welcome at the plcopen presentation - ad universidad...

PLCopenfor efficiency in automation

printed at 4/10/2008 www.PLCopen.org

Welcome

at the

PLCopen presentation



PLCopen:

changing the worldof industrial automation

Eelco van der WalManaging Director PLCopen



“Agenda”

� the activities - introduction PLCopen

� the basis - introduction IEC 61131-3

� the example - 7 steps to success



PLCopen Mission

We want to be the leading associationresolving topics related to

control programmingto support the use of

international standards in this field.



Programming in its environment

Database Tools Visualization / HMI Project designTools

DocumentationTools

ProgrammingTools

Debugging Tools

Networking Tools ConfigurationTools

Simulation Tools



Organization

TECHNICAL PROMOTIONALCOMMITTEES

PLCopenStandardization in Industrial Control programming

TC1 TC2 TC3 TC4 TC5 TC6 PC1 PC2 PC3 PC4 PC5

General Meeting, BOM, MD



TC1: Standards

� IEC 61131-3 is enhanced with Corrigendum & Amendments

� Development of joint PLCopen position for IEC

� Communication of information from IEC to PLCopen

� Improvement proposals

� Focused to update, published 2003



TC2: Functions

� Definition of Function Block libraries & calling conventions

� … for example…

� Motion Control Library: the integration of different

technologies: logic and motion



TC2 – TF Motion Control� Part 1 – FBs released Nov. 2002

� Part 2 – Extensions - released June 05

� Part 3 – User Guidelines released April2004 (on-going)

� Part 4 – Interpolation – under construction

� Part 5 – Homing extensions – V 0.99 forcomments

� Over 20 companies certified

� Check website for full list



TC3 : Certification…without testing there is no standard…

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

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



TC3: PLCopen Compliance Levels

ApplicationProgram

FB

Variable

CodeBody

FB

Variable

CodeBody

FB

Variable

CodeBody

ApplicationProgram

FB

Variable

CodeBody

FB

Variable

CodeBody

FB

Variable

CodeBody

Conformity Level &Reusability Level

Re-usability of Function (Block)libraries

Base LevelPortability of minimal systems



Compliance: Results



Compliance:Results and Status Base Level (May ‘05)

� Accreditation installed: two institutes accredited

� Base Level definition ready for IL, ST, FBD, LD and SFC

� Base Level Test software ready for IL, ST, FBD and SFC. LDin preparation

� Conformity Level and Reusability Level ready for ST – firstproducts certified

� 26 software packages certified (see website for status)



TC4: Communication

� Communications interfaces

� Interfaces to add-on packages

� Application interchange format

� Mapping of Profibus has been done

� Mapping of CANopen has been done



TC5: Safety

� Support for safe programmingtechniques

� Focus to IEC 61508 “FunctionalSafety of Safety Related systems”

� Guidelines for the use of the IECstandard

� Basis for easier commissioning� In combination with the Function

Blocks� First results published April 2005



TC6 : XML

Opening up the

development environments

by specifying XML formats for

IEC 61131-3



TC6: XML

� Definition of XML schemes for all the IEC languages

� Representation of graphical information

� Interface to other tools

� Basis for distribution of Function Block libraries

� Released as V. 1.0 – official release, in June 2005

� Consists of a technical doc, the XML schema, andexplanation.



TC6 - XML

Developmenttool

OtherDevelopment

tool

OtherDevelopment

tool

Producer ofgraphical and

logicalinformation

Consumer ofgraphical and

logicalinformation

XML

XML

XML

XML



Coupling XML Schemes

PLCopen Schema Supplier Schema

Differences



TC6 – XML : status

� Official release June 2005

� Available on website www.plcopen.org for free dowload

� First implementations expected this year



PLCopen as a World-wide association

Office in Japan

Main Office in Europe

Office in North America Office in China



General Promotion

� PC1: General Promotion

� PC3: Promotion North America

� PC4: Promotion Japan

� PC5: Promotion China



PC2: Common training program

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

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

and listed / referenced to (see website for listing)



the future is here

TC1 : Standards links toIEC 61131-3

Harmonizing the way people look tocontrol



Fiction?Imagine

* you are in industrial control* working with 4 different brands of controls* using different dialects in their programming languages* struggling to match the level of your software engineers with

the operators and maintenance people on the factory floor* & seeing that your competitor does better

Why? What’s wrong ?



Out of the jungle

The current variety of problems can bevastly reduced via standardization

... and such a standard is available



IEC 61131-3“The best thing that happened

to industrial control”Sugar Lantic on Automation Maillist



The 7 parts of the IEC 61131 Standard- 1 General overview, definitions IS- 2 Hardware IS- 3 Programming Languages IS- 4 User Guidelines IS- 5 Messaging Service Specification IS- 7 Fuzzy Logic IS- 8 Technical Report

IS = International Standard



IEC 1131 versus IEC 61131

� The good news is – there is no difference

� It is an international harmonization of all the IEC standards

and the localized versions



IEC 61131-3 Programming languages /Industrial Control Programming

Standardizing the way people work with controls



IEC 61131-3 Programming languages /Industrial Control Programming

...with support for peoplewith different backgrounds



The IEC 61131-3 Standard

Common Elements

Programming Languages



IEC 61131-3 : Common ElementsVariables & Data Types

What is this?

01010101 10101010

Historically

• Reference to a physical memory location

• Reference to a physical Input



IEC 61131-3 : Common ElementsVariables & Data types

Temperature_Sensor_1 : Integer

• Symbolic representation via labels

• Restricted area for I/O mapping

• Hardware independent software code

• Result: higher transparency & readability

• And less errors



IEC 61131-3 : Common Elements

Software Model

• Configuration• Resources

• Tasks



IEC 61131-3 Software ModelConfiguration

Communication Function



IEC 61131-3 Software ModelConfiguration


Resource Resource



IEC 61131-3 Software Model

Task Task Task Task

Resource Resource

Configuration





Executioncontrol path

Task

Program Program

Task

Program

Task

Program

Task

Resource Resource

Configuration





Global and direct variables

Access path


Variableaccess path

FBTask

Program ProgramFB FB

Task

Program

Task

ProgramFB FB

Task

Resource Resource

Configuration


FunctionBlock

Variable



IEC 61131-3 vs conventional PLC

Global and direct variables

Access path


Variableaccess path

FBTask

Program ProgramFB FB

Task

Program

Task

ProgramFB FB

Task

Resource Resource

Configuration


FunctionBlock

Variable



Conventional PLC vs IEC 61131-3

Task 1

Program

Task

Resource

Read inputs

Do Calculations

Set Outputs

Endless Loop:

Task 2

Task 3

Task 4

Time based

Events based

Events based

Time based



Common Elements: Tasks

IEC 61131-3

EmbeddedPLCs

PC basedControl SoftLogic

Drives

LON nodes

DCS



Common Elements : Tasks & Datatypes

RPM =2000Windows CE 3.0

IEC 61131-3 tasks

SCADA & HMI tasks

I/O Communication tasks

OPC

Multi –functional Operator Panel

I/O Communication bus



IEC 61131-3 : Common ElementsCOMMON ELEMENTS

a.o.Data Types & Variables

Configuration, Resources, Tasks

Programming Organization Units, POUs

* Functions

* Function Blocks

* Programs



Functions …..* Standard functions

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

* Your own defined functions:FUNCTION SIMPLE_FUN : REAL

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

END_VARSIMPLE_FUN := A*B/C;END FUNCTION



…. & Function Blocks� Standard Function Blocks

FUNCTION_BLOCK

I NPUT OUTPUT I N_OUT EXTERNAL

LocalType

HysterisisQXIN1

XIN2EPS

BOOLREALREALREAL



…. & Function Blocks� Standard Function Blocks� Additional supplied

Function BlocksFUNCTION_BLOCK


LocalType

HysterisisQXIN1

XIN2EPS

BOOLREALREALREAL




Function Blocks� Your own defined Function

Blocks

FUNCTION_BLOCK


LocalType

HysterisisQXIN1

XIN2EPS

BOOLREALREALREAL




Function Blocks� Your own defined Function

Blocks� All FBs are highly re-usable

in same program, differentprograms or project

FUNCTION_BLOCK


LocalType

HysterisisQXIN1

XIN2EPS

BOOLREALREALREAL



Function Block exampleHysterisis

QXIN1XIN2EPS

BOOLREALREALREAL

1

EPSEPS

0

XIN2

Q



Function Block exampleFUNCTION_BLOCK HYSTERISISVAR_INPUTXIN1, XIN2 : REAL;EPS : REAL; (* Hysterisis band *)

END_VARVAR_OUTPUTQ : BOOL := 0

END_VARIF Q THENIF XIN1 < (XIN2-EPS) THENQ := 0 (* XIN1 decreasing *)

END_IF;ELSIF XIN1 > (XIN2 + EPS ) THENQ := 1; (* XIN1 increasing *)

END_IF;END_FUNCTION_BLOCK

HysterisisQXIN1

XIN2EPS

BOOLREALREALREAL

1

EPSEPS

0

XIN2

Q



Programs : design via building bricks

Automation

application

Start : BOOL;Emergency : BOOL;Limit : INT;

PROGRAM

GLOBAL

LocalType

FUNCTION

INPUT

LocalType

FUNCTION_BLOCK

INPUT OUTPUT IN_OUT EXTERNAL

LocalType



Structure & Advantages of POUs

� Create own Function Block Libraries (per application area)

� FBs are tested and documented

� Make libraries (world wide) accessible

� Re-use as much as possible

� Change programming to creating networks of FBs

� Save 40% on next project



Sequential Function Chart, SFC� Powerful graphical technique for

describing the sequentialbehavior of a control program

� Used to partition a controlproblem

� Shows overview, also suitable forrapid diagnostics

Step 1 N FILL

Step 3

Step 2 S Empty

Transition 1

Transition 2



Sequential Function Chart, SFC� Powerful graphical technique for

describing the sequentialbehaviour of a control program

� Used to partition a controlproblem

� Shows overview, also suitable forrapid diagnostics

� The basic elements are STEPSwith ACTION BLOCKS andTRANSITIONS

� Support for alternative andparallel sequences

Step 1 N FILL

Step 3

Step 2 S Empty

Transition 1

Transition 2



SFC : alternative sequences

Step 1 N FILL

Step 3

Step 2 b S Empty

Transition 1b

Transition 2b

Step 2 a S Empty

Transition 1a

Transition 2a




Common Elements




The IEC 61131-3 Programming LanguagesInstruction List Structured Text

Function Block Diagram Ladder Diagram

C:= A AND NOT B

A B C

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

LD A

ANDN B

ST C

ANDA C

B




Common Elements


Top Down

Bottom Up



IEC Programming EnvironmentsMany of them offer:� graphical programming

screens� support for multiple

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

function� software verification during

design



What are the benefits ?



Users? Which Users?

Education

InstallationMaintenance

Programming

Process cntrlDiscrete Mnf

System IntegratorYOU ??



Users? Which Users?• Automobile production lines

• Water treatment plant

• Food processing and packaging machinery

• Cable manufacturing

• Semi-conductor clean room automation

• Theme-park roller coasters

• Nuclear waste treatment plant

This wide range encompass different skills



Benefits� Reduced waste of human resources (in training,

debugging, maintenance and consultancy)



Benefits� Reduced waste of human resources (in

training, debugging, maintenance andconsultancy)

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





� Creating a focus to problem solving viasoftware re-usability (reduced applicationinvestment and supplier dependency)

Reduced misunderstandings and errors






� Reduced misunderstandings and errors

Programming techniques usable in more environments(general industrial control)






� Reduced misunderstandings and errors� Programming techniques usable in more

environments (general industrial control)

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







environments (general industrial control)� Combining harmoniously different

components from different locations,companies or countries, or projects

Increased connectivity (investment protection)







environments (general industrial control)� Combining harmoniously different

components from different locations,companies or countries, or projects

� Increased connectivity (investmentprotection)

Function"LIMIT"

Function"TEST"

Function Block"Turning"

Function Block"Feeding"

Function Block"Heating"

SoftwareLibrary



How to use IEC 61131-3

an example:

Structuring Software Developmentwith IEC 61131-3

7 steps to success



Software Development CycleDesign

/Development

/Installation

/Maintenance..

phases



… software development cycle...enhancements…..

….. new requirements ...

…. new functionality ….

…. new wishes ...

“… the never ending story of software ”



… software quality factors..

� Failure Rates: difference between hardware and software

� External Quality (‘Perceived value’) versus Internal Quality

� Correctness, reliability, robustness, integrity, persistence,

safety

� ease-of-use



What’s the topic here?

Structuring Software Development with IEC 61131-3

meaning: internal Software Quality

In the sense of:

Understandable, Reusable, Verifiable, Maintainable, Isolation



Why Structuring ?

� The ever increasing role of Software on system quality: errorscost money

� Requirements increased dramatically: 100 lines of codes now10,000 lines

� SW development: not a one-man job anymore, but a team withdifferent know how and background

� Commissioning, Installation, Maintenance, and Improvementsare essential parts of the development process



Advantages of Structuring

• Better Overview

• Better Basis for (internal) Communication

• Better Focus to problem solving

• Basis for reusable software

• “Self-documenting”



How does that look in IEC 61131-3 ?

7 Steps to Success

with a

Fermentation Control System



Fermentation Process

Heater band

Acidic reagent

Alkali reagent

Harvest valve

pH sensor

Temperaturesensor

Feed valve

Agitator



How to create a control programfor this

in a structured way?



Step 1 :Identification of external Interfaces to the System

� Feedback from the temperature sensor� Feedback from the pH sensor� Feedback from the valve positions� Feedback from the motor (speed)� Output to the valves� Output to the motor� Output to the heater band



Step 2:Definition of the main signals between System and Plant

� In this example there is no coupling to the plant, but it couldhave been, like:

� … coupling to main vessels with liquids� … coupling to transportation system / filling station after

harvesting



Step 3:Definition of all Operator interactions, overrides and

supervisory data

� For the operator we define:� …a ‘Start’ button� …a ‘Stop’ button� …a ‘Duration’ input

Now we have defined all the interfaces



Step 4:Brake down from top in logical partitions

� MainSequence - filling, heating, agitating, fermenting, harvesting, cleaning.

� ValveControl - operating valves used to fill and empty the vessel's

� TemperatureControl - for controlling the temperature

� AgitatorControl - agitator motor control

� pHControl - PH-control



Step 5:Definition of the required POUs(Programs and Function Blocks)

� Using the definitions above and

� representing it in the graphical way …



Fermentation Control ProgramTempControl

MainSequence

FillState

Agitation

pH

PV

PV

PV

SetPoint

Temp

ValvePositions

AgitateSpeed

TempSensor

pHSensor

Duration

Stop

StartStart

Duration

Stop

pHControl

AddAlkaliAddAlkali

AddAcidAddAcidSetPoint

AgitateControl

MotorSpeedMotorSpeedSetPoint

ValveControl

FillFill

HarvestHarvest

State

CoolCool

HeatHeat



MainSequence inSequential FunctionChart, SFC

N InitialisationS1

N FillingS2

N HeatingS3

N FermentingS4

N HarvestingS5

N CleaningS6

Presenting the mainprocess states



The Actions Blocks

and Transitions

can be programmed

in any of the four

IEC Programming Languages



The IEC 61131-3 Programming LanguagesInstruction List (IL) Structured Text (ST)

Funktion Block Diagram (FBD) Ladder Diagram (LD)

LD A

ANDN B

ST C

C:= A AND NOT B

A B C

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

AND

A C

B



Step 6:Definition of scan cycle time requirements

for the different parts of the application

� In this example we have only one cycle in continuous mode

� The remaining time can be used for other cycles like:

� …. the filling / transportation system

� … checking boundaries and error conditions (in a parallelsequence)



And last but not least: Step 7:Configuration of the System:Definition of Resources, Tasks

and linking of programs with physical I/O

� Depending on the system involved

� Includes physical mapping of symbols to I/O

� Mapping of the resource (read: CPU’s in the system)

� Definition of the scan cycles and events (as defined in Step6)



Conclusion� The Software development process has changed:

• more requirements..

• more functionalities..

• more code..

• more people involved..

• … more requirements / wishes

� Structuring and Decomposition are essential parts ofmodern software development

� IEC 61131-3 has the right basis to fulfill your requirements



The association PLCopen

Together we can make it happen:

Standardization in Industrial Control Programming

WE NEED YOUR SUPPORT FOR THIS !Join the organization PLCopen



More Information...

www.plcopen.org� Free-of-Charge electronic Newsletter ‘PLCopening’ (in english)

email: [email protected]



Thanks !

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