

IPC FEC FC20 Mini controller with flash memory for the application.

FST With FST a system of this type can be programmed in double-quick time,because the process being controlled is a sequence of movements which areideal for programming with the STEP command in FST.

Packaging technology, cardboard box, sequence control

Hardware

Software

Keywords


Handling devices, being special-purpose robots, are always tied to a particular type ofmachine. Nevertheless, they must be designed in such a way that they can be adaptedto a range of different machine variants. As far as controlling a handling device isconcerned, this means that for example the stroke lengths, slewing angles of the shaftsand interlocking times have to be adjustable. Simple handling devices have oftendeveloped into complex process interfaces or gateways, which in addition to theirhandling functions also have roles to play in production data acquisition andnetworking. This is an area where using an industrial PC is very much the obviouschoice.

A major German manufacturer of handling devices for injection moulding machineswas also faced with this task, because the family of devices covers precisely thisrange from simple gantry robots to process interfaces. The company decided to go forthe PS1 system across the board. Not only does this make stockkeeping easier, it alsomeans that staff training can be limited to one type of control electronics. One reasonwhy this decision also has a positive effect on development times is that the system isvery simple to program, like a PLC. This can be illustrated using the example of asprue removal device.

The device can be mounted on any injection moulding machine. After the injectionprocess, the device takes hold of the sprue part in the area of the opened mould andtransfers it to a container. The injection moulded part itself is separated automaticallyfrom the sprue and drops into a different container. Within the production process, theremoval operation not only represents an unproductive length of time, it is also linkedto energy loss, because the open mould quickly cools down. The shorter the timetaken for removal, the lower the energy loss and the more productive the plant is inoperation. The electronics hardware can meet this requirement without any difficulty.The challenge in this case is for the pneumatic components. But the control program,

From a handlingdevice to a gateway

Sprue removal device


too, has to take account of this. It must not be permitted to operate with generouslydimensioned waiting times.

The key components of the handling system are the following:

_ The x-axis, which runs parallel to the ejector on the injection moulding machine. Itis implemented with two short-stroke pneumatic cylinders which allow a maximumtravel of 50 mm.

_ The y-axis is arranged perpendicular to the ejection system; a pneumatic lineardrive with a maximum stroke of 500 mm was used for this. The z-axis is in the formof a rotation axis with a slewing angle of 90°. The gripping tool is a pair of tongsmounted on one end of the y-axis cylinder. All of the axis cylinders and the tongsare driven via 5/2-way valves.

The requirements that need to be met by the control system of an arrangement of thisnature are satisfied by the PS1 system in the best possible way. All control tasks canbe mastered with the central processing unit and the digital input/output options. Aswell as this, the IPC fits into the gap in the switchbox which all of the other componentsleave free.

One fundamental prerequisite for the choice of hardware was simple programmability.The FST software makes the programming of step-by-step sequences easier thanks tothe STEP operation and the ability to easily administer up to 64 differentprograms/tasks. The control program is modular and therefore its structure means it iseasy to maintain. The plant functions are implemented in two modules: the keyinterrogation part establishes the connection to the operating personnel, while control ofthe handling components is dealt with in the main program. The FST programmingsoftware supports step control in that the steps are managed by the system and theprogrammer is relieved of the task of setting up a step variable and interrogating it.

BP11 3-slot busboardHC16-F PC/CHIP CPU with FST kernelIM10 16-bit digital input moduleOM10 16-bit digital output module

Of the 16 digital output signals which the OM10 module makes available, 4 are used tosend commands to the injection moulding machine (ejector, mould closure and corepuller).

Handling system, injection moulding, step programming, positioning

Program language

Hardware

Keywords


Huge storage containers are used for storing foodstuffs, grain, chemicals, viscose – infact raw materials of a great variety of types. That is nothing unusual. But the largerthese containers are, the more expensive and difficult they are to build and, later, torepair or replace as necessary. And it is here, in the repair or complete overhaul of suchcontainers, that the Swedish company Uddcomb comes into its own. They havedeveloped a procedure by means of which existing containers which have becomebrittle or have developed a leak are lined from the inside with a new steel container.This sounds very simple, because it is a kind of pot in a pot. Actually carrying this out,though, is not so easy, because the new internal container cannot simply be insertedinside the old one. No, it has to be welded together from individual metal plates insidethe container. This is the only way of ensuring that the new internal container isprecisely matched to the existing container.

In principle, the yards and yards of seams can also be welded by hand, but in mostcases this would make complete renewal uneconomic. Uddcomb has developed awelding machine which automatically moves along the welds inside the container in asuspended position. The welding machine is moved with the aid of stepping motors,and the welding current is used as a measure of the correct distance for the weldingwire.

The control system needed for such an unusual welding machine has to be extremelyflexible. As well as this it should be small, because the entire system is forever havingto be transported from place to place. The containers that need to be repaired do notcome to Uddcomb, instead the refurbishment team always has to travel to wherever

Fully automaticwelding in giantcontainers


there is another container waiting for a new interior lining. Being constantly on the roadis not the normal operational situation for a machine control system. With the IPC PS1,this works.

BP50 5-slot busboard with power supplyHC16-F PC/CHIP CPU, EPROM, RAM, flash2 x AM11 Stepping motor moduleIO10 8 x analog input moduleOM21 Digital input/output module each 8-bit

FST was chosen as the programming language; it is simple and quickly adaptable,supports the positioning task and is very well known to the people putting the projectinto practice.

Welding, stepping motor, positioning, mobile application

Hardware

Software

Keywords


Feeding small parts such as screws, rings, springs, perfume bottles, nuts, toothbrushheads and a myriad of other parts in the proper orientation is an age-old problem inautomated production. There are countless applications that use shaker conveyors,which have all sorts of elaborate mechanical "chicanery" to make sure that the partsare always fed in precisely the orientation required by the next stage of production.

The Checkbox takes a new approach. In this case, no mechanical obstacles are usedbut instead a camera is used to check the orientation. In a teach-in process, the controlsystem is taught what the "correct" part should look like. The computer compares thecaptured image with the stored image and issues a command to blow out or eject thoseparts that are not positioned correctly.

The particular advantage of this method is that the Checkbox is highly flexible in use.The teach-in process takes a matter of a few minutes. The correctly oriented part has tobe passed beneath the camera several times, the computer saves the image – that'sall. In contrast, setting up a mechanical obstacle course can be a matter of hours orsometimes even days.

The second advantage of the Checkbox is that not only can the parts be checked thatthey are fed in the proper orientation, they can also be examined for entirely differentproperties, such as their shape, colour, material etc. In this way, the Checkbox canalso be used for sorting, not only feeding.

Feeding, checking andsorting small partswith the Checkbox


The centrepiece of the Checkbox is the camera and its associated image processor.The image processor has been developed by the Checkbox team, and in technicalterms is quite a gem. This is because with the Checkbox, as is always the case inautomated production, what matters is speed: thousands of parts per minute aresupposed to pass through the system. This is only possible if the CPU is designedexclusively for the purpose of image processing (image capture, image comparison)and the response to evaluation of the image. The Checkbox team used the IPC PS1Professional as the basis for its design. The busboard and the input/output modulesare original PS1 components, while the CPU is a Checkbox development.

Example configurationBP50 5-slot busboard with power supplyOM21 Input/output module each 8-bitCheckbox image processor

C/C++ is the right programming language for a task such as this.

Image processing, shaker, Checkbox

Hardware

Software

Keywords


Brandtex A/S was founded in Denmark in 1935, and is today one of the largest textilecompanies in Scandinavia. The various subsidiaries of the Brandtex group produce alltypes of textiles, ranging from children's clothes, jeans, young fashion and swimwear toknitwear and men's wear and ladies' wear. Around 2,000 staff are employed around theworld in the design, production and sale of textiles.

Particularly in the textile sector, international competition is extremely tough. For acompany based in Europe, impeccable automation technology is vitally necessary inorder to be able to sell textiles in accordance with market conditions: in this case thismeans on the one hand offering value for money, but much more than this, beingflexible. Setting fashion trends means offering high-quality designs and convertingthem very quickly into real products. Following fashion trends means converting thestandards set by fashion into products in double-quick time.

It is at this interface between fashion and automation technology that Brandtex andFesto come together. Recently Brandtex began operation with a new generation ofautomatic sewing machines, for sewing trousers and skirts. The installation iscontrolled by an IPC PS1.

Of course it is not a problem to build automatic sewingmachines. These are available in a great variety of designs and versions. As far asBrandtex was concerned, it was not simply a matter of a sewing machine but rather ofhigh performance in conjunction with low investment optimised for the task in hand.The control system to be used as well as the chosen pneumatics therefore also had tobe subjected to the dictates of rigorous cost control. A number of components playedtheir part in keeping the costs of the sewing machine down.

Firstly there is the activation of the positioning system required for the sewing process.The power section for a stepping motor is activated directly from the inputs/outputs ofthe CPU. All of the parameters for the stepping motor, such as the position, speed,starting ramp and brake ramp etc., are entered in a module in the FST software. Theoutputs specify the frequency and direction for the stepping motor directly. The inputsread directly from the sensors on the shaft. There is no need for a separate steppingmotor controller.

Then there is the CPU and the entire IPC PS1 system. The HC01 CPU is specificallydesigned for small- to medium-sized autonomous plants, and in terms of its price fitsvery well into a project as critical as this.

Thirdly there is the programming software that is used. With the FST software, theprogramming process is adapted to the way that the engineers think.

Making beautifulclothes in Denmark


Fourthly we come to the Festo valve terminals used in this system, which enable thepneumatic power section to be activated quickly and easily, and are also extremelycompact.

One particularly important factor regarding the use of an automatic sewing machine isalso that the operating personnel do not usually have much idea of electronics orcomputers. The necessary operator actions must therefore be kept simple, clear anduncomplicated. At Brandtex they use an EXOR terminal for the purpose of operatorcontrol. This terminal is itself equipped with a computer, so it can access the controlsystem independently. Clear and uncluttered software allows the data andcommunication rules to be entered in the simplest possible way.

BP31 8-slot busboardPS10 Power supply unitHC01 CPU with 8 bidirectional I/Os2 x IM11 16-bit digital inputs2 x OM11 16-bit digital outputs

HC01, positioning, stepping motor, EXOR display, valve terminals, FST, textileindustry

Hardware

Keywords


When Grandmother tells stories of how the barley used to be harvested and stored, oldmemories are aroused and a picture is painted of manual farming in a natural idyll.

When the grain harvested today's agricultural reality isput in central storage in order to be able to supply a major city with flour for an entireyear, what is needed are huge silos which can be filled and emptied fullyautomatically. In Australia there is an industrial park comprising silos, conveyor belts,grain hoists and access roads for the trucks bringing or fetching the grain. The systemincludes a total of 16 silos, two hoists and 6 conveyor belts, and depending onrequirements it has to be persuaded to put grain in storage, release it from stock,relocate the valuable goods within the system or carry out a number of similar tasks.Festo Australia has used an IPC PS1 Professional for this purpose, which can beoperated in its entirety from two locations with the aid of EXOR ECT touch panels. Oneither of these two panels the operator can enter whether grain is to be stored, relocatedor released, and from where to where this is to be done. The precise route through thelabyrinth of conveyors and containers is found by the control system itself.Two jobs can be processed simultaneously, so it is impossible for the two operatorsworking at the panels to get in each other's way.On its route through the containers, the grain is steered with pneumatic cylinders whichreport back their position to the control system with the aid of an integrateddisplacement measurement facility. The speed with which the grain flows is controlledby the opening angle of the gates. The valves for triggering the pneumatics are groupedon three sets of Festo valve terminals, which in turn are connected to the controlsystem via the Festo fieldbus. This has the effect of considerably reducing the cost ofinstalling the system.

BP40 14-slot busboardPS10 Power supply unitHC16-F PC/CHIP CPU, EPROM, RAM, flashCP30 RS232c interfaceCP61 Festo fieldbus master3 x IM10 16-bit digital input module3 x OM10 16-bit digital output module3 x IO12 8 x analog input module3 x IFB1 03 Type III valve terminals with Festo fieldbus node2 x ECT-16 EXOR touch display

The programming makes use of the multitasking system provided by the FST softwareand, in addition, the MultiCI driver, which ensures that the touch panels have directaccess to all variables in the control system.

Agriculture, silo, pneumatic cylinder position detection, touch panel

Storing grain

Hardware

Software

Keywords


In the fully automatic high-performance road tarring machines that are used around theworld, machines which can lay up to 90m of asphalt per minute, a rugged controlsystem is needed in order to perform a varied set of tasks.

These include:_ Controlling every aspect of the vehicle hydraulics_ Operator prompting via a graphics monitor for the driver_ On larger vehicles, networking via a CAN fieldbus to the control console for the

tarring machine operator._ On special vehicles, networking to a hand-held terminal for personnel

accompanying the vehicle on foot_ Complete recipe management and control of the mixtures of tar, chippings and

colouring

The complexity of the tasks calls for programming in a high-level language – in thisexample it is in C – in a modular system environment.The IPC PS1 is particularly well suited to this application. It is compact, robust,modular and therefore flexible, programmable in a high-level language, and the specialmodules are based on an open standard.A remote maintenance facility via GSM modem has been included on many vehicles.Configuration example for a small vehicle:

BP40 14-slot busboardPS10 Power supply unitHC16 PC/CHIP CPU, EPROM, RAM, flash4 x IM10 16-bit digital input module2 x OM10 16-bit digital output moduleIO12 8 x analog input module2 x IO60 4 x analog output module

Optional CAN interface

Programming in C

Road tarring machines, vehicle hydraulics, operator prompting, CAN, C/C++, GSMmodem, remote maintenance

Controlling mobileroad tarring machines

Hardware

Software

Keywords


The production of hard disks, floppy disks, CD ROM drives or else are a minortechnical miracle. For a long time now we have got used to the idea that the massstorage devices in our PCs do their job year after year. And yet each of these devicesis a masterpiece of mechanical precision and miniaturisation. During operation, forexample, the clearance between the read-write heads of a hard disk and the disk is onlya few micrometers, far less than for instance the thickness of a human hair. Awarenessof this fact alone should make it plain that production of such devices themselves haveto take place in a clean room, to ensure that under no circumstances can dust, dirt orany other foreign matter be allowed to enter the device.On the other hand, eventually any part produced will have to leave the clean room,because the office where the computer will be expected to do its stuff for the customerreally cannot be called a clean room.

Pick & Place Unit s

PP1 . . . PP8

Pick & Place Unit s

PP1 . . . PP8

Product ion o f mass s torage devices

Clean Room

Further production

Points Point s Poin ts

Tes t TestTes t

For reasons of cost-saving, if no other, the clean room has to be kept as small aspossible. As many production stages as possible, therefore, should take place outsidethe clean room.

One of the major manufacturers for mass storage devices produces hard disks in manyAsian countries. Festo in collaboration with an engineering company has contributed toachieving a further automation of hard disk manufacture, and thus making it even moreproductive.

This involved setting up fully automatic pick-and-place units at the end of the cleanroom production process; these transfer the finished disks onto a conveyor systemwhich leaves the area of the clean room. On the opposite side, now under largelynormal ambient conditions, the disks are turned over, identified by barcode readers andsent to a testing station according to type.

On first impression, that sounds nothing special: transfer – transport – transfer –transport – distribute. One special feature of this application was that the automatic

Sending electronicdevices from the cleanroom for testing


system had to be integrated fully into an existing production facility that was previouslyoperated by hand. The traditional procedure was for the disks to be placed on stainlesssteel trolleys in the clean room; these trolleys were then rolled out of the clean room,and in the testing area the disks were taken out of the trolleys again by hand and givenover to testing, sorted according to type. It is also worth noting that the pick-and-placedevices work on one side, inside the clean room. The entire pneumatic systemtherefore had to be designed in such a way as not to cause contamination in the cleanroom. Secondly, we can assume that the disks are not produced in a leisurely mannerone after the other, but thousands of disks every day. The equipment list for merely thefirst of three project stages is correspondingly extensive: 26 IPC PS1 Professionalmodules were installed, 52 pick-and-place units with HMP cylinders, 180 type CPVpneumatic valve terminals, and a great deal more besides.

The IPC PS1s for the pick-and-place units are equipped with Profibus DP mastermodules. The systems at the sorting gates have HC02 CPUs and digital I/O modules.All systems are fitted with Ethernet interfaces and are networked with a central PC. AVisual Basic program written especially for this application runs on this PC, monitoringall of the connected stations and issuing error messages in plain text. Among otherthings, these messages are based on the fact that all cylinder movements aremonitored by a timeout feature.

The pick-and-place units consist of the following:BP 31 8-slot busboardPS 10 Power supply unitHC16-F PC/CHIP CPU, EPROM, RAM, flashCP 14 Ethernet interfaceCP 62 Profibus DP masterIM 11 16 x digital input moduleOM11 16 x digital output module2xCP 35 Serial interface

The sorting gate controllers consist of:BP 31 8-slot busboardPS 10 Power supply unitHC02-F AM186 CPU, flash, EthernetIM 11 16 x digital input moduleOM11 16 x digital output module

2xCP 35 Serial interface

All control programs are written in FST, the monitoring PC program is written in VisualBasic.

Clean room, pick-and-place, handling, Visual Basic, Profibus DP, Ethernet

Hardware

Software

Keywords


Metallised plastic polypropylene safety capacitors are capacitors that are made up ofseveral thousand winding layers. The capacitor elements are packed in oil in a metalhousing. The housing has a type of expansion joint to enable it to expand if thecapacitor undergoes thermal expansion as a result of overload or a fault. The "SI" in thename MKP-SI capacitor refers to the property that one of the capacitor's connectingwires has a predefined break point. The connecting wire is attached in such a way thatif the housing expands the wire is subjected to tension. The wire breaks at thepredefined break point; in the event of a fault, therefore, the capacitor is electricallyisolated and therefore harmless.

The application described here is not responsible for the entire capacitor productionprocess, "only" for the attachment of the connecting wires including the predefinedbreak point. As is usually the case nowadays in automation technology, the primarydemands made of the system were flexibility and speed while maintaining constantquality.

_ Flexibility means that around 100 types of capacitor have to be produced, each withdifferent dimensions. And flexibility in this case also means that additional typedata can be added on-line at any time. A small database administers all geometricdata applicable to the various types so that the machine is always prepared forevery job that comes along.

_ Speed means that a cycle time of less than 8 seconds per capacitor has to bemaintained.

_ Quality means that, along with technical functionality, the consideration of safetyplays a very important part. The predefined break point in the connecting wire is asafety feature that, when the capacitor is subsequently put to use, is responsible forthe safety of much larger systems and processes.

Plümer Elektrotechnik, a company based in Berlin, is responsible for the controlsection. It chose the IPC PS1 Professional because it is sufficiently flexible to satisfythe various requirements that the system has to meet in terms of control technology.For the purposes of our example, this means:

BP40 14-slot busboardPS10 Power supply unitHC12 PC/CHIP CPU, EPROM, RAMCP50 InterBus master4 x AM11 2 x stepping motor module, in this case for controlling 7 stepping motor

axles (Portescape motors with Nanotec power section)

PS1-IM10 16-bit digital input modulePS1-OM10 16-bit digital output modulePS1-DIS1 LCD displayPS1-FC/FD10 Floppy disk controller and drive, in this case as a boot drive and as

storage for the customer's type database.

Manufacture of MKP-SIcapacitors

Hardware


Plümer Elektrotechnik decided on Pascal as the programming language for thisinstallation. The program is divided into two groups, which can never be executedsimultaneously. These are a real-time-capable control section with a cycle time of < 20ms and use of the watchdog for monitoring run-time errors, and an operating andparameterisation section without real-time capability which allows access to the typedatabase with the aid of the floppy disk drive.

A sophisticated error monitoring function monitors every step of the control technologysequence. Every cylinder movement, for example, is monitored by a timer module. Ifthe movement does not occur within a specified time, an error message is displayed onthe DIS1 with indication of the cylinder, limit switch and valve. To the advantage of themaintenance personnel, therefore, all standard errors that may occur in the controltechnology are carefully monitored and are displayed in plain text. Short stoppagetimes are the benefit of having a monitoring program as well-devised as this.

Capacitor manufacture, quality requirements, stepping motor, InterBus, Pascal,database, error monitoring

Software

Keywords


The importance of spray cans in many people's day-to-day life is huge. Although theyare very rarely spoken about, their possible uses and the areas in which they are usedare so varied that it is likely to be very difficult to exclude any everyday field of use.The most common contents of spray cans are cleaning agents, lubricants, oils, paintsetc., which are then available for easy and convenient use. Now that CFCs have beenreplaced by compressed air and the can itself is usually made of recyclable metal, thediscussions surrounding environmental compatibility have largely subsided. It is justthat someone has to make the cans. And this is where the PS1 system helps.

Most spray cans are made in such a way that inside the can a plastic tube is attachedto the valve, extending down to the base of the can. This ensures that, provided the canis held upright, virtually all of the contents can be used. For many applications there isalso the possibility of attaching a tube to the outside of the valve, with the aid of whichthe oil, cleaning agent or whatever else the can contains can be sprayed with greataccuracy exactly where it is needed. It is these tubes which have particularly grabbedour attention.

These days, nothing carries on as usual in the old, easy-going way. Of course it is notenough to cut a tube to length and put it in position. In the PS1-controlled plants, 650tubes per minute are cut to length, the length is checked, and the tubes are attachedand are tested in position – that is one tube every 92 ms. The combination ofsophisticated mechanical engineering and well thought-out control technology makesthese speeds possible.

The company responsible for the mechanicalengineering side is Fischer in Bad Oldeslohe. A unit that from the outside looks like aCNC machine processes the tube material, cuts it to different lengths as required andinserts the tubes.The company responsible for the control technology is Däter in Hamburg. Mr.Peemöller has put together a system that is made up of two separate PS1 systems.

Production of spraycans

The tube in the can

Fast, faster, fastest


The control system consists of the following:BP40 14-slot busboardPS10 Power supply unitHC27 32-bit CPU4 x IM11 16-bit digital input module3 x OM11 16-bit digital output moduleIO60 4 x analog input moduleCP10 2 x RS232 moduleKobolt servocontroller and servoamplifier for the positioning system.

A separate CPU for operator guidance - the human-machine interface - isaccommodated on a second busboard:BP11 3-slot busboardHC16 PC/chip CPU, EPROM, RAM, flashBG20 DisplayThe operator's station communicates with the control computer via an RS232c

interface.

The entire system is programmed in MULTIPROG, the programming package thatconforms to IEC 6 1131-3.

Spray cans, cutting to length, positioning, testing, IEC 6 1131, MULTIPROG

Hardware

Program language

Keywords


Tree trunks: they can be thick or thin, hard or soft – that's how it is with tree trunks.Boards at a DIY store or at a timber merchant may be thick or thin, long or short, bestquality or not so good. But if you want boards with a thickness of 18 mm, then theyshould be precisely 18 mm thick, exactly like those you bought 6 weeks ago. Betweenyour DIY store with its boards that are always exactly 18 mm thick and the tree in theforest there is a great deal of work. One of Europe's biggest manufacturers of band-sawmachines for sawmills is having its band saws equipped with the IPC PS1.

The tree trunks delivered to the sawmill need to be sawn into boards to a thickness thatprecisely matches the details of the customers' orders. The demands imposed onboard production are not so very different from the demands made on the production ofitems such as valves or alarm clocks: constant quality of the end product, even if theprimary product – the tree trunks – is highly variable; high flexibility, with batch sizesalternating between just 1 and several hundred; and speed of production. Of course, theprimary product has to be handled quite differently from products such as small screws.The huge trunks in some cases have diameters of over 1 metre. They are placed ontrucks that remind you of railway goods wagons. There they are clamped in place andtaken to the saw. There is no-one standing by the saw holding a metre rule to measurewhat thickness the board should have: instead, positioning is carried out with high-performance frequency-controlled three-phase motors and with hydraulic shafts. Therequired thickness for each order is entered at a control console, the clamping trestleson the truck clamp the trunk and guide it with an accuracy measured in millimetres tothe band saw – or to the double band saw, if a second, offset and separatelypositionable band saw is also connected. The idler wheel on the band saw alone mayhave a diameter of up to 1.8 m - while the IPC PS1, in contrast, is barely larger than oneor other of the fixing bolts.

Sawing up thick treetrunks


Clamping, starting, stopping, sawing etc. are all classical control tasks which can bedealt with by any PLC. The positioning of what nowadays may be up to 6 axes, on theother hand, requires a quite considerable level of computation work because the axeshave to be coordinated with each other. And user guidance, with entry of the job details,log printing etc. is a typical task for a PC.

In the IPC PS1, all of these tasks are brought together. A single CPU takes care ofcontrolling, positioning and user guidance. Depending on the size of the saw machine,12x or 20x busboards are used. Positioning is controlled with AM20 modules, and theCPUs are usually 486s.

The software follows hot on the heels of the distribution of tasks: the control section isprogrammed in S5. The S5 operating system is embedded in a multitasking kernel, sothe positioning and the user interface are written in C/C++. An ideal combination.Because the tough sawmill environment requires a simple interface to the controltechnology. And these days Step5 is also familiar to electricians at sawmills. Userprompting and positioning, on the other hand, are reserved for the PS1 engineer.

Sawmill, positioning, S5, C/C++

Open- and closed-loopcontrol with a CPU

Hardware

Software

Keywords


Can you imagine entrusting your application to chance, random events? Or even that itis conceivable that it is the task of a controller to work "at random"? Well, there is suchan application.

In order to boost the sales of products that are packed in cans, sometimes surprise giftsare included with them. A drinks manufacturer, for example, arranged to includevouchers for lavish holiday trips in the tops of their drinks cans. A customer who buysthe can with the "golden nut" and actually finds the voucher and redeems it has won avaluable prize.

The manufacturer of the drinks cans, or rather the manufacturer of the tops for the drinkscans, therefore has to see to it that the vouchers – a prescribed number of vouchers ineach production batch – are included in the tops. And the inclusion of the special cantops must be done at random.

To do this, a small station was developed which inserts the tops with vouchers into theproduction process according to a random principle. The top itself is of coursefunctionally identical to every normal top, but it has that little something extra on board...

The IPC PS1 that controls this random insertion machine has to be able to provideprecise information, however, on when tops have been inserted, how many are still leftto be inserted and so on and so forth.

In addition, the controller is integrated into the company's network, because the"golden" tops should of course only be inserted if the customer actually requires this.

In collaboration with Festo Ireland, a manufacturer hasdeveloped a machine of this type, connected the controller to the central database inthe company network and implemented local operator control and visualisation with anEXOR display.

BP40 14-slot busboardPS10 Power supply unitHC16-F PC/CHIP CPU with FST kernelCP61 Festo fieldbus slaveIM11 16-bit digital input moduleOM11 16-bit digital output moduleCP14 Ethernet interface

The station is programmed in FST, because programming the automatic insertionprocess is quickest in FST.

The dimensions of the tops differ depending on the production batch. The insertion armis therefore positioned with a servopneumatic regulator, the SPC200 from Festo.

Controlling at random

Networking with the officevia Ethernet – every CPUcan do that.

Hardware

Software


The operating terminal is programmed with the EXOR designer software, which alreadyincludes the driver for FST controllers and supports development on even complex andsophisticated operating interfaces in the simplest possible way.

The system is networked with the company's local area network and the companydatabase via Ethernet. The Festo fieldbus slave is integrated into the system becausethe production master computer has a Festo fieldbus master and as a result is able toreceive status messages from the station very easily.

Random generator, Festo fieldbus, Ethernet, SPC200, EXOR, positioning, database,FST

Keywords


For many years now, the proportion of software costs in automation projects ascompared with hardware costs has been rising almost continuously. Every new set ofprogramming software has to try and square the circle yet again, because the demandsmade of good programming software are fundamentally contradictory:

_ Because hundreds of thousands of mini controllers control applications on a smalland even miniature scale, the software must be fast and easy to operate. For manymembers of staff in project departments, creating a fully finished project every dayis an imperative. Complicated configuration routines would only interfere with theprocess.

_ Because large projects, in particular, can quickly become confused and chaotic,especially if they have to be constantly changed because of endless follow-uprequests, the software has to be powerful in order to support systems withthousands of input/outputs and complex task structures.

_ The familiarisation time for beginners must be short – or really should not benecessary at all. Everything must be self-explanatory, intuitive and simple.

No programming software manages this entirely. Compromises always have to bemade.

The FST software approaches these compromises from a highly original angle. Itallows programming to be performed in the way that you would describe a machine.

"If a part is available here, then this cylinder should advance."This becomes:IF part_presentTHEN SET cylA_forward

This IF ... THEN ... OTHRW structure, so familiar to programmers in high-levellanguages, in conjunction with the SET and RESET operations for activating anddeactivating a digital output, is so neat and easy to remember that the first lines of theprogram can be written and understood very quickly even by beginners.

What is more, because more than 80% of all machines represent a sequence controlsystem in automatic operation, the FST software supports the programming of suchsequences by operating independently. A typical automatic handling machine, forexample, has to guide the gripper through the following sequence:- lower - close - raise - move - lower - open

The FST software uses the STEP operation for this purpose. This automatically forcesa program into a single step, the active one.

Programming withFST

IF ... THENOTHRW

STEP


STEP StartIFTHENSTEP LowerIFTHENSTEP Close

As a result, sequences of this type lose their terrors and can be programmed in thetwinkling of an eye.

Although the sequence is the central element for most machines, it is far from being thelargest part of the program. Setting up, manual operation, error messages, organisationand many other things require a due amount of attention. To allow this, the FSTsoftware provides an easy-to-handle multitasking structure. Within each project,program 0 enjoys a special status as it constitutes the "mother" of all of the otherprograms and is launched on startup. A further 63 programs can be added as needed,and operate simultaneously.

Multitasking


You can never have enough of them: flags, timers, counters, input/output addresses, toname but a few. FST takes this to its logical conclusion: 10,000 flag words (that is160,000 individually addressable bits), 256 timers and 256 counters are sufficient foreven large-scale projects.

Increasingly, however, today's automation projects are not merely large, they are alsodecentralised: a large number of small controllers, each with small projects, operate inconcert. Small, clearly organised, fast, easy-to-program projects in small controlsystems provide in total a more easily manageable and clearly arranged whole than asingle giant monster. The FST software supports the networking of controllers with theassistance of traditional fieldbusses such as Profibus DP and FMS, CAN, ASi, Festofieldbus etc., but also now Ethernet - the fieldbus of today. With Ethernet it is possibleboth to exchange data between the controllers and to program the controllers. From asingle Ethernet connection, direct access can be gained to all of the controllers outthere on the network. Central programming of distributed controllers is the key concepthere. With FST, from the mini controller to the major system, this is already realitytoday.

No programming software can satisfy every requirement. It is only a matter of timebefore someone will ask for this or that feature that "my" job needs, but which "they"have forgotten about. FST has an open interface for modules and drivers. New modulescan be written in C/C++, and new drivers too. In this way, FST is open to expansion,modification, and adaptation – for small controllers just as much as for large ones.

One example of how this open structure is used is the WEB server. A driver allowsaccess to the I/O level of the controller via an intranet or the Internet. On the basis ofthe TCP/IP driver, the controller with the WEB server understands HTML code, thelanguage of the Internet.

Are you interested in FST? More information is available here:http://www.beck-ipc.com/fsthttp://www.festo.com/fst

Variables

Networking

Modules and drivers

WEB Server

Networking and remote maintenance 35

These days there is much philosophising about "decentralised architectures","decentralised automation technology" and a great deal besides. Much is written aboutthe fact that small controllers, small programs and small systems are clearer and moremanageable than large and centralised systems. The theory goes that a large numberof small, autonomous systems are more stable in operation than a large, centralisedsystem.

Well, after all is said and done, people do choose the large controller again, with manythousands of input/outputs, because it is too much trouble for them to rack their brainsabout the small subgroups; and because it is too much like hard work to program everysingle station individually; and because it is too complicated to network all stationswith each other and to bring up the network in the right order; and because ...

Anyone who says "decentralised" is the best option must also point out ways in which"decentralised" can be made practicable. Anyone who says "decentralised" is the wayto go needs a network that actually supports decentralised structures and does notsimply grind to a halt when some component or other fails. Anyone who promotes the"decentralised" theme must illustrate that programming can be carried out centrally andthat troubleshooting can be performed from a central location.

Networking with Ethernet, programming via Ethernet, operation via Ethernet, remotemaintenance via intranet and Internet, process visualisation.

In this section you will find several examples in which decentralisation is takenseriously. Enjoy reading about them.

Networking andremote maintenance

How does it look inpractice?

36 Networking and remote maintenance

They are round, and look nicest when they are colourful: toy balls. The technique ofpad printing can be used for printing a huge variety of subjects which lend colour tochildren's play. But also ball-point pens, cigarette lighters, small packages orspectacles, in other words relatively small objects with curved or uneven surfaces, canbe printed economically in large numbers in this way. To make sure that the imprint hitshome, mini controllers from Beck are used together with pneumatic feed units fromFesto.

Not multi-coloured but with a single-colour imprint, table-tennis balls fly across the tableand golf balls soar through the sky. The toy balls for children are usually larger andalso more brightly coloured. The concept that Printing International has devised with itslatest pad printing machine offers the solution for both variants: a modular system.Every module, in this case the print head, can print both on its own and in concert withothers. If it is left on its own, just one colour is applied.

Used in combination, multi-colour printing becomespossible. Advanced network technology and efficient programming tools characterisethe pad printing machines from this Belgian manufacturer. The printing mechanism ispneumatically driven.

Pad printing is an indirect gravure printing process in which the subject is etched intothe plate; ink transfer takes place with the aid of a flexible medium, known as the pad.

The printing machine consists of a vertical feed unit, a Festo cylinder. This executesthe pad's printing movement. The horizontal feed unit moves the printing plate betweentwo fixed positions, towards the pad or towards the "ink cup". This process is repeatedafter every imprint.

Controlling the pad printing machine is fundamentally a rather simple task. If it isintended to print several colours and several subjects on a single object, the actions ofthe print modules must be coordinated with each other. The possibility of activatingdifferent print heads selectively is offered by the IPC FEC FC34 Front End Controller,the mini controller from Beck IPC GmbH. In a network version using Ethernet, it takescare of every aspect of control of the machine.

Pad printingon a network

Pad printing brings colourinto play


With Ethernet, connections can be plugged in and disconnected without adverselyaffecting ongoing operation. The modules making up the printing machine can easilybe checked and put into operation individually. The conversion phase for the machineas a whole is totally flexible, because the modules can be contacted as required andindependently of each other.

If there is a combination of several equally ranked controllers, the question alwaysarises as to which one has the upper hand in the event of parallel access. PrintingInternational has found an easy way of solving this conflict: as soon as at least twomodules begin to interoperate, a single "head controller" is added. Here, too, the FECshows its strength in action – it directs the entire system with the aid of the FSTprogramming system, in which the "Step" sequence operation is already integrated.Whether the ball will then find its way step by step into the goal or across the green intothe hole – at the moment that is still beyond the capabilities of the FEC.

IPC FEC FC34

Pad printing, modularity, F34, Ethernet, FST

Optimum networking -flexible programming

Hardware

Keywords


Every modern town has one now: a pedestrian precinct. And the way they are organisedis much the same everywhere: in daytime, during the usual opening times, thepedestrian precinct is supposed to be precisely what the name suggests: they arereserved exclusively for the use of pedestrians. In the early morning and the evening,though, delivery vehicles should be able to bring in goods as easily as possible, andalso be able to pick up goods as necessary.

But how can the observation of these regulations be monitored? Or should we simplyrely on the law-abiding nature of motorised road users?

In Belgium, the method used to maintain the rules is as simple as it is amazing.Retractable posts have been installed at the entrances to the pedestrian precincts.During the day, when the area is for pedestrians only, they are raised, but at night theyare lowered into the ground.

The job of raising and retracting the posts is taken care of by pneumatic cylinders. Thetask of triggering the valves is the responsibility of a small controller – and the neatthing about this solution is that the controller is connected to the local policeheadquarters by modem. The cylinders are automatically raised in the morning, and inthe evening they are lowered again. Once a day the PC (the computer, not the officer!)at police headquarters polls each controller to establish whether the cylinders are up ordown as they should be, and in order to synchronise the clock in the controllers.

A car has been driven into the pedestrian precinct and the driver has forgotten the time.How can he get out? Well, the controller can be called up from the police station and inexceptional cases the post can also be retracted during the day to allow access to theroad.

Securing pedestrianprecincts

Boundary between apedestrian precinct and aroad

The master computer atpolice headquarters


Windows NT PC with Visual Basic Soft ware

Modem

Modem ModemModemModem

FEC FC30 FEC FC30FEC FC30FEC FC30

2 Cylinder 2 Cylinder 2 Cylinder 2 Cylinder

with valves with valves with valves with valves

The controller is an IPC FEC FC30. A particular advantage of this is that it has twoserial interfaces. One is used for the modem, and one – during commissioning andmaintenance – for the programming unit. The police computer is a standard WindowsPC with a Visual Basic application that accesses the controllers.

IPC FEC FC30Pneumatic cylinders, type DNCValves, type CPEModemPC Windows NT

Remote control, telemonitoring, modem, traffic control technology

Hardware

Keywords


TURNILS AB is a Swedish company that is one of the world's largest manufacturers ofsun-shades, awnings, sun-blinds and everything related to such products. With exportsmaking up around 80% of sales, Turnils is a global player in a market that for average,unaware consumers such as us appears relatively trivial. How many people have spentmuch time thinking how sun-shades are made?

The experts at Turnils do a lot of new thinking every day. What makes it more difficultis that sun-shades and awnings, in much the same way as clothing, are highlydependent on fashion as far as colours are concerned. And they are purely seasonalproducts. If good weather is forecast in a particular area, sales rise. Persistent rain forweeks on end leaves orders in the doldrums.

In view of the need to be able to respond very quickly, it is particularly important tohave a perfect overview of the current situation in production at all times. Theproduction planners and machine experts have therefore integrated an IPC PS1 systeminto the existing manufacturing setup, to function as a data collector. The process datais gathered from 19 production robots and 17 injection moulding machines to beevaluated in a Windows PC, giving the production management team an excellentoverview of the status of production whenever it needs it.

Recording processdata and arranging foressential repairs

Additional serialinterfaces are simplyplugged into thebusboard.


In a further step, the IPC was fitted with a modem. If a problem occurs in production, theemergency maintenance service can be summoned via the modem. As a result it hasbeen possible to further expand the number of unmanned shifts and reduce responsetimes in the event of a fault.

BP31 8-slot busboardPS10 Power supply unitHC16-F PC/CHIP CPU, EPROM, RAM, flash2 x IM11 16-bit digital input moduleCP31 2 x serial interfaceFC/FD10 Floppy disk controller and driveModem

FST, the universal software with file handling capability and support for serialinterfaces, was once again the software used here.

Modem, ghost shift, production statistics

Hardware

Software

Keywords


In the world of automated production, the reconstruction of individual steps inproduction or testing after the event has become enormously important. During the 70sthe concept of CIM - Computer Integrated Manufacturing - was illustrated by theexample that a manager can interrogate the limit switches in the production plant fromhis PC. The problem was that the manager wasn't in the least interested in these limitswitches, and networking technology also needed another few years of developmentwork until this vision could be made reality. Today it is not a matter of being able tointerrogate data just for the fun of having data. What is important is being able to ensureunbroken tracking of production data and testing data.

When, for example, the bolts on the engine block of a new engine are tightened, it isnot only important to know that a bolt has been inserted at all but also that the bolt hasbeen tightened using the defined tightening torque and that bolting has therefore beensuccessfully completed using the defined force. Cooper Power Tools (CPT) hasdeveloped its own bolting controller for dealing with bolting tasks of this nature. Thecontroller is capable of carrying out conclusive checking of the bolting during thebolting process. The data arising for each individual bolt must be saved automatically,and must remain available for at least 10 years.

Bol t t ightener

Bol t t ightener

Bol t t ightener

Bolt t ightener

Bolt t ightener

Bolt t ightener

Bol t t igh tener

Bol t t igh tener

Bol t t igh tener

Bol t t ightener

Bol t t ightener

Bol t t ightener

Ethernet

CPTbol ting

controller

CPTbolting

controller

CPTbol ting

controller

CPTbolt ing

con troller

Interface PC

Bol tingserver

WindowsNT

CPT has therefore networked its own bolting controller with an IPC PS1 system, and inturn it has integrated the PS1 system into the customer's in-house Windows NTnetwork. The data from the bolting controllers is stored on the IPC PS1's local harddisk; it is then transferred on a cyclical basis to the NT network, where again it isbacked up on hard disk. Every day the production data is written to CD, and the CD isplaced in storage. In addition, the NT network is regularly backed up as part of thegeneral data backup procedure for the IT systems.

Data backup on thenetwork


In general terms, in this application the IPC PS1 Professional acts as a gatewaybetween the bolting controller and the customer's local network. As well as the simplegateway function, though, it fulfils two other tasks.

Firstly, the local hard disk acts as a buffer store. The storage facility is actuallydivided into two: in step with production, the data is initially stored in a battery-backedRAM, then in a cycle of a few seconds it is written to the hard disk before finally in acycle of a few minutes being transferred to the local network.

Secondly, with the aid of its input/output modules the IPC PS1 can also carry outcontrol tasks "on the side". This feature has had the result that, in the course of time,control tasks have also been transferred to the gateway, for example for belt control,component feeding etc.

In this way, a simple gateway has turned into a controlling and storing gateway.

The basic equipment set generally looks like this:BP31 8-slot busboardPS10 Power supply unitHC20-50 32-bit CPU with 586 processor, Compact Flash slotHD51 2 GB hard diskIM11 16-bit digital input module

OM11 16-bit digital output module

Programming is carried out in C/C++, the simplest method in a gateway optimised forthe Windows network.

Gateway, Windows NT, hard disk, buffer storage

Hardware

Software

Keywords


The Russian company Svetogorsk operates one of that country's largest factories forpaper products of all kinds. A high-bay warehouse was built there in 1987, extendingover 6 floors and with up to 20 rows, each with up to 40 pallets. In 1999 work wasstarted on modernising the high-bay warehouse. On 3 of the 6 floors, initially, thehandling equipment was replaced with vehicles driven by frequency-controlled electricmotors. In addition, the data management system and control of the store system wererenewed.

The head controller for the system as a whole is an IPCPS1 Professional system with an HC20. HC01 CPUs are used on the modernisedfloors. The HC01 CPUs control the vehicles, which have to be positioned with anaccuracy of 6mm within the rows, each of which are 80m long.The HC20 controller is equipped with 8 serial interfaces, some of which are in the formof RS485 bus systems. These are used for communication with the modernised floorsand with the floors that have been left in their old condition for the time being.Ethernet is used for communication with the operator terminal. This is where all thedata management work for the high-bay warehouse is carried out, as well as operationof the system, on a standard PC.There are a number of subcontrollers each responsible for a single vehicle. HC01CPUs are used for this. The positioning system uses the fast counter input provided bythe HC01, which picks up signals from a rotary pulse generator.In the course of the year it is intended to convert the remaining floors as well.Altogether, in the final configuration, 56 PS1 Professional systems are plannedthroughout the building.

Head controller:BP31 8-slot busboardPS10 Power supply unitHC20-50 32-bit CPU with 586 processor, Compact Flash slotCP12 Ethernet interface3 x CP3X Serial interface

Individual controller for a number of rows in the high-bay warehouse:BP50 5-slot busboard with power supplyHC01 AM186 CPU with 8 digital I/OsOM21 Digital input/output module each 8-bit

The software was developed by AKMA Ltd (e-mail: [email protected]), a companybased in St. Petersburg. AKMA has devised its own real-time kernel for DOS systems,and this is used in this application. The languages it uses are C/C++ and Assembler.An integral part of the real-time system is a monitor for troubleshooting; this allowsdirect access to the variables in the CPU for development work and fault finding.

High-bay warehouse, Real Time, Ethernet, fieldbus

Modernisation of ahigh-bay warehouse

Hardware

Software

Keywords


Isabellenhütte is a company in Dillenburg, central Germany, with a tradition stretchingback 500 years. This company is living proof that long-standing tradition need not leadto fossilisation but can instead very much bring about advancement and a wealth ofideas. Today the Isabellenhütte is considered one of the world's leading manufacturersin the field of electrical resistor materials – whether in the form of resistors for theproduction of printed circuit boards or in the form of thermal wires and resistance wires.

The manufacture of thermal wires and resistance wires entails first drawing ever finerwires, and then also twisting several fine and extra fine wires to produce the final wire.This process of twisting a number of extremely fine wires together is performedautomatically on machines specially made for this purpose. The reels for the initialproducts and end products are designed so as to enable the units to operate for up to 36hours without interruption. The operating personnel ensures that the machines runaround the clock, 7 days a week – human intervention is only needed in order tochange the reels.What happens, though, if shortly after the new reels are put in place a fault occurs, forexample a thread breaks or a reel becomes jammed? It used to be the case that theplant had to wait – until help arrived more than a day later.

Mr. Eichmann is the engineer responsible for the machinery at Isabellenhütte,especially for production of the special-purpose machines that the company builds andprograms itself. In order to reduce the length of stoppage times in the event of faultsduring the "ghost shifts", Mr. Eichmann now uses a small control cabinet with an IPCPS1. The IPC PS1 receives digital fault signals from the manufacturing equipment. Thefault groups are indicated with the output module. What is more important, though, isthat a message is sent to the responsible emergency repair service with the aid of amodem connected to the RS232 interface.

The fault is reported to the emergency repair team on a paging service (Scall)wristwatch receiver. The downtime for the machines is now reduced to the length oftime that the emergency team needs to get to the factory and repair the machinery.

BP11 3 x busboard with power supplyHC15 PC/CHIP CPU, EPROM, RAMOM20 Digital input/output module each 8-bitMC10 PCMCIA moduleModem

For Mr. Eichmann, Basic is the fastest and easiest method of achieving success.

Fault monitoring, ghost shift, modem, Scall receiver, Basic

Calling the emergencyrepair service

Twisting thermal wires

Automatic fault detection

The PS1 system calls forhelp

Hardware

Software

Keywords


As an exhibit to be used for presentation purposes at trade fairs, a device has beendeveloped that illustrates the possibilities offered by mobile telephony in conjunctionwith automation technology in a particularly attractive way. A traditional type ofautomatic chewing gum dispenser, of which there are hundreds of thousands in usewherever it is hoped to do a trade in small sweets or gifts for a few pence, was fittedwith an electric drive. Control of the drive is taken care of by an FEC FC38. This is amini controller with an integrated GSM modem.

The GSM modem and the controller communicate via the second serial interface onthe FC38, the EXT interface. As a consequence the FC38 can basically beprogrammed in any programming language, provided that it supports the EXT interface.As well as this, a special software package was developed, TCM-SMS, whichevaluates SMS messages. This package firstly enables the controller to send an SMSmessage. It is also possible, however, to issue commands to the controller with the aidof SMS messages, in other words for example to switch outputs, read out inputs etc.The software was adapted for the chewing-gum dispenser in such a way that it isenough just to make a phone call to the machine. The call and the calling number arelogged. In this process, though, the call is not answered (that would incur call chargesfor the calling mobile phone every time). The fact is merely recorded that an attempthas been made to make a call. When a call is logged, the motor is activated to enablethe machine to give out a small gift.

IPC FEC FC38

GSM, remote control, remote maintenance, mobile phone

Calling the machine

Hardware

Keywords


Many experts are still not really happy to let the words "Internet" and "automation" passtheir lips in the same sentence. The "toy" and knowledge database that is the Internetseems just too far removed from the clear and predictable (or so they should be)applications in automation technology. It is only gradually that many users arebecoming aware that the technologies of the Internet offer enormous opportunities forautomation: remote maintenance, remote control, visualisation and a good deal more.

As an illustration of what is possible with very simple means, a number of examplesare available on the Internet._ If you go to http://fc34demo.beck-ipc.com you will find an FC34, i.e. a real mini

controller, showing that already today it can be used as a WEB server at the sametime as being used as a controller.

_ At http://fstdemo.beck-ipc.com you can see online on the Internet how the languageof the Internet, HTML, can be used to display and change process variables.

_ And at http://webdemo.beck-ipc.com the IPC@CHIP shows that it can make a smallmeteorological station available on the Internet.

IPC FEC FC34 Mini controllerDGO cylinder Linear driveCPV valve terminals

BP11 3-slot busboard with power supplyHC16-F PC/CHIP CPU, EPROM, RAM, flashAS11 Input/output module, each 8-bit, with pushbuttons and LEDCP14 Ethernet interface

IPC@CHIP The entire IPC on one chipDK40 Evaluation board

Internet, WEB server, FST, remote control, remote maintenance, visualisation

Control and operationvia the Internet

HardwareFC34 Demo

FST Demo

WEB Demo

Keywords


Many programming methods used in automation technology are good, well known,simple or complicated, or they may have unique properties which enable them to tackleone task or another particularly well. Only one programming method is internationallystandardised, internationally accepted, and internationally established – programmingin accordance with DIN IEC 6 1131-3.

This standard, actually adopted many years ago now, is the only internationallyrecognised method of PLC programming. Not only that, it is the only PLC programmingmethod that is promoted, tested and distributed by an independent institution, thePLCOpen.

At the same time, IEC 6 1131-3 allows the user a great deal of freedom. Fiveprogramming languages are standardised:

The text-based languages Instruction List and Structured Text, the graphical languagesFunction Block Diagram and Ladder Diagram and Sequential Function Chart fororganising sequential systems.

The IPC systems, ranging from the FEC mini controller to the large IPC PS1Professional system, are all programmable with MULTIPROG, one of the leading IEC1131-3-compatible software packages.

MWT has not only translated the standard into practice, it has also introduced toolswhich simplify handling of the standard and make it user-friendly: wizards for makinguse of functions and function blocks as well as dialog boxes for the declaration ofvariables – familiar to all PLC programmers as the allocation list.

Programming in linewith IEC 6 1131-3 withMULTIPROG

The Edit Wizard and theonline help ensurehandling of IEC 6 1131 tobe fast and easy.

The 5 languages of thestandard

Wizards and dialog boxes


From the very beginning, IEC 6 1131-3 has taken account of the fact that modernautomation technology cannot work without networks. For this reason, MWT canmanage entire networks in a single project, with dozens of CPUs. When IPC centralprocessing units are used with Ethernet, every controller can be accessed via Ethernet– from a central location with one Ethernet connection and one programming unit.

Programming according to IEC 6 1131-3 has long ceased to be an exotic exception.The range extends from mini controllers to large networked systems.

For programming anddebugging via TCP/IPonly the IP address isnecessary.

Networks


IEC 6 1131 detaches itself from the usual data types in the PLC world. In addition tobits, bytes and words, it supports a large number of other data types. Depending on thepossibilities offered by the particular hardware, INT, DINT, DWORD, UINT, REAL andSTRING can be used, among others. This considerably extends the potential uses ofPLC programming. MULTIPROG exploits this potential, and also offers a large numberof options for converting data types.

At last it is now also possible to use local and global flags in PLC programming. Thename “Start” can be used perfectly well in several programs, and in each program itrefers to a different flag – and is therefore local. This makes handling flags mucheasier.

In traditional PLCs, the number of timers or counters that a controller provides isspecified. MULTIPROG may include just one block for an on-delay function, forexample. The block can be called as often as the application requires (and the memoryin the CPU allows). Limits are set by the application, no longer by the programmingsystem.

Today’s Ladder Diagram uses NO contacts, NC contacts, coils and so on in just thesame way as Ladder Diagram has since the start of PLC development. Every block,whether for example for a counter, a calculation, a flip-flop or any other subprogram, canbe integrated into Ladder Diagram. These blocks look precisely the same as inFunction Block Diagram. This means that the boundaries between Function BlockDiagram and Ladder Diagram are disappearing; the two can be used immediatelyalongside each other in every program or block.

The project tree ofMULTIPROG

Data types

Local/global flags

Timers and counters

Ladder Diagram /Function Block Diagram

Measurement technology, data processing and quality assurance 51

Sitting in your living room poring over the statistics on the discharge of pollutants fromold contaminated industrial sites and the consequences for the quality of our drinkingwater is one thing. Gathering the data for those statistics is quite another.

Writing a specification and an accompanying form for the acquisition of data on thetensile forces of wheel bolts on a car is one thing. Actually collecting the data andstoring it in a meaningful way is quite another.

Discussing the sense or lack of it behind catalytic converters, diesel particle filters andspeed limits on roads is one thing. Obtaining the necessary data for a scientificassessment is quite another.

The PC architecture underlying the entire system of IPC FEC and IPC PS1 controllersin conjunction with optimisation for minimising power consumption provides the idealprerequisite for operation as a data collector.

In this section you will find various examples which concentrate on the acquisition,storage and transmission of measurement data. Enjoy your read.

Measurementtechnology, dataprocessing and qualityassurance

52 Measurement technology, data processing and quality assurance

To comply with environmental directives, operators of abandoned potassium mine spoilheaps are obliged to provide continuous proof of the salt loading in the neighbouringriver and if necessary, if certain levels are exceeded, to initiate countermeasures.

In order to monitor this type of problem, the conductivityof the water is constantly recorded at six decentralised measuring points (upstream anddownstream of a potash heap in each case), and the chloride concentration iscalculated from that.

The IPS1 system in this case acts as a data logger. The data source, a conductivitymeter, makes its measured values available at the COM2 (CP30) port face everysecond. The implemented software then has the task of breaking down the serial datastream into the required data components and of converting the conductivity into thechloride concentration. Over an interval of two hours the mean value is calculated andthe minimum and maximum values are identified. These 3 values together with thetemperature are assigned a time stamp and stored. For reasons of furnishing proof, themomentary measured values are logged every minute for a period of 30 days in a ringmemory on the memory card. In the event of an incident, the data can be read out fromthe memory card.Five of these measuring stations are housed in a small control cabinet close to theriver bank. Every conceivable type of weather experienced in central Europe is thrownat the PS1. In several months of continuous operation, the system successfullypassed its test in action.On the basis of this measurement data it was possible to prove that neither fluctuationsin temperature (moisture condensation) nor decidedly chilly temperatures of below -5°C(even over a number of days) had resulted in any failures.

The decision to choose the MC10 module with a 1MB SRAM card as the storagemedium proved to be the correct one in these harsh ambient conditions.

The COM1 (HC12) operates the trunked mobile radio unit. The switch output pin7 of theCGA port is used to check the radio unit into the trunked radio network at least once aday.The COM3 takes over the role of a service interface. System parameters can bevisualised and modified on location with the aid of a notebook.

Three of these measurement systems are located far away from civilisation. They aresupplied with power from photovoltaic installations. In this instance it was important tosave every possible milliampere. This is why the HC20-40 is used, with its two serialinterfaces and the flash memory. Any components that are not required, such as VGA,are deactivated in the setup. This offers advantages with regard to power saving.Especially as the local fauna is unlikely to be interested in reading the measurementson a monitor.In order to make the measurement data accessible to the plant operator, at intervals oftwo hours it is automatically transmitted via public trunked mobile radio to a mainframe(AS/400), where it is archived. This task is dealt with by another PS1 system. It acts asa radio server, and communicates with the AS/400 via the in-house LAN topology.

Collecting andprocessingenvironmental data


As far as the radio interface is concerned, a highly efficient and cost-effective means ofdata transmission was organised by using the MAP27 API with the SDM/EDMfunctions.The entire system operates autonomously. Manual access to the functionality is onlynecessary for the purpose of administrative procedures. In this case the decentralisedmeasuring stations can be operated by remote control in remote mode. Theinfrastructure of the trunked mobile radio network means that the data can be accessedanywhere in Germany. A significant contribution to the overall stability of this highlyindependently operating measuring system is the watchdog function that isimplemented.Every aspect of the functionality of the measuring system including the radio interfaceto the MAP27 API was written in C/C++.

Device Radioserver

Measuringstation

Measuringstation

Number 1 3 3

BOSCH KF-CHIP radio unit X X X

BP11 3-slot busboard X

BP50 5-slot busboard X X

CP10 Ethernet interface X

CP30 RS232 interface X

HC12 PC/CHIP CPU X X

HC20-40 32-bit CPU,486 processor, CF, flash X

LF340 WTWconductivity meter X X

MC10 PCMCIA module X X

SM14 TTL/RS232 adapter X

ZL16 Zero power RAM disk X X

ZL31 1 MB SRAM X X

ROM-DOS, firmware: FunkServ, LF_Val, MAP27.LIB

Environmental monitoring, telemonitoring, remote maintenance, conductivitymeasurement, data logger, preservation of evidence, ambient conditions, power supply,public trunked mobile radio, radio server, autonomous measurement systems, C/C++,watchdog

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Research work carried out at the Bauhaus University in Weimar includes thesupervision of historically valuable buildings and structures such as churches andbridges. The aim is to prevent deterioration. The relevant physical quantities relating tothe structure are monitored and diagnosed using mathematical models, so that ifnecessary a restoration plan can be drawn up in good time.

The consultant engineers, ISL Ing-Büro für Systemlösungen in Erfurt, use the IPC PS1as a long-term data storage facility.

Critical measuring points include the beams of a church tower, for example, whensubject to changing wind load and the varied influences of weather.

Another application is the long-term observation of the load behaviour and response toweathering of a historically valuable bridge. What needs to be done here is todocument the "healing success" with data from about 1 year before, during and after therenovation of such a bridge.

The hardware basis is provided by the Spider 8 measuring instrument from HBM andthe PS1 system. The entire functionality of the Spider 8 is stored as an image in thePS1. The Spider 8 and PS1 communicate via the COM interface using a correspondingsoftware protocol.

Various modes are implemented on the user side:

a) Direct coupling between PS1 and notebook (usually at the time of initialinstallation or when adjusting the measuring bridges on location)

b) Coupling of PS1 via modemc) Coupling of PS1 via GSM radio unit (inaccessible terrain with no infrastructure, no

230V supply, no telephone connection)d) Coupling between PS1 and private mobile radio equipmente) Autonomous data transfer to the server (script-controlled)

In modes a) to d) the operator obtains an image of the entire system displayed on hisPC/notebook. In remote mode he can parameterise the installation, configure it,balance (calibrate) sensors, define filter rates and sampling rates, etc. Themeasurement data is transmitted using a transfer protocol (X-modem). A formula editoris implemented which enables the integer measured value to be presented as aphysically relevant measured quantity.

In the subsequent expansion stages dynamic and event-controlled measurements willalso be used with the assistance of HC20 or HC50 modules. As a result it will bepossible, for example, to assess bridges under rapidly changing loads (trucks, trains).

A major contribution to the overall stability of this autonomously operatingmeasurement system is provided by the watchdog function that is implemented.

Observation ofhistorical buildingsand structures


The PS1 proved its mettle both in use in severe environmental conditions (during thebuilding phase) and in relation to its all-weather resistance (at times in externaltemperatures of -5°C according to the measurement data).

The entire functionality of the measurement system including the transfer interface waswritten in C/C++.

Long-term measurementBP11 3-slot busboardHC12 PC/CHIP CPUZL16 Zero power RAMMC10 PCMCIA moduleZL31 1 MB SRAMCP30 RS232 interfaceZP11 ModemSpider 8 HBM

Dynamic long-term measurementBP11 3-slot busboardHC20 32-bit CPU, CF, flashMC10 PCMCIA moduleZL32 2 MB SRAM2*CP30 RS232 interfaceModem

4*Spider 8 HBM

ROM-DOS, firmware: S8PS1D, S8ContrlWin, Trans_Srv

Physical properties of structure, telemonitoring, remote maintenance, long-term datastorage, environmental conditions, modem, radio, autonomous measurement systems,C/C++, watchdog

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When tyres are fitted they initially have to be inflated to a relatively high pressure so asto achieve a perfect fit with the wheel rim. The pressure is then reduced to theappropriate mounting pressure.

Depending on the type of tyre, the initial pressure may be 5 bar, for example, and thefinal pressure 1 bar. Inflation and to some extent pressure reduction is carried outautomatically.

The difficulty with pumping air into the tyre is that air is supplied through a valve. Thevalve acts as a throttle. This has the effect that it is never possible to measure thepressure and pump in air at the same time. Consequently, the tyre is always inflated foronly a short time, then the pressure is measured, inflated, measured...

At the Swedish manufacturer, the intelligent solution produced with the IPC PS1 hasreduced the time needed for inflation by 50%. To achieve this, the IPC recalculates theassumed inflation time at every inflation stage on the basis of a previous inflationprocess. It is only when the inflation level is calculated to have reached 90% that theinflation process is interrupted, a measurement is taken and a new calculation isperformed, etc.

This is therefore a self-optimising closed-loop process control function.

PB31 8-slot busboardPS10 Power supply unitHC16 PC/chip CPU, EPROM, RAM, flashIM10 16-bit digital input moduleOM10 16-bit digital output moduleI010 8 x analog input moduleBG10 4-line LCD display with 4 function keys

Programming is carried out in Pascal, because the emphasis is less on controlling theinput/outputs than on the calculation algorithm.

Self-optimising closed-loop process control, pressure measurement, Pascal

Compressed-air fillingstation for tyres

Hardware

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Soil tests which investigate the density or compaction of the soil are very important inagriculture. Also the question of the extent to which the tyres of a tractor compact thesoil, for example, is important for assessing the possible ways in which the vehicle canbe used.

In Belgium a vehicle has been developed that carries out measurements of soilcompaction automatically and saves the measurement results. To do this, it measuresthe force that is needed to enable a rod to penetrate the ground down to a specifieddepth.

The IPC PS1 controls two of the axes, X and Y. In the X-axis a stepping motor is usedin order to obtain a series of measurement results, which are then saved. In the Ydirection the measuring rod is extended and the force is recorded. The measurementdata is stored in Excel format in the flash drive belonging to the CPU, and at the end ofa series of measurements it is read out via RS232. In the office the data is then editedand evaluated using standard software.

BP50 5-slot busboardHC17 PC/CHIP CPU, EPROM, RAM, flashOM20 Digital input/output module, each 8-bitAM11 Stepping motor moduleIO12 8 x analog input module

Pascal

Soil examination, Excel, flash drive, force measurement

Automated soilexamination

Hardware

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Tipptronic is a semi-automatic gear-shift system for cars. The driver selects a gear withthe selection lever, and the gear is set electronically. There is no clutch for the driver tooperate. The electronics also monitors whether the selected gear makes sense.Changing into reverse gear when travelling at 70 miles per hour on the motorway istherefore made impossible electronically. It goes without saying that the selection levermust always issue an unambiguous instruction to the electronics. And this instructionmust precisely correspond to what the driver wants to do.

Hüco electronic GmbH manufactures these Tipptronic components and tests thesystem with the IPC PS1 Professional. The core of the Tipptronic is a curved printedcircuit board with Hall sensors. The purpose of the test stand is to check whether theHall sensors correctly signal the position of the selection lever.

The various positions of the selection lever are simulated with the aid of pneumaticcylinders, triggered by Festo valve terminals, with a magnet mounted on them. Thegear selection status is output on LEDs. The state of the LEDs is picked up byphotoresistors and is reported back to the testing system.

What was important during the development of the test stand was that the system hadto be very easy to adapt to new requirements, new shapes, and new types. From thebeginning, the test cabinet was designed to allow space for expansion.

A number of files are created for each component type, for example the job file, the limitvalue file and the CAQ file, where the measured data is stored. Altogether eachmeasurement procedure currently amasses 37 measured values.

The measurement system is operated using a standard keyboard and monitor – as faras the measurement itself is concerned. The photo shows the control cabinet with theIPC PS1 together with the 14" monitor and the keyboard, as well as to the left of thesethe label printer. In addition the AS11 module with its 8 pushbuttons and LEDs is usedin order to switch back and forth between various limit value files.

Testing Tipptronicsystem modules


BP40 14-slot busboard built into a 19" rackPS11 Power supply unitHC20-80 32-bit CPU with 486 processor with mathematical coprocessorHD50 1 Gbyte hard diskFC/FD10 Floppy disk controller and driveAS11 Combined 8-bit digital input/output moduleCP30 RS232 interface for the label printerOM70 6 x relay output moduleIM12 32-bit digital input module2 x IO12 8 x analog input moduleOM22 Digital input and output module, each 16-bitOM11 16-bit digital output module

The approach to programming was split into two: the control section including the testsequence was written in Step5, while the user interface, measured value acquisition,evaluation and data backup were written in C/C++. The two programming systems areconnected via the real-time multitasking system on the basis of RT Kernel.

Tipptronic, S5, C/C++, measured value acquisition, Hall sensor

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Testing, testing, testing ...

It is a fact that we are all familiar with: the more complex the module, the more elaboratethe testing becomes. The Checkbox is a system for feeding correctly oriented smallparts that checks the parts at the same time (see the description of the Checkbox in thesection on control technology). The electronics for this are without doubt among themost demanding examples known. This is because the CPU is optimised forevaluation of the camera images and simultaneously controlling the input/outputs in thesystem.

Apart from the in-process tests which every electronic module undergoes in the courseof production, a final test is absolutely essential. In the case of the Checkbox hardwarethis has to be very flexible so that the test can be adapted to various versions of theCPU.

Once again, the IPC PS1 was chosen as the centrepiece of the testing station,although without doubt one reason for this was that the Checkbox team were alreadythoroughly familiar with the IPC PS1.

An HC16 CPU, which in this case is able to concentrate entirely on testing, is quitesufficient here. A BG20 takes care of the graphical representation of the whole testingprocess, and input/output modules provide signals for the electronics under test, towhich it has to respond.

Testing Checkboxmodules


Needless to say, the test procedure also includes storage of the test data andsubsequent evaluation in a database.

BP50 5-slot busboard with power supplyHC16 PC/CHIP CPU, EPROM, RAM, flashOM22 Digital input/output module, each 16-bitIO10 8 x analog input moduleIO60 4 x analog output moduleBG20 LCD display

Programming is carried out in C/C++, because that is everyday routine for the Checkboxteam.

Electronics testing, Checkbox

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Inert-gas-shielded welding is one of the most commonly used welding techniques whenproducing circumferential welds for bicycle frames or similar products.As in so many cases, the testing of welds such as these is now a vital part of themanufacturing process. Where automatic test procedures are used, it makes sense torecord the welding parameters while the actual welding operation is still in progress.These include the welding current, the flow of shielding gas and the welding voltage.Weber Robotertechnik GmbH has developed a system which detects the keyparameters determining the quality of the welded seam independently of the weldingcontrol system. The SDC – the welding data controller – is integrated into the weldingsystem and is totally transparent for the welding controller.The SDA – the welding data display – processes the data. In the simplest case, thisincludes calculation, with the result being a decision to accept or reject the weld,through to detailed graphical output on a printer or onto a network on a higher-levelcontrol desk.

Inside the SDA there is an IPC PS1 Professional beavering away, which is ideallysuited to the task because it provides all of the necessary input/output modules to theSDC, the system remains small enough and programming of the PC-based system isno problem for the developers at Weber.

BP50 5-slot busboard with power supplyHC12 PC/CHIP CPU, EPROM, RAM, flashIO10 8 x analog input moduleCP70 Printer interfaceCP31 2 x serial interface

Programming is carried out in C/C++.

Welding, inert-gas-shielded welding

Monitoring weldingdata

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By measuring the carbon monoxide (CO) and oxygen (O2) at the flue gas outlet headerof a gas-fired power station, conclusions can be drawn as to the level of gasconsumption and waste gas emissions by the power station.

In order to reduce gas consumption and therefore also emissions in an existing gas-fired power station in Spain, a measuring system with an IPC PS1 is installed at theflue gas outlet header; this exchanges data with another IPC in the central control roomvia an RS485 interface. In the control room the data is visualised and incorporated inthe process control system.This feedback arrangement therefore enables process optimisation to be implementedwithin power station operation.

The rugged and compact design of the PS1 system allows it to be used directly at themeasurement location (the flue gas outlet header) under the difficult ambient conditionsprevailing there for direct recording of the analog measurement signals from the gassensors. This results in a cost-effective measurement system.

IPC at the flue gas outlet headerPS1-PB31 8-slot busboardPS1-PS10 Power supply unitHC12 PC/CHIP CPU, EPROM, RAMIM10 16-bit digital input moduleOM10 16-bit digital output moduleIO11 8-channel analog input module

IPC in the process control roomPS1-PB31 8-slot busboardPS1-PS10 Power supply unitPS1-HC12 PC/CHIP CPU, EPROM, RAMPS1-VM12 VGA module

Additional components:Measurement system for CO and O2 (gas sensors)

Link between the two IPCs over a distance of about 200m via RS485

Programming was carried out in C, because in that way adaptation to the existingsystem was easy and flexible.

Process optimisation, measurement of gas emissions, process control system,process visualisation, RS485, C/C++

Optimisation of a gas-fired power station

Hardware

Software

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A test station in which pneumatic cylinders are tested in various steps is controlled byan IPC PS1. The crucial test step is the leak test performed with the cylinder at itsvarious operational stages (extended and retracted). The test principle used ismeasurement of the pressure drop. The cylinder is pressurised and hermeticallysealed. The pressure drop within a defined period of time and depending on the size ofthe cylinder must not exceed a specified value.

Various pressure levels are set with the aid of a proportional valve, depending on thetype of cylinder involved. This calls for the use of a computer-controlled D/A converter.In order to be able to evaluate the test results in the central computer, the test systemis connected to the company's local area network and thereby to the QA computer.After conclusion of the test phase, the program is stored in an EPROM. This meansthat no mass storage is required, the system is immediately ready for operation onstartup and operational reliability is enhanced.

PB31 8-slot busboardPS10 Power supply unitHC12 PC/CHIP CPU, EPROM, RAMIM10 16-bit digital input moduleOM10 16-bit digital output moduleCP11 Ethernet interfaceIO70 2 x analog output moduleDIS2 LCD display

The entire program is written in Turbo Pascal. The LAN is a Novell network, so themeasuring station is a Novell client.

Quality assurance, pressure regulation by proportional valve, Ethernet, Novell, Pascal

Quality assurance incylinder manufacture

Hardware

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A research project conducted in collaboration with UNICEF is intended to provideinformation on, among other things, the connection between energy transfer in theatmosphere and the phenomenon known as the jetstream. The required data iscollected in a balloon. In addition to the measuring instruments, the balloon alsocontains a telecommunications unit that operates via a satellite link. This means thatthe aerial alignment has to be continuously corrected in order to track the appropriatesatellite.

Data collection and aerial control are taken care of by an IPC.

The IPC receives the digitised measured values from a device for measuring the fieldstrength of radio waves, assigns a time stamp to the values and stores them. Becauseumpteen thousands of measurements are taken in the course of a flight, the data isstored on a floppy disk.

The alignment of the aerial is adjusted using an electric linear drive, which is controlledfrom a digital output on the IPC. All of the indicating and operating options offered bythe IPC system are reduced to a minimum, to keep energy consumption down. Theoperator actions required for starting the system are therefore performed via a key and

LED module.

IPC PS1 is predestined for this application because of its PC compatibility, its ruggedand compact design and the possibility of running it in energy-saving 12 V mode.

PS1-BP50 5-slot busboard with power supplyPS1-HC12 PC/CHIP CPU, EPROM, RAMPS1-AS11 Input/output module with 8 pushbuttons and 8 LEDsPS1-OM20 Digital input and output module, each 8-bitPS1-FC10 Controller for a floppy disk drivePS1-FD10 Floppy disk drive

Programming was carried out with Quick Basic; this meant that the values taken frommeasuring the field strength could be transferred using a simple digital interface.

Measured data acquisition, measurement of field strength of radio waves, satellitetelecommunications, energy consumption, Quick Basic

Acquisition ofmeasured data andcontrolling an aerial ina measuring balloon

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Rubber (caoutchouc, India rubber) and similar materials are used in an endless numberof different forms and an endless number of different applications: as vibration dampersor seals, as toys or braking elements, bonded or screwed, and so on and so forth.

A huge range of different requirements have to be met, depending on the particular use.And depending on these requirements, different mixtures of the parent materials have tobe used. With a great deal of experience and sophisticated calculation algorithms it ispossible to draw conclusions as to the composition of the material and the mixing ratioof the starting materials on the basis of stress tests.

Scarabaeus is a company that has developed the know-how to perform and evaluateslow-running automated load tests. The particular skill in this connection is to matchthe temperature and the course of the stress tests to each other correctly, and to recordthe material behaviour accurately in a single series of measurements. The series ofmeasurements with its ups and downs of material deformation and material reactioncan be evaluated mathematically. The evaluation provides an indication of whether thematerial is suitable for the stated purpose or in what way the mixing ratios need to bechanged in order to better adapt the material to the requirements.

The hardware for the control system consists of two separate IPC PS1 systems. One isresponsible for controlling the stress test, and one deals with recording themeasurement data. The measurement data is sent cyclically to a higher-levelcomputer, which takes care of graphical representation and further evaluation of thedata.

Several versions of the entire system were programmed in C/C++, because this offersthe best flexibility in dealing with data and communications. The disadvantage of thisform of programming, though, is that troubleshooting in the program is relatively

Examination of rubbercompounds


difficult. This is because the high-level language system always assumes that theprogram editor and the target system are available at the same time on one computer.In this case, however, the target system is the IPC PS1, while the programmingworkstation can be any Windows PC. For this reason the programming was switched toMULTIPROG. This programming system provides the possibility of dealing with thewidest variety of data types, including real numbers, and performing calculations withthem. The Structured Text programming language is also similar to the familiar C orPascal environment, which meant that familiarisation went very quickly.

A typical system has roughly the following components.BP50 5-slot busboard with power supplyHC20-50 32-bit CPU with 586 processor, Compact Flash slotOM21 Digital input/output module, each 8-bitIO40 4 x analog input moduleCP30 Serial interface

MULTIPROG

Material test, rubber, MULTIPROG

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Even if it is the case that hydraulic, pneumatic, vacuum or other valves are nowadayssupplied more and more often with fieldbus connections, there is barely a singleproduct line that is produced exclusively with a fieldbus connection.

The CAN bus has a particularly important part to play in the field of automobiles andtrucks. This is not solely due to the fact that CAN was originally developed for carmanufacture. It is also a fact that the CAN chip, in other words the hardware for CAN, isparticularly inexpensive thanks to mass production, and this makes CAN interesting forlarge-scale applications such as cars, trucks etc.

If a manufacturer intends to supply valves for this field of work, he will usually offer anexisting valve series with the addition of a variant with a CAN interface.

In manufacture, this additional variant imposes new requirements on the organisation ofproduction. Above all it is necessary that the newly introduced variant should also betested: 100% test, statistical quality control, backing up of the test data, constant,reproducible test criteria – all necessary adaptations to the new variant of the valvewith a CAN interface.

ATEGA, a company based in Völklingen, near the Franco-German border, hasdeveloped a small test box to cope with this problem; it is simply integrated into theexisting production chain. It is only when confronted by valve types with a CANinterface that the test does not apply directly to the valve solenoid but instead is run viathe ATEGA test box. The box uses the CAN protocol to switch, test and check thevalves. The essential advantage of this is that the manufacturer is able to retain hisestablished production line and simply has to slip the CAN valves in between. Thanksto the PS1 system, the test box is small and manageable despite being equipped withthe BG10 for operator guidance.

ATEGA has also made it possible to integrate special customer-specificcommunication protocols in addition to the standard fieldbus protocols by means of auniversal PS1 module that they have manufactured themselves. An ATEGA levelconverter takes care of the task of adaptation and tests the product; in all of this,production remains as flexible as before.

Testing CAN valves

The Atega box on the testline


BP31 8-slot busboardPS10 Power supply unitHC27 CPU 486 DX25CP30 RS232 interfaceOM21 8-bit digital input and output moduleOM70 6-bit digital relay output module, 8ACP81 CAN interfaceDK10 Blank module with the ATEGA adaptationBG10 Operating terminal

All of the programming is done in C++. For this, ATEGA uses a developer CPUequipped with a hard disk for code development, debugging and compiling. Thefinished EXE file can then run in a CPU with a smaller hard disk.

Fieldbus, CAN, flexible testing, quality control, C++

The Atega box indevelopment

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Soot content – why do we need to know about that? Now that emissions of sulphur andnitrogen oxides are not as significant as they once were, because flue gasdesulphurisation in power stations and catalytic converters in cars are taking effect,measuring soot content is becoming more and more important. What this means,though, is not measuring the soot that you can knock off the washing hanging in thegarden, as was still common in the vicinity of coal-fired power stations or steelworkssome 30 years ago. This is about measuring extremely fine soot particles which arerespirable and which have adsorbed pollutants on their surface. These particles areproduced in internal combustion engines. Soot of this size can be measured with anAethalometer, anywhere from the Antarctic to the centre of Frankfurt. And the IPC PS1is always there as well.

Software that was developed at an American university, the computer technology of IPCPS1 Professional, production technology honed in a Slovenian high-tech workshop,marketing capacity provided by an expert in Bad Homburg – all of this combinedproduced the Aethalometer, an automatic measuring instrument used in environmentalprotection.

The air is directed through an optically homogeneous quartz paper. A sophisticatedsystem of sensors detects changes in the colour of the paper. The computer calculatesthe soot content in the air from the rate of change of the blackness of the paper and theflow of air through the paper. The data is time-stamped and saved. Depending on theparticular application, the data is temporarily stored in the system, fed directly into anetwork or retrieved by modem at specified times.

In environmental protection, it is always a requirement that measurements should beprecise and reliable. The Aethalometer helps to achieve this.

BP50 5-slot busboard with power supplyHC16 PC/CHIP CPU, EPROM, RAM, flashIO70 2 x analog output moduleIO41 4 x analog input moduleFC/FD10 Floppy disk controller and driveOM10 16 x digital input moduleDIS 2 LCD display

The programming was carried out in C/C++, as would be expected from an Americanuniversity.

Soot measurement, Aethalometer, environmental protection, telemonitoring, modem,C/C++

Measuring sootcontent in the air

International cooperation

How does that work?

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Keywords


Two measuring receivers, each of which is controlled by an IPC via a separate RS232C interface, have the task of monitoring a radio station's HF band. This converterstation is located on Mount Kilimanjaro at about 6000 m above sea level. Becausefrequent power failures have to be expected in such a situation, a 12 V car battery isused as a simple uninterruptible power supply unit.

The IPC PS1, which records, stores and preprocesses the measured values from thereceivers, is integrated into an Ethernet network via which it is operated by remotecontrol.

The IPC PS1 is particularly well suited to this task thanks to its ruggedness, its PCcompatibility and its ability to work with a 12 V supply while consuming little power.

PS1-BP11 3-slot busboard with power supplyPS1-HC17 PC/CHIP CPU, EPROM, RAM, flashPS1-CP30 Serial interface (2 x)PS1-CP10 Ethernet interface

Additional components:2 measuring receiversBattery and charger

Pascal

Measured data acquisition, remote control, Ethernet, 12 V operation

Monitoring a radiostation's high-frequency band

Hardware

Software

Keywords


Modern-day automation technology has long since advanced beyond the boundaries ofBoolean algebra. Whether it is a matter of processing analog measured values, storingtest data, the visualisation of production returns or the continuous acquisition ofoperational data – the simple ANDing of a number of digital inputs is a necessary partof this, but it is no longer enough.

Today's engineers who are now emerging from university or technical school aremoulded by a world of PCs, by communications and measured data, and by thefeasibility of what can be achieved with software and hardware.

Every graduate of a technical degree course today has at least some idea of whatprogramming in C/C++ means. And many have even done some programmingthemselves and have learnt what possibilities and freedoms this language offers.

All of the central processing units of the IPC system, whether the mini controllers of theIPC FEC or the Pentium CPU of the IPC PS1 Professional, are always a PC as well,and as such can be programmed in C/C++.

The fact that this method of programming very much lends itself to many applicationssuch as gateways, user guidance, measured value processing etc. quickly becomesquite clear. The fact that one family of controllers offers this possibility is unique. Atmany points in this book there are reports of examples which are based onprogramming in C/C++.

Programming in C/C++

Process control systems, laboratory technology and hydraulic engineering 73

Our drinking water meets high quality standards – thanks to drinking water treatment,the filtering of drinking water, inspection, and much more besides.

Pharmaceuticals or chemicals are subjected to the most careful testing before they arebrought into circulation. A single test is meaningless in this context. Hundreds,thousands, or millions of tests are needed in order to obtain reliable findings.

Washing powder is supposed to ensure that ourwashing emerges fresh and clean from the washing machine. How do themanufacturers know what the formulation has to be in order to achieve the bestpossible results? By an endless number of test wash cycles, all monitored, logged andcontrolled by automation systems.

Process control engineering needs control loops, time, and repetition. The PC-basedsystems of the IPC PS1 are ideally suited to tasks such as these.

In this section you will find a few examples from process control engineering. Enjoyyour read.

Process controlsystems, laboratorytechnology andhydraulic engineering

74 Process control systems, laboratory technology and hydraulic engineering

Many plants and systems used in water treatment have been implemented with the IPCPS1 system in recent years, and previously with the FPC 405.

Examples of these include:_ Filtration plant for drinking water with a particularly interesting system for controlling

the Keystone flaps, which is implemented with an FPC405 software regulator andFesto proportional valve.

_ Water flow regulation for filter cleaning_ Air pressure regulation with fan for filter cleaning_ Telemonitoring of process variables (pressure, temperature, flow rate)_ Test station for Keystone fittings_ Well control, telemonitoring, optimisation_ Measured data acquisition system_ Integration of control systems on the basis of the ViP process visualisation system_ Integration of data into a database (production, distribution, maintenance ...)_ Process visualisation with ViP WIN_ Control of the aeration system, the water storage tank and the pumping stations_ Control, monitoring and regulation of the entire water treatment works consisting of

wells, water treatment filtration plant (aeration, filtration plant with sand filter andintegration with the ozone block)

_ Filtration plant with carbon filter_ Pumping station with water storage tank monitoring system and control room_ Well control systems for various groups of wells over an area_ Control of the pressure filter plants_ Various filtration technologies are used, including sand filters, carbon filters (similar

to sand filters) and pressure filters.

The Novi Sad water treatment for example works underwent modernisation in 1996. Thefiltration plant consists of 2 buildings, each with 12 sand filters. Each filter has an areaof 36 m2 and a flow rate of approximately 60 l/s. Altogether, the waterworks suppliesabout 1500 l/s of drinking water.

A sand filter works at its best when the flow through the filter is within defined limits.One method of regulation is to measure the flow and control the flap for clean water.Because of the geometry of the pipes, and due to a lack of space, this is not alwayspossible. Flowmeters are expensive. One alternative method is to measure the waterlevel in the filter. The level is kept constant. The geometry and diameter of the pipesensures that the untreated water is distributed evenly to all filters. Maintaining aconstant level means maintaining a constant flow.

Water treatment

Sand filter technology


Each filter has 6 Keystone flaps controlled by Festo valves for:_ Untreated water_ Clean water (controlled)_ Sewer_ First filtrate_ Cleaning water_ Air for filter cleaning

Control of the flap for clean water is carried out:1. discontinuously with 5/3- or two 3/2-way valves

or2. continuously with the proportional valve.

Variant Advantages Nachteile

1 No analog outputs arenecessary and manualoperation is easy to implement

High level of air consumptionand difficult to regulate

2 Air consumption is low andregulation is carried outcontinuously

Analog outputs are necessary

The control loops are implemented in accordance with variant 2, with good experience.The regulators are stable. One controller controls 12 filters. A software regulator has 12control loops. A mathematical model was specifically designed for this purpose. Theregulator parameters are optimised with technologists at the waterworks. The flapsmust not change position quickly because otherwise the water quality woulddeteriorate. The parameters can be adjusted with the ViP process visualisationsystem, which is also used to observe the behaviour of the control loop.

Optimum filter cleaning is achieved with a certain rate of water flow. The regulationsystem was set up to ensure this. The operator can define the setpoint values for theflow rate and the time (duration) in the ViP process visualisation system. A controllerwith a software regulator assumes the function of the regulator. The values are storedand later evaluated.

Control of water flow forfilter cleaning

Untreated water Clean water


Filter cleaning begins with the feeding of air from below. The rate of air flow isregulated. Too much air can blow the sand out of the filter. The operator can define thesetpoints for the flap position and the time (duration) in the process visualisationsystem. A controller with a software regulator assumes the function of the regulator. Thevalues are stored with an industrial data acquisition system and subsequentlyevaluated.

The distribution of water requires that the pressure and, if applicable, the flow should bemeasured at various points and the values transmitted, visualised and stored.

The local stations are implemented with IPC PS1 modules. The data is transmitted bytelephone, over leased lines. The ViP process visualisation system is installed in thedispatcher centre. A special-purpose communications driver takes over the data fromthe remote stations. The collected data is displayed with ViP Trend2 and stored.

Before and after the Keystone drives are repaired, the customer would like to perform atest. A number of different parameters are measured. In addition, a service engineer cantest and adjust the limit switch.

The plant for aerating the untreated water comprises two buildings, each with two mainpipes. The untreated water arrives with a flow rate of Q0 and a pressure of P0. Theregulator must maintain a constant pressure in four pipes. This ensures that the water isevenly distributed and the plant operates at optimum efficiency. A controller andsoftware regulator are provided for the purpose of regulation. A PC with ViP forvisualisation and parameterisation of the plant is installed in the control room.

Air pressure regulation forfilter cleaning

Telemonitoring of processvariables

Test station for Keystonefittings

Aeration for untreatedwater

Sewer Water for filter cleaning

Sewer Fan


The level in the water storage tank is signalled to the pumping station and controlcentre by radio. In the control room, this information is used for closed-loop control ofthe entire system. Operation by remote control is also possible, and is used forcontrolling the flaps or pumps. A separate IPC PS1 station is used for data acquisition.A radio modem and radio transceivers are used for communications.

The command centre for the wells is equipped with the system for remote control andmonitoring of the individual wells on the basis of the VIP software. BHD wells areequipped with transmitters for water level, pressure and motor current, and with IPC andProfibus communication modules.

Data is transmitted via Profibus. The command centre and the central control room arelinked by modem via dedicated lines.

Optimisation software analyses the values and presents the operator with arecommendation as to what subsequent action needs to be taken.

A large number of measured values are gathered at the command centre. About 40analog signals are connected to a controller and are visualised and evaluated with aViP station. The PC with the ViP process visualisation is part of the network, and thecollected data is analysed and processed on various workstations.

All of the control stations mentioned above should be integrated into one controlconsole. Water production (wells and the filtration plant) and distribution (pumpingstations, water storage tank and network) are integrated into a VIP WIN online databasesystem. All technical and real-time data is stored in one common database and ismade available to various workstations.

The maintenance team has its own workstation that

Water storage tank control

Well control

Measured dataacquisition system

Integration of controlsystems

Q0, P0

Q11, P11

Q12, P12

Q21, P21

Q22, P22


displays all alarms and preventive maintenance data. All information about pumps,flaps and other devices is stored in the database. This makes maintenance workeasier, and increases the availability of the plant. The plant technologist carries outprocess analysis at a workstation at which all online data, recorded operational dataand special-purpose calculation programs are available to him. Laboratory data isentered manually, and evaluated together with the other data.

Proportional valves, waterworks, wells, filters, filter cleaning, flow rate, fans, Keystoneflaps, process control systems, telemonitoring, process visualisation, remote datatransmission via modem and radio, operational data acquisition

Keywords


Many blue cheeses count as delicacies for the cheese connoisseur. And the meremention of a genuine Irish Cheddar is enough for some people to start salivating inanticipation.

After a little thought, however, it very quickly becomes plain that the maturing of cheesefrom milk or the process of blue cheese "going mouldy" does not just happen"somehow", but has to be carried out under reproducible, precisely defined conditions.One external and necessary prerequisite for reproducibility and hence also consistentquality is the cleaning of and maintaining the cleanliness of all pipes, tubes,connections and valves. The requirements regarding cleanliness in the food sector areimmense. On the one hand this is a matter of the actual process of cleaning, which atheart is a relatively simple form of sequence control. A series of process steps, startingwith flushing and proceeding through heating and the addition of various cleaningagents, has to be worked through consecutively. A particularly critical task, on the otherhand, is checking and logging the results of the cleaning work. It is not enough simplyto go through the usual tasks one after the other, it is also of the very greatestimportance to check precisely that the cleaning work has indeed brought about thedesired result, and to record that fact.

An Irish cheese producer controls and monitors every aspect of cleaning the pipes andtubes with the IPC PS1 Professional. In collaboration with Festo Ireland, the systemwas set up in such a way that an IPC is responsible for each section of piping thatbelongs together. A master computer collects the data via a fieldbus, and makes itavailable to a process visualisation system. The process visualisation system isresponsible for recording and storing the process data. In addition, the operatingpersonnel at the central visualisation station are presented with a clear overview of allprocess data.

The master computer is equipped as follows:BP40 14-slot busboardPS10 Power supply unitIO10 8 x analog input moduleHC16-F PC/CHIP CPU with FST kernelCP61 Festo fieldbus masterIM11 16-bit digital input moduleOM11 16-bit digital output moduleCP14 Ethernet interface

All of the IPC PS1s are programmed in FST, as is the master computer. The reason forthis is above all that it is very easy to program the actual cleaning process, as well asthe fact that it provides excellent support for the fieldbus and the Ethernet interface.

Food industry, process visualisation, Festo fieldbus, Ethernet, FST

Ensuring cleanlinessin cheese production

Hardware

Software

Keywords


The production of thermocylinders for thermostats in the automotive industry has beenautomated. The existing production machine, which operated semi-automatically, isnow controlled by an lPC; this allows the production parameters to be changed easilywhen required. Because a 100% test is required at the end of the production process, atest station was also automated with the aid of an IPC controller.

The test station performs a statistical analysis of the results of measurement of adefined test variable, and in the event that the predetermined limit values areexceeded, it proposes readjustment of the parameters in the production machine. Inaddition, the measured values can be processed with a standard spreadsheet program.The method of statistical process control implemented in this way ensures that thelevel of production quality achieved is consistently high.Storage of the test results ensures that the traceability required by the DIN EN ISO9000 ff series of standards can be guaranteed.

Separate programs have to be developed for the production station and the test station,but these are networked and exchange data between each other. Standard software isused on the test PC.

The advantages of a PC-compatible controller such as that provided by the PS1system in a design created for a manufacturing environment are quite obvious in thissituation.

The production station essentially contains the digital inputs and outputs required forcontrolling the production machine, together with an analog input module that enablesthe production machine to be monitored:

BP50 5-slot busboardHC12 PC/CHIP CPU, EPROM, RAMIM10 16-bit digital input moduleOM10 16-bit digital output moduleCP70 Printer interfaceIO10 8 x analog input moduleDIS2 LCD displayIn addition: printer and standard software package for analysis of the data.

Company: Dauphinoise Thomson, France

Statistical process control, quality assurance, DIN EN ISO 9000ff

Statistical processcontrol in themanufacture ofthermocylinders

Special features

Hardware

Keywords


In sewage treatment plants there is a large amount of operational data that needs to bemonitored and visualised. In this application the IPC PS1 operates as an autonomousdata acquisition system alongside the control system for the sewage works as a whole.

16 analog and 80 digital signals are recorded.

The analog signals are archived and statistically analysed.The digital signals are evaluated as faults, counters or elapsed time meters.

The preprocessed data is passed to a visualisation system via an RS232 link.

Thanks to its rugged and modular design, its compact dimensions and its ability to beprogrammed in high-level languages, the IPC PS1 is a highly suitable yet at the sametime cost-effective choice for decentralised data acquisition systems of this type. Aswell as this, its low energy requirements are another obvious benefit in this connection.

A typical configuration consists of the following:BP40 14-slot busboardPS10 Power supply unitHC16 PC/CHIP CPU, EPROM, RAM, flash5 x IM10 16-bit digital input moduleOM10 16-bit digital output moduleCP31 Serial interface (2 x)2 x IO11 8 x analog input moduleZP70 Printer interfaceRadio-controlled clock with connection to RS232cPrinter

The engineering consultants Ingenieurbüro Katz, who were responsible for every aspectof implementation of the system, used C/C++ as the programming language: above allthis offers flexibility in data management and the control of serial data transmission,and is easy to use with the IPC PS1.

Data acquisition systems, statistical analysis, C/C++, sewage treatment plants, printer,clock

Data acquisition insewage treatmentplants

Hardware

Software

Keywords


System engineering GmbH Ilmenau is a company that uses the PS1 system in variousconfigurations for solving a variety of problems. One of the most recent applications isthe control of a biological trickling filter scrubber. This is a reactor built on a pilot scalewith the objective of removing hydrocarbon compounds from the exhaust air fromproduction plants by biological means.

The trickling filter scrubber consists of a cylinder, aboutthree metres in height, through which the air that is to be cleaned flows as well as aflow of liquid to supply the biomass with water and trace elements. The bacteriathemselves are situated on carrier structures inside this cylinder.

In order to deal with the task in hand, about 20 analog and digital signals have to bemonitored, such as liquid levels, temperatures, flow rates of gas and liquid, and pHvalues. The process is influenced by means of a variety of actuators: mass flowcontroller, electrical and pneumatic valves and any number of pumps, the speeds ofwhich in some cases are controlled using frequency converters.

Controlling abiological tricklingfilter scrubber


BP40 14-slot busboardPS10 Power supply unitHC20 32-bit CPU, CF, flashIM11 16-bit digital input module2 * IO11 8 x analog input module, currentIO12 8 x analog input module, voltageOM12 32-bit digital output moduleIO60 4 x analog output moduleCP3x RS232 interfaceAll sensors and actuators are electrically isolated from the IPC modules by couplingrelays or analog couplers.

The software used for the controller is a small process control system on the basis ofWinErs, software developed by engineering consultants Ing.-Büro Dr.Schoop. Thedrivers for this were developed at SEI. In addition to the possibility of allowing graphicalplanning of the controller, this system also provides modules for data acquisition,archiving and visualisation. The installation is operated from a PC running MicrosoftWindows, which is connected to the IPC either via a null modem cable, a modem orEthernet. This means that monitoring can also be performed from a remote location. Instandalone operation without an operating computer, the accruing measurement data isbuffered in the IPC's CPU for up to several days. Various operating modes are runthrough automatically (startup, cleaning, operation), while control in manual mode isalso possible.

The illustration shows part of the control system as asequencer. In this way, WinErs can be used both for programming and later forvisualisation of the control system.

Biological exhaust air purification, level measurement, temperature measurement, flowrate, pH value, process control, telemonitoring

Hardware

Software

Part of the control systemas a sequencer

Keywords


Of course you know that "plastic" is not degradable. This is why we have recyclingmarkings on packaging, why we segregate different types of waste, why there is anongoing discussion on replacing plastic packaging with paper packaging, for example.In the meantime, however, biologically degradable types of plastic have beendeveloped. These are produced, for example, by microorganisms (such as bacteria)"eating" raw materials and in so doing converting them into types of plastic which inturn can be decomposed by other bacteria.

The microorganisms are alive – a prerequisite for them being able to "work" at all. Thedegree of well-being of these organisms can be identified from their consumption ofoxygen – in much the same way as with us humans. When we are fit and producing ourtop performance we consume more oxygen than when we are worn out and tired.

On the basis of the level of oxygen consumption, therefore, it is possible to draw directconclusions as to the productivity of the system. Measurement of the oxygen providesinformation on the progress of production, on the speed of production and finally onwhether production is completed – this is because at some time or other the bacteriawill start to consume the desired end product. After all, it is biodegradable.

In addition to the use of oxygen measurement within the production of materials, thismethod of measurement can also be used to establish whether bacteria are capable ofdecomposing certain materials: contaminated soil, mixtures of chemicals and manyother similar substances can be selectively fed to bacterial cultures to be "eaten" – thebioactivity sensor determines whether the bacteria are able to eliminate thecontaminants.

The core of the system for determining the cell state is an oxygen electrode. Theelectrode requires a defined voltage supply and a specific method of signalconditioning. An independent input module was developed specially for this purpose,and was integrated into the IPC PS1 system.

In order to obtain a meaningful analysis of the data from the oxygen electrode, apowerful computer system is required. The program must be structured in such a waythat the test can be adapted to a range of different tasks. After the system has beenconfigured, the data has to be logged, stored and displayed. This is where theopenness of the PC is ideal. At the same time, it should be possible to put the systemto use directly in production or in mobile laboratory systems, which is why suitabilityfor industrial use was called for. The compact IPC PS1 is therefore an obvious choice.

Determining thecell state ofmicroorganisms

What does the "cell state"tell us?

What does the PS1system do?


HC15 PC/CHIP CPU, EPROM, RAMOM74 16-bit relay output moduleOM70 6-bit relay output module with max. 8A switching capacity for direct control

of the pumpsIO12 8 x analog input moduleIPC-OXi Company-developed analog module for the oxygen electrode

The IPC-OXi module:Electrode bias voltage: -500 to -900 mVMeasured current: up to 10 µA. Variable adjustment of the gain with

external potentiometerOperating voltage: 12 to 36 V from the PS1 busboardOutput voltage: 0 to 10 VPower demand: approx. 1 WConnection of 2 Clark electrodes per module

Programming was carried out in C/C++ with the aid of the Borland C compiler. First aprogram flowchart is drawn up by hand for the purpose of program planning, and this isthen converted into C code. The Quinn-Curtis library is used for visualisation of themeasured values.

Measuring bioactivity, Clark electrode, bacteria

Hardware

Software

Keywords


Diehl Automation GmbH produces the entire control system for the first mobile fillingstation for liquefied natural gas (LNG) in Germany, on the basis of the PS1 system.

Liquefied natural gas is one of the energy options of the future for traffic on our roads.LNG is based on natural gas, the stocks of which according to today's understandingwill last longer than the stocks of mineral oil. The essential advantage of using LNG ininternal combustion engines is that an LNG-powered engine emits 80% less carbonmonoxide (CO) than a petrol engine and 60% less than a diesel engine. Oxides ofnitrogen (NOx) are reduced by 65% and 80% respectively, while benzene and sootparticles are not produced by LNG engines at all; the generation of ground-level ozone,the cause of summer smog, is reduced by 60%. LNG therefore stands out because ofits environmental friendliness – in comparison with traditional petrol or diesel engines.

The temperature of LNG is –161° C; it is in the liquid state at this temperature, andmust be stored in appropriately isolated tanks.

The mobile filling station that was developed and built for Messer Griesheim GmbH isdesigned to deliver supplies of LNG for vehicles which are intended to prove thesuitability of LNG engines in real, everyday use.

Diehl Automation calls the control system DAS5. The basis for the hardware isprovided by the IPC PS1 with analog and digital I/Os in conjunction withcommunication to a control system via a modem. The software uses the RT kernel tocreate a real-time-capable multitasking system. Building on this, function blocks werewritten for all functions of the filling station. This modular software concept makes foreasier maintenance and troubleshooting. This is because the individual functions suchas cooling, filling the tank, refuelling vehicles etc. are each provided as separatemodules.

Filling up with liquefiednatural gas

Mobile LNG tank

Diehl DAS 5


A GSM modem connected to an RS232 interface sends a log fax about every refuellingand filling operation to the central control desk at Messer Griesheim. As a result,Messer Griesheim always has an up-to-date overview of the operational status of theLNG filling station.

BP40 14-slot busboardHC27 486 CPUCP30 Additional COM2 (for terminal) and COM3 (for GSM modem)MC10 PCMCIA interface (for program updates via SRAM card)AS11 Pushbuttons and LEDs for maintenancex IM11 16 digital inputsOM40 16 digital outputs with connection to Festo CPV valve terminalsOM70 6 relay outputsIO11 8 analog inputs

Filling station, remote data transmission, fax, RT kernel, GSM

Sending a log fax bymodem

The control cabinetmounted on the truck

PS1 configuration

Keywords


Water is the stuff of life. Drinking water is a vitally essential commodity. The quality ofthe drinking water provided must be healthy and pure. The PS1 system helps tosafeguard the supply of drinking water.

Water comes out of the tap and disappears down the plughole. That's all. Have youever stopped to think about everything that is necessary to maintain the cycle of waterextraction, water distribution, water disposal and water purification? Hardly any of usstep back to give this any thought any more. To make sure that we don't have to think,other people have done some serious thinking – and have used the PS1 system.

The extraction of drinking water in the vicinity of rivers is often based on the use ofwells. The wells, which may be more than 100 m deep, draw groundwater that has beenfiltered through the sand strata in the area alongside the river. The water is pumped to awater treatment plant, which removes contaminants which have not been trapped by thenatural sand filtering, and is finally pumped to the consumers.

In order to supply a mid-sized city of around half amillion inhabitants, dozens of wells are required. Every well represents a considerableinvestment. It is generally the case that entire families of wells are built. Often thismeans several "small" wells being arranged around a "larger" well. The way in whichthe water is drawn from the well is one of the decisive factors in the longevity of a well.If the well is constantly pumped empty, to the very limit, this is just as damaging as if itis not used at all for a long period of time. The role of the PS1 system is to optimisewater extraction with this in mind.

Festo Austria has supplied and installed the entire set of remote maintenance andtelemonitoring equipment for well installations of this type. A well installationconsisting of about 10 wells extending over an area totalling perhaps 5 km in diameteris combined to form a single group. Each individual well is "taken care of" by an IPCPS1. The wells are networked with each other by means of Profibus FMS, and the datais collected in a separate IPC PS1 for each group. A small local control consolebelonging to the group of wells includes a standard PC, where visualisation of the groupis provided on site with the aid of VIP, the process visualisation system from FestoAustria.

Functions for telemonitoring, remote diagnosis, remote control and data acquisition areall implemented on the control console.

The group IPC is connected via a modem to a higher-level control station that enablesall of the groups of wells to be brought together under one umbrella and visualisedaccordingly.

As a result, in the specific project we are referring to here, in Novi Sad, it is possible forthe first time to view and manipulate well parameters from a central control room withthe aid of VIP, the visualisation of industrial processes.

Providing for cleanwater

Wells by the Danube

Remote maintenance


Every well is assigned its own IPC, which operates autonomously to ensure optimumcontrol of the pumps for the well. To help it do this there is a system of sensors thatprovides information about the water level, pressure, flow rate, electricity consumption,pump parameters etc. The electrical parameters of the three to four pumps for each wellare monitored by a separate measuring device. These measuring instruments areconnected to a PS1-CP30 via an RS485 interface. Networking with the other stationsand the control console is via Profibus FMS.

The unusual situation of a well installation requires special protective measures for theelectronics. Above all, there are three particular aspects that are important:

Firstly, the immediate surroundings of the well are cooled to a large extent by the waterextracted from deep in the earth. In winter, though, it can become bitterly cold anddamp. For that reason, all of the control cabinets are heated.

Secondly, in a distributed system of this nature it is quite possible for the power supplyto fail fairly frequently. Consequently, an uninterruptible power supply is fitted in thecontrol cabinet for each local control console; this safeguards the power supply for aperiod of roughly 15 minutes. That is enough time to be sure of informing the controlcentre that the power has failed.

Thirdly, in a system that is spread out over distances of several kilometres there is arisk of lightning strikes on the connecting lines. To counter this, all sensors aredecoupled by means of surge voltage protectors, the actuators are controlled with theaid of relays and the Profibus is run via fibre optic cable. A converter from RS485 tofibre optic cable is provided for this purpose at every station.

The overall effect of these protective measures has stood the test excellently inpractice.

Well control

Environmental conditions


Example of a PS1 configuration:BP31 8-slot busboardPS10 Power supply unitHC16-F CPUI048 Analog input moduleIM11 Digital input moduleOM21 Digital I/O moduleCP61 Profibus FMS moduleCP30 with RS485

The systems are programmed with FST software. One of the key reasons for choosingthe FST software was the openness of the software for additional drivers. For example,an external firm of engineering consultants, being familiar with the driver interface forthe FST software, wrote a driver for the RS485 interface to the measuring devices and adriver for controlling the modems. To this must be added the fact that the Cl, theinterface for troubleshooting, is so simply designed that a large range of software anddevices are very easily able to access systems programmed with FST.

Well control, pump parameters, telemonitoring, remote diagnosis, RS485, Profibus,process visualisation, lightning protection, environmental conditions

A control cabinet with aheater

Hardware

Software

Keywords

Edutainment and simulation 91

Have you ever driven a formula 1 racing car? Did you think it was out of the question?Well, perhaps you can after all. Because advanced simulation technology, which waspreviously only available for the training of aircraft pilots, has now found its way intomuch more widespread use. Pneumatic or hydraulic drives, sophisticated controltechnology, video sequences which allow the depiction of every road from everyviewing angle – all of these are already in use today. One aspect is the excitement andfun to be had in a simulated car race, but there is also the possibility of impartingknowledge, for example in museums. In those applications, figures and images are setin motion in order to make history and literature come to life and be easier to learn.

In this section you will find a few examples of edutainment applications using the verylatest automation technology. Have fun reading about them.

Edutainment andsimulation

92 Edutainment and simulation

How can history be made into something that can be experienced, or even sensed andfelt as if at first hand? What does it actually mean when we hear and read aboutseafarers who went on voyages of discovery many years ago?

At the Heureka science museum in Finland, an attempt has been made to answer thisquestion using modern simulation technology. In 1878/79, the explorer Adolf ErikNordenskiöld and his crew were the first to traverse the Northeast Passage in his shipthe "Vega". A reconstruction of the forward section of the "Vega" is on show at theHeureka science centre, mounted on a pneumatically driven platform. The system isset in motion by means of an intelligently arranged cylinder combination in such a waythat people standing on it are given the impression of being on a ship on the high seas.Within the controller's multitasking system, each cylinder has a separate programdedicated to it which controls the valves. Each cylinder can be set individually, withthe settings ranging from storm to calm seas, and from light waves to full sail. A trulyimpressive experience.

The octahedron of the pneumatic cylinders and the associated controller are designedin such a way that they can create motion in all sorts of different models. As a result,

Discoveries on thehigh seas


Heureka is making the simulation technology itself an exhibit of the museum: a smallmodel of a ship, about 1 m long, uses exactly the same simulation technology as the"Vega", only on a smaller scale. This is learning about history and technology bysensing it and experiencing it.

BP50 5-slot busboardHC16-F PC/CHIP CPU, EPROM, flash, FST kernelOM22 Digital input/outputs, each 16-bitIO10 8 x analog input moduleIO60 4 x analog output module

FST, the multitasking programming system, can provide a separate task for everycylinder.

Edutainment, simulation

Hardware

Software

Keywords


Usually, as we know from many examples in our experience, a zoo keeps animals incages or artificial enclosures, behind glass or fences. The Victoria Open Range Zoo inAustralia takes a quite different approach. There the animals are allowed to run free asif in the wild. Over an area of about 200 hectares, the animals have a habitat at theirdisposal that is left in its natural state.

Visitors to the zoo can go out and observe the animals on a safari tour. To do this, theytravel in large, air-conditioned buses. To a certain extent, therefore, in this case it is thehuman visitors who are sitting behind glass, while the animals live in the open.

In order to make visiting this zoo safer and more comfortable, Rambler ConceptVehicles has developed a safari bus in which giant windows can be opened and thedoors can open up the entire side of the bus to allow people to get in and out.

Because of the large forces involved, the doors are driven with hydraulic cylinders,while the windows are moved by very slimly built DNC cylinders. The panorama side ofthe bus is controlled by an IPC FEC, which obtains its electrical supply directly fromthe 24 V system available on the bus.

A particularly ingenious feature is the way the window cylinders are controlled, forexample. They are moved carefully with their own low-pressure circuit until they arefinally fully closed at the end under normal pressure.

IPC FEC FC20 Mini controller with AM186 processor

FST

Vehicle technology, door control, tour bus

Keepers in the wild

Hardware

Software

Keywords


At the vocational training school in Hamburg, a group of teachers have got together toenable them to give practical instruction in modern automation technology. Two thingshad to be done to make this possible.

Firstly, the teachers sat down with trainees to develop dynamic models that can beused for practising programming, commissioning and troubleshooting. And secondly,the school bought controllers which can be programmed according to the internationalstandard IEC 6 1131-3, and which can also be networked with Ethernet – both IPC PS1systems and IPC FEC Compact controllers.

In a second phase, the controllers will also be used as PCs in information technologylessons, which means that IT in general and programming in C/C++ or Pascal will notbe seen merely as theoretical toys but as tools that can be put to practical use.

IPC FEC FC34-MWT the mini controller with Ethernet, programmable withMULTIPROG

IPC PS1 with HC02 CPU and various analog and digital input/outputmodules

MULTIPROG, C/C++

Vocational training, networking

Learning to usemodern automationtechnology

Hardware

Software

Keywords


The IPC@CHIP® is considered to be the world's smallest industrial PC. Even ifsuperlatives such as these are always questionable, the combination of processortechnology, memory, flash memory for the safe storage of applications and data even inthe event of a power failure, serial interface, Ethernet network and access to theinput/output level in a single chip is a quite outstanding technical gem. Although thefirst chips were only delivered as recently as November 1999, just a year later there arefinished products on the market with quite exceptional qualities.

Although the independent development of automationsystems by individual companies is not the main concern of this little book, theIPC@CHIP and its applications are so directly involved in automation technology thatthey are worthy of a place here.

In this section you will find a few examples of applications with the IPC@CHIP. Enjoyyour read.

Applications with theIPC@CHIP


CAN is an unusual and special type of fieldbus. Because of its origins in automotiveengineering, it is optimised for a high standard of reliability in data transmission, fastresponses and relatively short transmission distances. The CAN bus has beensuccessfully introduced in many applications, and thanks to its particular qualities it iswell established. Increasingly, though, the data from these CAN-based applications isalso coming to be required in local networks. Nowadays, however, these networks arealmost always Ethernet networks.

Two companies, Port GmbH and EMS Wünsche, have got together to develop anEthernet - CAN gateway to deal with this problem. The gateway ensures that the CANbus can operate without interference, while the data is made available in the Ethernetnetwork.

Inside the EtherCAN_186/RMD there is an IPC@CHIP doing its stuff on the Ethernetside, and on the CAN side a Full-CAN processor.

One notable fact about the EtherCAN module is that it was developed in its entiretywithin 5 months of the first delivery of the IPC@CHIP. On the one hand this proves thedegree of know-how available to the development team from Port and EMS, but at thesame time it illustrates the simplicity with which the IPC@CHIP can be put into serviceif the people involved have knowledge of programming PCs.

IPC@CHIP SC12

C/C++ is the programming language of choice for applications of this type.

http://www.port.de

CAN, Ethernet

Ethernet - CAN gateway

Hardware

Software

Internet

Keywords


!ASCO is a system house in the field of weighing and metering technology which hasdeveloped a universal basic printed circuit board with the IPC@CHIP for its ownapplications and those of its customers.

Depending on how it is equipped, the printed circuit board can be used either as a low-cost microcontroller or an embedded PC.

Optiterm, as the board is named, is ideally suited to carrying out control tasks in the!ASCO load cells, recording measured values and making the data available on thenetwork for further processing.

IPC@CHIP SC12

C/C++

http://www.asco-online.com

Weighing technology, measuring technology, network

Controlling with theIPC@CHIP

Hardware

Software

Internet

Keywords


The vocational academy or Berufsakademie (BA) in Mosbach offers courses leading toa qualification as Dipl.-Ing (BA) in a variety of subject areas. In the subjects ofelectrical engineering, information technology and mechatronics, the IPC@CHIP isused for course work and project work.

The aim is that the students should gain experience in the development of printedcircuit boards with microcontrollers (hardware) and in the programming of such systems.With the IPC@CHIP, it is also possible at the same time to bridge the gap to the studyareas covering automation engineering and network technology. To help to do this, anexperimental printed circuit board was developed with the IPC@CHIP at BA Mosbach.All of the data relating to the printed circuit board is public, which means that thestudents can use it as the basis for their own developments.

IPC@CHIP SC12

C/C++ is the programming language for the engineer.

http://www.ba-mosbach.de

Engineering studies, experimental printed circuit board, training and further education

Learning with theIPC@CHIP

Hardware

Software

Internet

Keywords


Rittal is one of the world's largest manufacturers of control cabinets. Many controlcabinets are used in computer centres, where monitoring the availability of thecomputer systems is a matter of crucial importance. This is why Rittal has had theCMC developed (short for Computer Monitor Control), which incorporates a controlcabinet monitoring facility. The variables that are monitored include the temperature inthe control cabinet, for example, but also vibration, which provides an indication thatsomeone is attempting to open the control cabinet by force. The CMC is integrated intothe network, so the monitoring data can be retrieved via the network both locally and – ifrequired – via the Internet or through a modem.

The centrepiece of the CMC is the IPC@CHIP, which isthe ideal choice for establishing the link between the sensor signals for monitoring andthe network technology.

IPC@CHIP SC12

C/C++ is the language of the computer world.

Control cabinet, monitoring, CMC

Monitoring with theIPC@CHIP

Hardware

Software

Keywords


All of the applications in this book are closely tied to the IPC system from Festo andBeck. A whole family of central processing units allows the creation of automationsystems which are all characterised by the fundamental philosophy of the IPC family.

Hardware

IPC@CHIP®

IPC FEC® Compact

IPC FEC® Standard


_ All systems are PC-based at their core. This means that essentially every CPU canalso be used as a DOS computer (or in the case of the 32-bit CPUs also as aWindows computer). Most of the applications are descriptions of PLC applications,though. Nevertheless, the PC core is always there in the background, because it isthis that opens up the possibility of easily linking with important state-of-the-artfunctions such as Ethernet networking, file handling, flexibility in the use of driversand modules, and much more besides.

_ All systems are small – in relation to their performance capability extremely small.Whether or not the IPC@CHIP® is in fact the world's smallest industrial PC, everyCPU is representative of the claim in its performance segment to build small, toenable the use of small control cabinets, to save space and energy – and in thisrespect is a world champion.

_ All systems are network-capable. Every CPU can be equipped with Ethernet, everyCPU – even the smallest – can be programmed via Ethernet and communicate viaEthernet. Advanced automation technology needs the Ethernet network – all of theCPUs in the IPC FEC range as well as the IPC PS1 range support Ethernet.

_ All systems are PLCs as much as they are PCs. Tens of thousands of CPUs areused in the same way as traditional PLCs with the PLC programming languages.And just as many systems could not do their job without the link to the PC world.

IPC PS1®

Index 105

Agriculture ........................................................................................................................20ASi....................................................................................................................................34Assembler ........................................................................................................................44

Basic ..........................................................................................................................45, 65Boolean Algebra...........................................................................................................9, 72

C/C++.........................................................7, 17, 21, 29, 34, 43, 44, 53, 55, 59, 61, 62, 63,..........................................................................67, 69, 70, 72, 81, 85, 95, 98, 99, 100, 101CAN..................................................................................................7, 8, 21, 34, 68, 69, 98Checkbox ..................................................................................................7, 16, 17, 60, 61CIM.................................................................................................................................. 42Clark Electrode................................................................................................................ 85COMX........................................................................................................................ 52, 87

Edutainment ...........................................................................................................8, 91, 93Ethernet .............................................................5, 8, 23, 30, 31, 34, 35, 36, 37, 44, 47, 49,........................................................................................53, 64, 71, 79, 83, 95, 97, 98, 103Excel ............................................................................................................................... 57EXOR............................................................................................................19, 20, 30, 31

Fax .....................................................................................................................................4Flash ....................................................................................................................43, 44, 67FST ............................................................................ 7, 11, 13, 15, 18, 19, 20, 23, 30, 31,................................................................................... 32, 33, 34, 37, 41, 47, 79, 90, 93, 94

Gateway ...........................................................................................................................43GSM...............................................................................................................21, 46, 54, 87

Hall Sensor.................................................................................................................58, 59Handling .....................................................................................................................12, 13

Internet..................................................................................7, 34, 35, 47, 98, 99, 100, 101IPC FEC

FC20................................................................................................................... 11, 94FC30......................................................................................................................... 39FC34............................................................................................................. 36, 37, 47FC38......................................................................................................................... 46

IPC PS1 moduleAM11 ............................................................................................................ 15, 24, 57AM20 ........................................................................................................................ 29AS11............................................................................................................. 47, 59, 87BG10 ............................................................................................................ 56, 68, 69BG20 ............................................................................................................ 27, 60, 61BP11........................................................................................... 13, 27, 45, 47, 53, 55BP31........................................................................................... 19, 41, 43, 44, 69, 90BP40................................................................... 20, 21, 24, 27, 30, 59, 79, 81, 83, 87BP50............................................................. 15, 17, 44, 53, 57, 61, 62, 67, 70, 80, 93CP10................................................................................................................... 27, 53CP11......................................................................................................................... 64CP12......................................................................................................................... 44CP14............................................................................................................. 30, 47, 79

IndexA

B

C

E

F

G

H

I

106 Index

IPC PS1 moduleCP30..........................................................................20, 52, 53, 55, 59, 67, 69, 87, 90CP31............................................................................................................. 41, 62, 81CP3X........................................................................................................................ 44CP61....................................................................................................... 20, 30, 79, 90CP70................................................................................................................... 62, 80CP81......................................................................................................................... 69DIS 2......................................................................................................................... 70FC/FD10....................................................................................................... 41, 59, 70FD10......................................................................................................................... 25HC01............................................................................................................. 18, 19, 44HC02................................................................................................................... 23, 95HC12............................................................................... 24, 52, 53, 55, 62, 63, 64, 80HC15................................................................................................................... 45, 85HC16......................... 13, 15, 20, 21, 23, 27, 30, 41, 47, 56, 60, 61, 70, 79, 81, 90, 93HC17......................................................................................................................... 57HC20....................................................................................................... 44, 54, 55, 83HC27............................................................................................................. 27, 69, 87HC50......................................................................................................................... 54HD50......................................................................................................................... 59HD51......................................................................................................................... 43IM10................................................................................ 13, 20, 21, 56, 63, 64, 80, 81IM11.......................................................................... 19, 27, 30, 41, 43, 79, 83, 87, 90IM12.......................................................................................................................... 59IO10............................................................................................ 15, 61, 62, 79, 80, 93IO11........................................................................................................ 63, 81, 83, 87IO12............................................................................................ 20, 21, 57, 59, 83, 85IO40.......................................................................................................................... 67IO41.......................................................................................................................... 70IO60.................................................................................................. 21, 27, 61, 83, 93IO70.................................................................................................................... 64, 70MC10 ................................................................................................ 45, 52, 53, 55, 87OM10........................................................................ 13, 20, 21, 56, 63, 64, 70, 80, 81OM11.................................................................................... 19, 23, 27, 30, 43, 59, 79OM12........................................................................................................................ 83OM20.................................................................................................................. 45, 57OM21.......................................................................................... 15, 17, 44, 67, 69, 90OM22............................................................................................................ 59, 61, 93PS10............................... 19, 20, 21, 24, 27, 30, 41, 43, 44, 56, 64, 69, 79, 81, 83, 90PS11......................................................................................................................... 59SM14 ........................................................................................................................ 53ZL31 ................................................................................................................... 53, 55ZP11......................................................................................................................... 55

IPC@CHIP................................................................. 8, 47, 97, 98, 99, 100, 101, 102, 103DK40......................................................................................................................... 47SC12................................................................................................... 98, 99, 100, 101

LNG............................................................................................................................86, 87

Modem............................................................................................................39, 41, 45, 55MULTIPROG..................................................................................7, 27, 48, 49, 50, 67, 95Multitasking..................................................................................................................... 33

I

L

M

Index 107

Novell ...............................................................................................................................64

Packaging technology .....................................................................................................11Pascal ..........................................................................................25, 56, 57, 64, 67, 71, 95PLCOpen......................................................................................................................... 48Positioning .......................................................................................................... 15, 29, 57Profibus ............................................................................................. 23, 34, 77, 88, 89, 90

Quality....................................................................................................................7, 24, 64

Random............................................................................................................................31Real-Time.........................................................................................................................44RS232.................................................................. 20, 27, 45, 53, 55, 57, 59, 69, 81, 83, 87RS485............................................................................................................ 44, 63, 89, 90Rubber ............................................................................................................................. 66

S5 ...............................................................................................................................29, 59Sawmill.............................................................................................................................29Scall ................................................................................................................................ 45SPC200 ..................................................................................................................... 30, 31

Telemonitoring ...........................................................................................................74, 76

Valve terminal ..................................................................................................................20VIP..................................................................................................................77, 78, 88, 89Visual Basic.............................................................................................................. 23, 39

Water ..........................................................................................................8, 74, 77, 78, 88WEB Server......................................................................................................................34Welding ..................................................................................................................... 15, 62Windows NT........................................................................................................39, 42, 43

N

P

Q

R

S

T

V

W

108 Index

Pneumatic Plc

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