1 Programable Logic Controllers RBT-235-SC61 Instructor: Dan Wolf dwolf/ 1/20/2014 WELCOME!

1

Programable Logic ControllersRBT-235-SC61

Instructor: Dan Wolfhttp://web.acd.ccac.edu/~dwolf/ 1/20/2014

WELCOME!

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Week #1 - The PLC DemoHome Assignments:

1. Complete and turn in the Student Information Sheet

2. Read the textbook sections as stated in the syllabus

Lab Assignment:

Module 1 – Intro and Wiring

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Student Information

1. Name

2. Student ID Number

3. Phone Number

4. Alternate Phone Number

5. Do you have easy access to a PC?

6. What other programming classes have you taken?

7.a.Do you have any hardware or electronics experience?

7.b. What areas?

8.a. What is your major?

8.b. Is your major a 2 or 4 year program?

8.c. What is your expected graduation date?

9. Your EMAIL address

4

Introductions

1. Introduction to the Instructor

2. Student Introductions

a) Name

b) Where do you work or what is your degree?

c) Why are you taking this class?

5

Administrative Information

1. Introductions2. Syllabus

a. Contact Information

b. Grading

2. Questions?

3. Beware of the “Wall”

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Software & Hardware Fields

Areas of Application

IN D U S T R IA L /E M B E D D E D

P ro du c t D e ve lo p m e n t,In d u stria l C o n tro l

C O M M E R C IA L

B a n ks , F in a n cia l, In ve n to ry,O rd e r E n try

G R A P H IC A L

A n im a tio n , W eb D es ig n ,W e b A p p lica tio ns

T h e S o ftw are Ind u s try

E M B E D D E D

P ro du c t D e s ign

F A C T O R Y A U T O M A T IO N

P ro cess C on tro l & M ea su rem e nt

S A F E TY a ndR E L IA B IL ITY

P ro du c t T e st a nd V a lida tion

T h e H a rd w a re Ind u s try

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RBT-235: Course Introduction

A course providing a working knowledge of programmable logic controllers (PLCs). Topics include terminology, basic and advanced relay logic programming, and connection and control of input/output devices. Emphasis is placed on interfacing, operating, and programming a wide range of robotic and industrial automation devices.

Prerequisites: None

8

Maximize Your Lab Time

Read the lab work prior to each class

Do not get behind in the labs

You will need the entire scheduled lab time each week

9

Budgeting Your Time

The college expects you to spend three home study hours for each hour in the classroom.

This course will require 3 * 3 = 9 hours of home study each week.

This is a technical / programming course. Nine hours is a good estimate.

10

Assignment #1

Questions to ask of two other students:

1) Name

2) Degree

3) Name of Pet

4) Employment

5) What do you want to learn from this class?

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What is a PLC?

As defined by the National Electrical Manufacturers Association (NEMA), a Programmable Logic Controller is: "a digitally operating electronic apparatus which uses a programmable memory for the internal storage of instructions for implementing specific functions, such as logic, sequencing, timing, counting and arithmetic, to control through digital or analog input/output, various types of machines or process".

In other words, it is a generic, computer controlled device that can be used to control a process such as required in a a factory manufacturing environment or a Disney fun ride.

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Input Devices Pushbuttons Selector Switches Limit Switches Level Switches Photoelectric Sensors Proximity Sensors Motor Starter Contacts Relay Contacts Thumbwheel Switches

120/230 VAC 24 VDC

– Sourcing

– Sinking

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Output Devices

Valves Motor Starters Solenoids Control Relays Alarms Lights Fans Horns

Relays– 120 VAC/VDC– 240 VAC– 24 VAC/VDC

Triac– 120/230 VAC

Transistor MOSFET– 24 VDC

14

Input Scan

Program ScanOutput Scan

Housekeeping

START

Each ladder rung is scanned using the data in the Input file. The resulting status (Logic being solved) is written to the Output file (“Output Image”).

The status of external inputs (terminal block voltage) is written to the Input image (“Input file”).

The Output Image data is transferred to the external output circuits, turning the output devices ON or OFF.

Internal checks on memory, speed and operation. Service any communication requests, etc.

PLC Operating Cycle

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Motor Solenoid 1 Solenoid 2

Solenoid 3

Sensor 1

Sensor 2

Ingredient A Ingredient B

Typical PLC Application

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Motor Solenoid 1 Solenoid 2

Solenoid 3

Sensor 1

Sensor 2

Ingredient A

Ingredient B

Operation of Mixer (Sequence of Control)

Solenoid 1– On = Sol 3 is off, and Motor is off, and

Sensor 2 is off, and Auto Switch is on– Off = Sol 3 is on, or Motor is on, or

Sensor 2 is on

Solenoid 2– On = Sol 3 is off, and Motor is off, and

Sensor 2 is on– Off = Sol 3 is on, or Motor is on, or

Sensor 1 is on

Motor– On = Sensor 1 is on, and Solenoid 2 is

off, and Solenoid 1 is off– Off = Solenoid 3 on

Solenoid 3– On = Sol 1 is off, and Sol 2

is off, and Motor has run for 30 sec.

– Off = Solenoid 3 has been

on for 60 sec.

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Basic Electric RefresherE = I * R

E = Voltage PotentialI = Current FlowR = Resistance (load)

Current (I) always flows in the direction from the highest voltage to the lower voltage(s).

E

I R

+5V

0 Volts Current Flow when LED is On

Current Flow when LED is On+5V

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Wiring Practice for Tonight

Do not apply power until I check your circuit!

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Alternate Wiring Diagrams

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Alternate Wiring Diagrams

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The End

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Week #2 - Wiring & PLC Intro

Home Assignments:

1. Informal Lab Material: Turn in lab samples


Lab Assignment:

Module 1

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Logicals - Truth Tables

AND Truth Table Input Input Output

A B F

0 0 0

0 1 0

1 0 0

1 1 1

OR Truth Table Input Input Output

A B F

0 0 0

0 1 1

1 0 1

1 1 1

XOR Truth Table Input Input Output

A B F

0 0 0

0 1 1

1 0 1

1 1 0

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Logicals – NOT Truth Table

NOT Truth Table Input Output

0 1

1 0

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Logicals – Conventional Definitions

1. AND: If A and B are High Then F = High

2. OR: If A or B is High Then F = High

3. XOR: If A or B is High (but not both) Then F = High

4. NOT: If A is High then F = Low If A is Low Then F = High

Logicals – Hardware Logic Diagrams

NOT

AND XOR

OR

Logicals – Switch Equivalents

+5V

F

A

B

AND Gate

OR Gate

+5V

A B

F

Logicals – Switch Equivalents

NOT Logic

XOR Gate

+5V

F

ANC

+V

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Programming PLC’s

The purpose of a PLC Program is to control the state of PLC outputs based on the current condition of PLC Inputs

Different PLC’s support different languages, but the most popular PLC language is know as “Ladder Logic”.

PLC Ladder Logic purposely resembles Relay Logic

Relay Logic versus Ladder Logic

Relay Logic is an electrical circuit.PB1 PB2

L1Relay Logic

Ladder Logic

Examine ON instruction: checks for ON state, does not care about NO or NC state

Ladder Logic is a logic circuit not an electrical circuit. It establishes an output based on logic continuity.

Ladder Logic Concepts

| | |/|

Read / Conditional Instructions

Write / Control Instructions

| | |/|

| | |/|

| |

| | |/| ( )

| |

( )

( )

( )

( )

| |

Start (Rung #1)

End (Rung #5)

Ladder Logic Concepts

Read / Conditional Instructions

Write / Control Instructions

No Logical Continuity

|/| | |

T F F

( )

( )|/| |/|

T T T

Logical Continuity

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Logical AND Construction

IF input 4 AND input 5 have power

THEN energize output 0

| |I/4

| |I/5

( )O/0

Logical Continuity

T T T

On

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Logical OR Construction

IF input 4 OR input 5 have power

THEN energize output 0

| |I/4

| |I/5

( )O/0

Logical Continuity

F

T

On

| |I/4

| |I/5

( )O/0

Logical Continuity

T

F

On

Complex Construction

|/|I/11

| |I/5

|/|I/7

|/|I/1

| |I/3

| |I/2

| |I/4

|/|I/0

| |I/1

| |I/1

|/|I/8

| |I/9

( )O/0

| |I/10

|/|

CR3

CR3 M1

PB1 LS1 SOL2

PB2LS1

LS3

LS4

Relay Logic vs. PLC & Ladder Logic

I/8

I/4 I/6 O/0

O/1

| | | | ( )

I/5I/7 B/0| | | | ( )

| |

|/|B/0

( )| |I/9

ProgrammableLogic

Controller

Inputs Outputs

CR

INPUT Address Assignment:PB1- I/4 PB2- I/5LS1- I/6 LS2- I/7LS3- I/8 LS4- I/9

OUTPUT Address Assignment:SOL2- O/0 M1- O/1

|/|

CR3

CR3 M1

PB1 LS1 SOL2

PB2LS1

LS3

LS4

Relay Logic to Ladder Logic

I/8

I/4 I/6 O/0

O/1

| | | | ( )

I/5I/7 B/0

| | | | ( )

| |

|/|B/0

( )| |I/9

Relay Logic versus Ladder Logic

Relay Logic is an electrical circuit.PB1 PB2

L1Relay Logic

Ladder Logic

Examine ON instruction: checks for ON state, does not care about NO or NC state

Ladder Logic is a logic circuit not an electrical circuit. It establishes an output based on logic continuity.

Input Instructions

Function Bit Example

I1 – INPUT 0 I:0.0/0 N.O Pushbutton Switch SW = Released = Open = 0 XIC SW = Pressed = Closed = 1

1 I:0.0/1 N.O. Pushbutton Switch SW = Released = Open = 1 XIO SW = Pressed = Closed = 0

2 I:0.0/2 N.C. Pushbutton Switch SW = Released = Closed = 1 XIC SW = Pressed = Open = 0

3 I:0.0/3 N.C. Pushbutton Switch SW = Released = Closed = 0 XIO SW = Pressed = Open = 1

Output Instructions

FUNCTION BIT EXAMPLE

O0 - Output 0 O:0.0/0 OTE – Output Energize

1 O:0.0/1 OTL – Output Latch

2 O:0.0/2 OUT – Output Unlatch

3 O:0.0/3

U

L

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Helpful Hints on the PLC Syntax

There are two (approximate) PLC identifier formats:1. The syntax for the Inputs and Outputs are similar to each

other. O:0.0/4 I:0.0/3 2. The syntax for the Binary, Counters, and Timers are

similar to each other. B3:1/12 T4:0/EN C5:0/CU

The two formats are confusingly similar:• The colon “:” after the I/O in format #1 is not used in

format #2• The period “.” in format #1 appears to be replaced by a

colon “:” in format #2

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The Project Planning Sheet

The Project Planning Sheet should be completed before you begin wiring or before you start the

RSLogix program.

1. Description of the Requirements2. Inputs3. Outputs4. Wiring Diagram5. Ladder Diagram

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The End

Thank You !

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Week #3 – PLC Demo & Try-out

Home Assignments:

1. Informal Lab Material

2. Mini-Quiz


Lab Assignment:

Module 1

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PLC Demo

Turn your PC on and follow your instructor throughout the demonstration.

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PLC Programming Process

1. Go Offline

2. Select the User tab

3. Drag a control from the User tab onto the rung. The red link squares will turn green when you approach them. Release the mouse button when the intended link spot is green.

4. Double-left click the control to add or change the address or parameter.

5. Click the Verify Project button to check your syntax

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PLC Control Drag Operation

Green link during a control drag operation.

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RSLogix Run Procedure

Summary of steps to run RSLogix:

1. Load RSLinx. Configure drivers as needed.2. Minimize RSLinx3. Load RSLogix4. Load Program from disk or start new

program.5. Verify Program6. Download to PLC7. Go Online

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Project Phases

1. Requirements Phase is based on “What to build”

2. Design Phase is based on “How to build it”3. Implementation Phase is based on “Now is the

time to build things”4. Test Phase is based on “Prove that you have

built the correct thing AND prove that it works correctly”.

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RSLogix 1500 Instruction Set Help

Start RSLogix 1500Help | SLC Instruction Help

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How much is your time worth?

11 participants in the workplace can cost the company $14.67 per minute.

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Lab Estimate Sheet

Estimated Time (hours)

Estimated Budget = Estimated Time * $70/hour

Actual Time (hours)

Actual Budget = Actual Budget * $70/hour

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The End

Thank You !

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Week #4 – Inputs & Outputs

Home Assignments:



Lab Assignment:

Module 1

55

Document your Programs

1. Right-click while on the symbol2. Left-click on “Edit Description”3. Use meaningful titles!

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Relay Example

N.O.

+12V

+120V

Relay120V Lamp

N.O.

Low voltage on switch causes the high voltage lamp to light.

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Relay Example – Sealing Circuit

Lamp is latched on even after the switch is released.Why might we need this?

N.O.

N.O.

+12V

+120V

Relay120V Lamp

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Relay Example – Reset Logic

Reset switch added to shut off lamp.

N.O.

N.O.

+12V

+120V

Relay120V Lamp

N.C.ResetSwitch

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Development Process – 4 Way Switch

Requirements:Implement a four-way switch where any one of three switches will turn on/off a light. This logic is to be used in a meeting room where there is a single switch at each of three entrances.

Design:Analyze the requirement and decide how this will be implemented. Create a truth table or boolean equation description of the relationship between the inputs and outputs.

Implementation:Create the ladder logic.

Test: Be Careful!

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Four-Way Switch - First Attempt

SW1 SW2 SW3 F

0 0 0 0

0 0 1 1

0 1 0 1

0 1 1 0

1 0 0 1

1 0 1 0

1 1 0 0

1 1 1 0

Enter a “1” in the F-column wherever a single switch is true.

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First Attempt Ladder Logic

S1

S1

S1

S2

S2

S2

S3

S3

S3

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Test and Verify !

1. Now enter and test your logic.

• Create a rung for each “1” in the output column.

• Use three inputs for each rung, Sw1, Sw2, and Sw3

• Use an XIC wherever an input is high and an XIO whenever a switch is low.

2. Quick testing may indicate that the logic is OK.

3. But careful testing will show a condition that does not work.

4. Our original assumption was to put a “1” in the truth table wherever a single switch is on. However we should have put a one whenever there was a “single bit change”.

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Four-Way Switch - Second Attempt

SW1 SW2 SW3 F

0 0 0 0

0 0 1 1

0 1 0 1

0 1 1 0

1 0 0 1

1 0 1 0

1 1 0 0

1 1 1 1

Enter a “1” in the F-column wherever there is a “single-bit change” to the input switches.

Our error was created because we made a mistake during the design phase.

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Second Attempt Ladder Logic

S1

S1

S1

S2

S2

S2

S3

S3

S3

S1 S2 S3

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Test and Verify !

1. Now enter and test your logic.

• Create a rung for each “1” in the output column.

• Use three inputs for each rung, Sw1, Sw2, and Sw3

• Use an XIC wherever an input is high and an XIO whenever a switch is low.

2. Careful testing will indicate that the logic is now OK.

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Development Process – Conveyor DemoRequirements:

The conveyor belt should move if power is on and if the operator seat is depressed. If the Maintenance override is active, the conveyor should move as long as power is on.If Panic is active, shutdown the conveyor.

Design:Create a truth table or boolean equation description of the relationship between the inputs and outputs. Arrange the input columns so the table is intuitive.

Implementation:Create the ladder logic.

Test: Be Careful!

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Conveyor DemoPANIC MAINT PWR SEAT F Mode

0 0 0 0 0 Not used0 0 0 1 0 Not used0 0 1 0 0 Not used0 0 1 1 1 Normal Mode

0 1 0 0 0 Maintenance0 1 0 1 0 Maintenance0 1 1 0 1 Maintenance0 1 1 1 1 Maintenance1 0 0 0 0 Panic Shutdown1 0 0 1 0 Panic Shutdown1 0 1 0 0 Panic Shutdown1 0 1 1 0 Panic Shutdown1 1 0 0 0 Panic Shutdown1 1 0 1 0 Panic Shutdown1 1 1 0 0 Panic Shutdown1 1 1 1 0 Panic Shutdown

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Conveyor Demo Ladder Logic

ABCD +

ABCD +

ABCD = F

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Larnaugh Map Simplification

70

Simplified Ladder Logic

ACD + ABC = F

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Simplified Ladder Logic

AC (B+D) = F

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The End

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Week #5 – Latches and Bits

Home Assignments:


2. Mini-Quiz


Lab Assignment:

Lab Estimate

Module 2

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The Bit & Byte

BIT - Either '1' or '0', the smallest number

BYTE - consists of eight bits

The byte has a range of:0 - 255 (base 10)00h - FFh (base 16)00000000 - 11111111 (base 2)Two bytes make a wordThere are two hex digits in a byte1Mbyte = FFFFFh = 1048575

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The Nibble

NIBBLE - consists of four bits

The nibble has a range of:

0 - 15 (base 10)0h - Fh (base 16)0000 - 1111 (base 2)Two nibbles make a byteThere is one hex digit in a nibble

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The Word

WORD - consists of sixteen bits

The word has a range of:0 - 65535 (base 10)0000h - FFFFh (base 16)0000000000000000 -

1111111111111111 (base 2)Two words make a double wordThere are four hex digits in a word

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Number Conversions

Decimal Base 10 Our own number system

Hex Base 16 The programmers’ number system

Binary Base 2 The computers’ number systemWe will convert to and from each of these number systems.

Hex Binary

Hex Decimal

Decimal Binary

See the appendix in the lab book

78

MS-Windows Scientific Calculator

79

Relay Instructions

L

U

OTE – Output Enable

OTL – Output Latch

OUT – Output Unlatch

O:0.0/1 Output Bit 1



80

Ladder Diagram of a Sealing Circuit

81

Ladder Diagram of a Latching Circuit

82

The BIT Instruction

83

The End

Thank You !

84

Week #6 - Timers

Home Assignments:


2. Read the textbook sections as stated in the syllabus.

Lab Assignment:

Module 2

Lessons Learned – ANDed Outputs

I:0.0/1

O:0.0/2

B3:0/3

LB3:0/3

O:0.0/1

Observation:

Inputs are OR Logic but the Outputs are AND Logic

Lessons Learned – Mixing OTE and OTL

I:0.0/0

O:0.0/0

O:0.0/0

L

U

I:0.0/1

O:0.0/0I:0.0/2

Button 0 unlatches Output 0 (1rst rung), thus it negates the latch of Output 0 on the 2nd rung. Output 0 will never latch!

OTE

OTL

Lessons Learned – Race Conditions

Enter this program and then press the Over-speed switch. Observe the reaction while the 3rd rung is trying to turn it off.

L

U

Overspeed SW

Overspeed Reset

B3:0/1

B3:0/1

B3:0/1 Alarm

Manual SW B3:0/1

Lessons Learned – Race Conditions

Solution: Enter this program and then press the Over-speed switch.

L

U

Overspeed SW

Overspeed Reset

B3:0/1

B3:0/1

B3:0/1 Alarm

Manual SW

Lessons Learned – Dual Rung Outputs

Left

Guard

Guard

Guard

Right Material

Limit

Avoid driving the same output from two different rungs as you can experience timing related side-affects. Better to merge the two rungs into one rung.

Lessons Learned – Sequence Anomoly

I:0.0/1

O:0.0/2

B3:0/3

L

U

B3:0/3

B3:0/3

B3:0/3I:0.0/2

I:0.0/3

UO:0.0/2

What sequence of pressing and releasing SW2 and SW3 will unlatch Output 2?

1. SW2 and SW3 together2. SW3 first3. SW2 first

91

Timer Types

BI-STABLE TIMER (free running)These run continuously - every time the timer expires, it is restarted. They are used for periodic events such as temperature monitoring. frmMain.tmrTimer_TimerThis is also known as an ASTABLE timer.

MONOSTABLE TIMER (one-shot)These run once and then stop. They are used to implement delays such as a 60 second crosswalk (street) sign. frmMain.tmrTimerDelay_Timer

Timer Instructions

TON – Timer Delay On

TOF – Timer Delay Off

RTO – Retentive Delay Timer OFF

EN

DN

TONTimer On Delay

Timer T4:8Time Base 1.0Preset 5 <Accum 0 <

TON

EN

DN

TOFTimer Off Delay

Timer T4:8Time Base 1.0Preset 5Accum 0

TOF

EN

DN

RTORetentive Timer On

Timer T4:8Time Base 1.0Preset 5Accum 0

RTO

93

The Timer On (TON) Circuit

94

The Retentive Timer (RTO) Circuit

Switch #0 must be pressed for three seconds.

Retentive Timer #3 stays on until Switch 1 is pressed.

95

Delayed Start Circuit

Switch #0 closure may be momentary.

Latched output stays on until Switch 1 is pressed.

MOV Instruction

The MOV instruction will move a value to another location when the input is enabled. In this example, it moves the value 10 into the Preset register of the C12:2 counter.

MoveSource 10

10<Dest C12:2.PRE

10<

MOV

MOV - Move

97

Lab Reports - An Overview

The title page should include your name, chapter# and lab title.

Printouts of the programs may be referenced in the text.

Discuss as many of the new lab concepts as possible.

Optional work is highly encouraged and required for grades above 89%.

One of the worst things to do is get behind on the labs.

Additional grading details are explained in the syllabus.

98

Lab Report Format

INTRODUCTION:Provide an overview of the topics that are involved in the lab.

BODY:List and discuss each experiment. Optionals should be identified.

Experiment #1

Experiment #2

CONCLUSION:Summarize each new instruction or concept.

PRINTOUTS:Include a printout of each program and it’s output

99

Lab Report Schedule and Grading

• Lab reports are due two weeks after the last work night for that lab.

• I require a majority of the labs before I will grade them.

• I will return the graded labs to you the week after I grade them.

• You must inform me in advance if your lab report will be late.

100

Spell & Grammar Check Reminder

Are you using MS-Word for your labs?

Are you using the Spell Checker and Grammar Checker?

To Configure:

Tools | Options | Spelling and Grammer

To run:

F7

101

Week #7 - Counters

Home Assignments:


2. Formal Lab Report – Vat Mixer Section 2.3.8

3. Mini-Quiz


4. EXAM NEXT WEEK!

Lab Assignment:

Module 2

102

Comments on Section 2.3.4 PPS

The different class teams each implemented variations of the requirements.

As a class exercise, this is great.

However, in a work environment, you must always seek clarification and approval from your customer (internal or external) as what makes sense to you may not make sense to the customer. In addition, each new feature adds risk, cost, and schedule; something that your company may not be able to accept.

103

Comments on Commenting

Uncommented Ladder Logic Diagrams are hard to understand.

All controls should be given a descriptive name (inputs, outputs, bits, timers, counters, etc.

Please use printouts whenever possible (instead of hand drawings) – especially on the more complex logic.

You can also add “rung-level” comments.

After you have it working, take time to review the logic in order to simplify it. But be careful you don’t break it or add side affects if you make improvements… Don’t make rushed changes!

BiStable Timer ConfigurationStart

T4:9/DN

T4:8/DN

T4:9/DN

EN

DN

TOF

Timer Off Delay

Timer T4:8

Time Base 1.0

Preset 5

Accum 0

TOF

EN

DN

TOF

Timer Off Delay

Timer T4:9

Time Base 1.0

Preset 5

Accum 0

TOF

Counter Instructions

CTU – Count Up

CTD – Count Down

CU

DN

CTUCount UpCounter C5:2Preset 5 <Accum 0 <

CTU

CD

DN

CTDCount DownCounter C5:2Preset 5 <Accum 0 <

CTD

106

Counter Example

Switch 0 requires five closures to enable Output 0

Switch 1 resets the counter and unlatches Output 0

107

I/O Port Nomenclature

Port - An electronic location typically used to allow the computer to access a hardware device.

1 = On = Set = +5Volts = High

0 = Off = Clear = 0Volts = Low

I/O Port InterfacingIntel

M icroprocessorRAM Mem oryROM Mem ory

Port PortPort Port

KeyboardDisplay MousePrinter

Output PortInput Port

D7

+5V +5V

D0

D6D5

D4D3

D2D1

D7

+5V

+12V

D6D5

D4D3

D2D1

D0

AC D rive M otor

120V AC

Data Bus

.

109

I/O Port Industrial Example

110

Bottle Sensors

111

Review Lecture

Review material

Exam Next Week – Take time to look at the past material and ask questions.

112

The End

Thank You !

113

Week #8 – Exam & Analog Input

Home Assignments:


2. Mid-Term Exam


Lab Assignment:

Module 3

114

Analog Definition

Digital - Only two states: 0 volts and +5V 1 = On = Set = +5Volts = High


Analog - Unlimited number of states between a lower and an upper value.

0V, 0.02V, 0.04V, 1.44V, 3.60V, 5.00V

Connection Diagram for an ADC

116

ADC Resolution

ADC Resolution is the smallest change in voltage that the ADC can measure.

A 16-bit converter has a resolution of:

1/(216) = 1/65536 = 0.0000152 times the full scale input voltage

I.e. it can measure a signal as small as:

0.0000152 * 10V = 0.000152 Volt (152uV)

Each “count” of the ADC value stands for 152uV

Volts / Bits = 10-0 / 65536 = 0.000152 Volts per bit

Analog Input ScalingANALOG VOLTAGE

INPUT DIGITAL INPUT

(RAW A-D) Base 10

0V 0000 0000 0000 0000 0 0.000152 0000 0000 0000 0001 1

0.5V 0000 1100 1100 1101 3277 1.0V 0001 1001 1001 1010 6554 2.0V 0011 0011 0011 0011 13107 4.0V 0110 0110 0110 0110 26214 10V 1111 1111 1111 1111 65536

Assuming:

• The analog input is from 0 to +10 volts

• The ADC is a 16-bit device (0 to 65535)

118

Examples and Practice

Assuming a 10-bit ADC and a 0 to +10V input:

1. What value do you expect if we apply 7.5V to the analog input?

2. If you are reading 9000h on the PLC, what voltage must be at the input?

119

Analog Input Sensors

• Thermocouples - for extreme temperatures

• Thermistors - for extreme chemical environments

• RTD - Resistance-Temperature-Device

• Pressure Transducers - for air, fluids

• Strain & Force Gauges - for mechanical measurements

• Acceleration and Torque - for movements

120

The End

Thank You !

121

Week #9 – Math Instructions

Home Assignments:


2. Mini-Quiz


Lab Assignment:

Module 3

122

“Experienced” does not mean “careful”

123

The End

124

Week #10 – Process Control

Home Assignments:


2. Read the textbook section as stated in the syllabus.

Lab Assignment:

Module 3

125

Analog Definition

Digital - Only two states: 0 volts and +5V 1 = On = Set = +5Volts = High


Analog - Unlimited number of states between a lower and an upper value.

0V, 0.02V, 0.04V, 1.44V, 3.60V, 5.00V


PC #1

8-Bit A-D Chip Digital Input Port CPUDigital In/Output

Port

RS-232Driver IC

UART Chip

PC #2

Tx

Rx

Gnd

COM1

COM1

Tx

Rx

Gnd

Signal

Gnd

TemperatureTransducer

0 to 5 VoltAnalog Data(Sensitive to

Electrical Noise)

8 Data BitsDigital Data00000000

to11111111

+12 Voltor

-12 VoltSerial Data50' distance

1 wire Transmit1 wire Receive1 wire ground

0 Voltor

+5 VoltSerial Data


V in

GN D

V ref

B 1

B 8

Sig n

EN B

A /D Conv erterTemperatureTransducer

/Enable

C lock

8-bit D ata Bus0-2Volt = 0-200 deg rees F

.01V = 1deg00 - FF h

5.1V

128

ADC Resolution

ADC Resolution is the smallest change in voltage that the ADC can measure.

An 14-bit converter has a resolution of:

1/(214) = 1/16384 = 0.000061 times the reference voltage

The PLC has a 16.384 Volt reference.

I.e. it can measure 0.000061 * 16.384V = 0.001 Volt (1mV)

Volts / Bits = (16.384 – 0) / 16384 = 1mVolts per bit

129

Analog Input Scaling - Engineering Units

Assuming:• The analog input is from 0 to +10 volts• The PLC reference voltage is 16.384 volts• The PLC resolution is 1mV• Actual Voltage = PLC Value * 1 mV

Volt In ADC Binary ADC Base 10 Value * 1mV

0 V 00 0000 0000 0000 0 0

1 mV 00 0000 0000 0001 1 0.001

2 mV 00 0000 0000 0010 2 2

2.378 00 1001 0100 1001 2377 2.377

5 V 01 0011 1000 1000 5000 5.000

8 V 01 1111 0100 0000 8000 8.000

10 V 10 0111 0001 0000 10000 10.000

130

Analog Input Scaling – MODE = ???

Assuming:

• The analog input is from 0 to +10 volts

• The PLC reference voltage is 16.384 volts

Volt In ADC Binary ADC Hex ADC Base 10

0 V 00 0000 0000 0000 0000h 0

1 mV 00 0000 0000 0001 00001h 1

2 mV 00 0000 0000 0010 00002h 2

5 V 01 0011 1000 1000 1388h 5000

8 V 01 1111 0100 0000 1F40h 8000

10 V 10 0111 0001 0000 2710h 10000

131

Lab Temperature Sensor – AD590

The lab temperature sensor has the following parameters: Temperature range from 0 to 200 F Outputs .01 volts (+10mV) per F Maximum output is: 200F * .01V = 2Volts Made by Analog Devices

Temperature Input

+12V

To PLCAnalog In

1K ohm

70degF = 25degC = 298uA è 298mV @ 1K ohm load

AD590Temperature sensor

Heater Controller

Amp meter

+12V

PLC

2N2222Hfe = 100

2N3055Hfe = 20-70Ic = 1A max

47K ohm

Start your tests with the 5V supply instead of the 12V supply.

Do not exceed 1A on the 2N3055 !

Temperature Setpoint

+9V

Setpoint298mV @ 70degF = 25degC

135

Bug Fix - Communication

Problem:The PLC will not communicate with the PC and you get the

following message:“No Response from Processor at selected path/node!”

Solution:Tools | Options | System Communication | Download

136

Bug Fix – No Run Mode

Problem:The PLC is in “Remote Program” mode and will not go into

“Run” mode.

Solution:A) Download and run your programB) The PC will say you are in “Run Program” mode.C) Comms | Mode | Run

137

The End

138

Week #11 - Sequences

Home Assignments:



Lab Assignment:

Module 3

139

The End

140

Week #12 – Sequence Project

Home Assignments:


2. Formal Lab Report: Robot Pallet Section 3.3.9

3. Mini-Quiz


Lab Assignment:

Lab Estimate

Module 3

141

The End

Thank You !

142

Week #13 – Review & Project

Home Assignments:


2. Formal Report is TBD: group project or waived

2. Course Review

Lab Assignment:

Module 4

143

Agenda

1. Safety Overview2. Introduction to Project Phases3. Plant Tour4. Review5. Closing Discussion

144

Agenda


145

Project Phases

1. Design

2. Implementation (Peer Reviews and Engineer Desk Testing)

3. Engineering Test (Lab Testing)

4. Factory Test (Factory Testing)

5. Field test (Field Testing)

146

Test Phases

1. Peer Reviews • Cheap; paper based; not very glamorous; MOST EFFICIENT

2. Engineer Desk Testing• Cheap; very limited capabilities

3. Lab Testing• Requires additional equipment; does not include the full

system; allows abnormal tests; significant simulation required4. Factory Testing

• Requires a support team to setup and maintain the equipment; requires considerable lab space; includes almost the entire system but some parts are simulated. Increased safety risks.

5. Field Testing• MOST EXPENSIVE; extreme visibility/risk with the customer;

very limited access to the equipment (2-6 hours/night); Requires an expensive support team. Highest safety risks.

147

Bug Detection and Correction Times

Each successive phase requires 10 times the effort to detect and fix a bug.

1. Peer Reviews• Multiple bugs found per hour

2. Engineer Desk Testing• Assume one bug requires 30 minutes to find and fix

3. Lab Testing• The same bug requires 5 hours to find and fix

4. Factory Testing• The same bug requires 50 hours to find and fix

5. Field Testing• The same bug requires 500 hours to find and fix

148

Agenda


149

Agenda


150

Agenda


151

Do you want to be a millionaire?

Tonight, I will show you how.

152

Success with Retirement Goals

1. Many companies match the first 3-6% of your contributions to a 401K retirement plan.

2. Assuming a salary of $50K/year and a company matching contribution of 6%, the company will be giving you $3000 if you contribute $3000 / 12 = $250 each month.

3. BUT, your contribution of $3000 is not taxable so you will also pay $750 less in taxes for the year (assume 25% tax bracket).

4. Your contribution of $3K yields you $3K + $3K + $750 = $6750

What would be a good reason to justify not contributing?

153

Success with Retirement Goals

1. Due to the power of accumulated interest, saving at an early age will net a you far greater amount at retirement than if you only start saving at the age of 30-40.

2. Someone entering the engineering profession today can expect to have $1-2M in his/her retirement account at age 60 – but only if you contribute (early and often)!

154

Two Quick Tips

1. Start now by contributing whatever you are able to – do not wait.

2. Each year when you get a raise or promotion, increase the amount that you contribute – you will never notice the difference.

An individual is allowed to save up to $5000 in a 2008 IRA and $15,500 per year to a company sponsored 401K plan.

155

EQ versus IQ

1. IQ – A measure of your ability to learn.

2. EQ – A measure of how you understand yourself and how you understand others. Also your understanding of how others affect yourself and how you affect others.

156

EQ – Top-Level Notes

1. A high EQ will almost always benefit you more than a high IQ.

2. EQ can be learned.

3. As you gain seniority, the value of EQ increases while the value of IQ decreases.

4. EQ can also be referred to as “People Skills”

157

EQ – How it is Measured

1. Self-awareness – your ability to accurately perceive your own emotions in the moment and understand your tendencies across situations.

2. Self-management – what happens when you act (or do not act). It is dependent on your self-awareness.

3. Social-awareness – your ability to accurately pick up on emotions in other people and understand what is really going on with them.

4. Relationship-management – This is your ability to use your awareness of both your own emotions and those of others to manage interactions successfully. This is the product of the first three skills.

EQ is the product of each of the above four skills.

158

Quick Tips

1. Think about your interactions with your co-workers.

2. Notice when emotions come into play and observe how they affect the conversation.

3. If you or others are uncomfortable, stressed, intimidated or fearful, then emotions are affecting the conversation.

4. Your emotions affect your thoughts so understanding your (or others) emotions will allow you to better control the conversation.

159

The End

Thank You !

160

Week #14 - Final Exam

Exam Time: 7:00 pm to 9:00 pm

All outstanding work is due.

161

Final Wrap-up

• Final Exam• All Labs and Materials are due

162

Fill-in Material

The material that follows will be discussed during the course when the schedule

allows.

Documents

1 Programable Logic Controllers RBT-235-SC61 Instructor: Dan Wolf dwolf/ 1/20/2014 WELCOME!