REPORT

INDUSTRIAL CONTROL SYSTEM

STUDIO 5000

By:

Andre Perwiratama

2213030095

DIPLOMA OF ELECTRICAL ENGINEERING COMPUTER CONTROL

FACULTY OF INDUSTRIAL TECHNOLOGY

INSTITUT TEKNOLOGI SEPULUH NOPEMBER

SURABAYA

2015

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CHAPTER IINTRODUCTION

A programmable logic controller, PLC, or programmable controller is a digital computer used for automation of typically industrial electromechanical processes, such as control of machinery on factory assembly lines, amusement rides, or light fixtures. PLCs are used in many machines, in many industries. PLCs are designed for multiple arrangements of digital and analog inputs and outputs, extended temperature ranges, immunity to electrical noise, and resistance to vibration and impact. Programs to control machine operation are typically stored in battery-backed-up or non-volatile memory. A PLC is an example of a "hard" real-time system since output results must be produced in response to input conditions within a limited time, otherwise unintended operation will result.

Before the PLC, control, sequencing, and safety interlock logic for manufacturing automobiles was mainly composed of relays, cam timers, drum sequencers, and dedicated closed-loop controllers. Since these could number in the hundreds or even thousands, the process for updating such facilities for the yearly model change-over was very time consuming and expensive, as electricians needed to individually rewire the relays to change their operational characteristics.

Digital computers, being general-purpose programmable devices, were soon applied to control industrial processes. Early computers required specialist programmers, and stringent operating environmental control for temperature, cleanliness, and power quality. Using a general-purpose computer for process control required protecting the computer from the plant floor conditions. An industrial control computer would have several attributes: it would tolerate the shop-floor environment, it would support discrete (bit-form) input and output in an easily extensible manner, it would not require years of training to use, and it would permit its operation to be monitored. The response time of any computer system must be fast enough to be useful for control; the required speed varying according to the nature of the process. [1]

Since many industrial processes have timescales easily addressed by millisecond response times, modern (fast, small, reliable) electronics greatly facilitate building reliable controllers, especially because performance can be traded off for reliability.

PLCs are well adapted to a range of automation tasks. These are typically industrial processes in manufacturing where the cost of developing and maintaining the automation system is high relative to the total cost of the automation, and where changes to the system would be expected during its operational life. PLCs contain input and output devices compatible with industrial pilot devices and controls; little electrical design is required, and the design problem centers on expressing the desired sequence of operations. PLC applications are typically highly customized systems, so the cost of a packaged PLC is low compared to the cost of a specific custom-built controller design. On the other hand, in the case of mass-produced goods, customized control systems are economical. This is due to the lower cost of the components, which can be optimally chosen instead of a "generic" solution, and where the non-recurring engineering charges are spread over thousands or millions of units.

For high volume or very simple fixed automation tasks, different techniques are used. For example, a consumer dishwasher would be controlled by an electromechanical cam timer costing only a few dollars in production quantities.

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A microcontroller-based design would be appropriate where hundreds or thousands of units will be produced and so the development cost (design of power supplies, input/output hardware, and necessary testing and certification) can be spread over many sales, and where the end-user would not need to alter the control. Automotive applications are an example; millions of units are built each year, and very few end-users alter the programming of these controllers. However, some specialty vehicles such as transit buses economically use PLCs instead of custom-designed controls, because the volumes are low and the development cost would be uneconomical.[11]

Very complex process control, such as used in the chemical industry, may require algorithms and performance beyond the capability of even high-performance PLCs. Very high-speed or precision controls may also require customized solutions; for example, aircraft flight controls. Single-board computers using semi-customized or fully proprietary hardware may be chosen for very demanding control applications where the high development and maintenance cost can be supported. "Soft PLCs" running on desktop-type computers can interface with industrial I/O hardware while executing programs within a version of commercial operating systems adapted for process control needs.[11]

Programmable controllers are widely used in motion control, positioning control, and torque control. Some manufacturers produce motion control units to be integrated with PLC so that G-code (involving a CNC machine) can be used to instruct machine movements.[citation needed]

PLCs may include logic for single-variable feedback analog control loop, a proportional, integral, derivative (PID) controller. A PID loop could be used to control the temperature of a manufacturing process, for example. Historically PLCs were usually configured with only a few analog control loops; where processes required hundreds or thousands of loops, a distributed control system (DCS) would instead be used. As PLCs have become more powerful, the boundary between DCS and PLC applications has become less distinct.

PLCs have similar functionality as remote terminal units (RTU). An RTU, however, usually does not support control algorithms or control loops. As hardware rapidly becomes more powerful and cheaper, RTUs, PLCs, and DCSs are increasingly beginning to overlap in responsibilities, and many vendors sell RTUs with PLC-like features, and vice versa. The industry has standardized on the IEC 61131-3 functional block language for creating programs to run on RTUs and PLCs, although nearly all vendors also offer proprietary alternatives and associated development environments.

In recent years "safety" PLCs have started to become popular, either as standalone models or as functionality and safety-rated hardware added to existing controller architectures (Allen Bradley Guardlogix, Siemens F-series etc.). These differ from conventional PLC types as being suitable for use in safety-critical applications for which PLCs have traditionally been supplemented with hard-wired safety relays. For example, a safety PLC might be used to control access to a robot cell with trapped-key access, or perhaps to manage the shutdown response to an emergency stop on a conveyor production line. Such PLCs typically have a restricted regular instruction set augmented with safety-specific instructions designed to interface with emergency stops, light screens, and so forth. The flexibility that such systems offer has resulted in rapid growth of demand for these controllers.

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CHAPTER IIDISCUSSION

PLC 1769 L18ERM-BB1B

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The Studio 5000® environment combines design and engineering elements into one standard framework. It optimizes productivity, shortens design cycles and reduces time to market. Studio 5000 helps you respond quickly to changes in market and business needs and reduces total costs of ownership. New design capabilities can increase automation productivity and reduce costs during a project’s lifecycle. The environment is the one place for engineers to develop all elements of their control system for operation and maintenance. Studio 5000 extends beyond one controller to be a system-wide development and design tool.

features :

Scalable and flexible solutions - Use modular code to simplify your application Efficient project design- Write code, organize it, test it, and duplicate it Effective content management - Create content, store it, share it, and reuse it Quicker downtime recovery - Logically find what you need to quickly troubleshoot

code Collaborative engineering - Enable multiple people to code, then compare and merge Support for more complex motion systems - Provide multiple update rates Supports Kinetix 5500 Integrated Safety Supports Integrated condition monitoring with Dynamix 1444 Multiple motion updates for complex motion systems Program parameters – Data at the program scope is isolated from other programs Logical Organizer – provides a way to create an organizational model of the system,

and allows operators to troubleshoot the system more quickly PIO (Partial Import Online) / Editing Enhancements – allow you to easily copy

content across projects or within project Compare and Merge Tool – allows multiple engineers to independently work offline,

and then merge their changes together Simpler "delete" of programs in Logix, for single programs or groups of programs,

online or offline Select multiple project components like AOI's, UDT's, Programs, and then copy/paste,

drag/drop, export/import them as one Support for Windows 8.1, including mobile support for tablets, in addition to

virtualization and remote desktops solutions Support for alarms Safe and standard connections for Safe Torque Off drive control Support for more than 1000 programs per task! Support for Kinetix 5700 servo drive with integrated safety

To use the Logix Designer application effectively, your personal computer must meet the following hardware and software requirements.

Processor 2.8 GHz Intel Core i5 or higherMemory 8 GB or more

Operating System

Windows 7

Professional with Service Pack 1 64-bit Home Premium with Service Pack 1 32-bit or 64-bit

Windows Server 2008

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R2 Standard Eidtion with Service Pack 1

This version of the Logix Designer application has not been tested but is expected to operate correctly on all Windows 7 and Windows Server 2008 RS editions and service packs.

Storage 20GB free ore moreGraphics DirectX 9, with WDDM 1.0 or higher driver

Minimum Requirements: 2.8GHz Pentium 4 processor, 2GB of memory, 16GB of storage and DirectX 9, with WDDM 1.0 or higher driver.

Launching Studio 5000 Configuration SoftwareIn this section of the lab, you will launch the Studio 5000 software, which will allow you to configure and program a controller.1. Read the Before You Begin section on page five of this document before proceeding.2. Double-click on the Studio 5000 icon on the Desktop to launch Studio 5000 software.The Studio 5000 Splash Screen appears.FYITo see what versions of Studio 5000 you have installed on your computer, select About under the Exploresection.

In this portion of the lab, you will create an offline project using a ControlLogix 1756-L75 controller.1. Select New Project under the Create section.2. When the New Project pop-up is displayed, type ‘1756-L75’ in the Search field.Notice the Name field is highlighted in a red box. This indicates a required field that must be configured before aproject can be created.3. Type ‘Controller1’ into the name field.4. Press the Next button.5. When the Project Configuration window appears, fill it in as shown below. Select V22 Select the 1756-A10 Chassis. Select Slot 1. Select No Protection. Add a project description. Click Finish

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Adding Ladder Logic to the Main RoutineIn this section of the lab you will add code for a simple motor start/stop seal-in circuit. You will experience the ease ofprogramming with Studio 5000 software. During the labs we will only utilize ladder logic programming, but Logix controllers alsocan be programmed using Function Block, Sequential Function Charts, and Structured Text. This allows selection of theprogramming language that best fits an application.You will continue to use the project already opened.1. In the Controller Organizer expand the MainProgram folder by clicking on the +. Once expanded, the

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MainProgram will appear as shown below:

2. Double-click the MainRoutine icon and maximize the ladder window if it is not maximized.This will open the routine editor. An empty rung will already exist as shown below: The “e”s next to the rung indicatethe rung is not yet complete.

3. From the instruction toolbar, left click and hold on the Examine On (XIC) instruction.

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4. Drag the XIC onto rung 0 until the green dot appears as shown above. Release the mouse button at thelocation you wish to place your instruction

5. Verify your rung appears like the figure below:

6. From the instruction toolbar left click and hold on the Examine Off (XIO) instruction.

7. Drag the XIO onto rung 0 to the right of the XIC instruction as shown above. Again a green dot will appear tothe right of the XIC instruction indicating where your new instruction will be inserted. Release the mousebutton at the location you wish to place your instruction.

8. Verify your rung appears like the figure below:

9. From the instruction toolbar, left click and hold on the Output Energize (OTE) instruction.

10. Drag the OTE onto rung 0 to the right of the XIO instruction as shown above. Again a green dot will appear

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to the right of the XIO instruction indicating where the OTE instruction will be inserted. Release the mousebutton at the location you wish insert the instruction.

11. Verify the rung appears as shown below:

We will now add a branch around the XIC instruction.12. Click on the XIC instruction to select it as shown below:

13. From the instruction toolbar click on the Branch instruction.A branch will be inserted on the rung.

14. Left-click and hold on the blue highlighted part of the branch and drag your selected leg of the branch tothe left side of the XIC instruction.

15. Place the branch over the green dot and release the mouse button.

16. From the instruction toolbar, left click and hold on the XIC instruction.

17. Drag the XIC onto your newly created branch until the green dot appears.The rung should now appear as shown below.

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18. Verify that the entire rung appears like the figure below.

19. Save the program by clicking on the Save icon on the toolbar. This will save the program in thedefault directory, which is C:\Users\LabUser\Documents\

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CHAPTER IIIMEASUREMENT DATA AND/OR RESULT

a. ExercissesDescription:Create a running led with a timer

Requirements: 8 numbers of total led will restart after end timer set on 2 seconds start with a self holding button

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CHAPTER IVDISCUSSION OF MEASUREMENT

1. self holding

keep the system to go continously after the button is pressed

2. timer

set the outpput to 1 agter the time is running out

3. registry

normally open, will be closed after the timer is running out

4. LED

the output of the process. in the process the LED will on one agter another every 2 seconds

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CHAPTER VSUMMARIZE AND CONCLUSION

PLC, or programmable controller is a digital computer used for automation of typically industrial electromechanical processes, such as control of machinery on factory assembly lines, amusement rides, or light fixtures. PLCs are used in many machines, in many industries. PLCs are designed for multiple arrangements of digital and analog inputs and outputs, extended temperature ranges, immunity to electrical noise, and resistance to vibration and impact.

this studio 5000 is used for programming the plc, here the plc is PLC 1769 L18ERM, using the ladder diagram we can make various things that can be used to control industrial machines, such as conveyor, wheel. lamps, etc

REFERENCES

http://www.amci.com/tutorials/tutorials-what-is-programmable-logic-controller.asp

https://en.wikipedia.org/wiki/Programmable_logic_controller

http://www.rockwellautomation.com/rockwellsoftware/products/studio5000-logix-designer.page

http://theautomationblog.com/seven-things-know-studio-5000-logix-designer-formerly-rslogix-5000/

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