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PLC原版国外教材（PLC Theory and Implementation).pdf
Section One - Introductory Concepts
Chapter 1 Introduction to Programmable Controllers
1-1 Definition
1-2 A Historical Background
1-3 Principles of Operation
1-4 PLCs Versus Other Types of Controls
1-5 PLC Product Application Ranges
1-6 Ladder Diagrams and the PLC
1-7 Advantages of PLCs
Chapter 2 Number Systems and Codes
2-1 Number Systems
2-2 Number Conversions
2-3 One's and Two's Complement
2-4 Binary Codes
2-5 Register Word Formats
Chapter 3 Logic Concepts
3-1 The Binary Concept
3-2 Logic Functions
3-3 Principles of Boolean Algebra and Logic
3-4 PLC Circuits and Logic Contact Symbology
Section Two - Components and Systems
Chapter 4 Processors, the Power Supply, and Programming Devices
4-1 Introduction
4-2 Processors
4-3 Processor Scan
4-4 Error Checking and Diagnostics
4-5 The System Power Supply
4-6 Programming Devices
Chapter 5 The Memory System and I/O Interaction
5-1 Memory Overview
5-2 Memory Types
5-3 Memory Structure and Capacity
5-4 Memory Organization and I/O Interaction
5-5 Configuring the PLC Memory—I/O Addressing
5-6 Summary of Memory, Scanning, and I/O Interaction
5-7 Memory Considerations
Chapter 6 The Discrete Input/Output System
6-1 Introduction to Discrete I/O Systems
6-2 I/O Rack Enclosures and Table Mapping
6-3 Remote I/O Systems
6-4 PLC Instructions for Discrete Inputs
6-5 Types of Discrete Inputs
6-6 PLC Instructions for Discrete Outputs
6-7 Discrete Outputs
6-8 Discrete Bypass/Control Stations
6-9 Interpreting I/O Specifications
6-10 Summary of Discrete I/O
Chapter 7 The Analog Input/Output System
7-1 Overview of Analog Input Signals
7-2 Instructions for Analog Input Modules
7-3 Analog Input Data Representation
7-4 Analog Input Data Handling
7-5 Analog Input Connections
7-6 Overview of Analog Output Signals
7-7 Instructions for Analog Output Modules
7-8 Analog Output Data Representation
7-9 Analog Output Data Handling
7-10 Analog Output Connections
7-11 Analog Output Bypass/Control Stations
Chapter 8 Special Function I/O and Serial Communication Interfacing
8-1 Introduction to Special I/O Modules
8-2 Special Discrete Interfaces
8-3 Special Analog, Temperature, and PID Interfaces
8-4 Positioning Interfaces
8-5 ASCII, Computer, and Network Interfaces
8-6 Fuzzy Logic Interfaces
8-7 Peripheral Interfacing
Section Three - PLC Programming
Chapter 9 Programming Languages
9-1 Introduction to Programming Languages
9-2 Types of PLC Languages
9-3 Ladder Diagram Format
9-4 Ladder Relay Instructions
9-5 Ladder Relay Programming
9-6 Timers and Counters
9-7 Timer Instructions
9-8 Counter Instructions
9-9 Program/Flow Control Instructions
9-10 Arithmetic Instructions
9-11 Data Manipulation Instructions
9-12 Data Transfer Instructions
9-13 Special Function Instructions
9-14 Network Communication Instructions
9-15 Boolean Mnemonics
Chapter 10 The IEC 1131 Standard and Programming Language
10-1 Introduction to the IEC 1131
10-2 IEC 1131-3 Programming Languages
10-3 Sequential Function Chart Programming
10-4 Types of Step Actions
10-5 IEC 1131-3 Software Systems
10-6 Summary
Chapter 11 System Programming and Implementation
11-1 Control Task Definition
11-2 Control Strategy
11-3 Implementation Guidelines
11-4 Program Organization and Implementation
11-5 Discrete I/O Control Programming
11-6 Analog I/O Control Programming
11-7 Short Programming Examples
Chapter 12 PLC System Documentation
12-1 Introduction to Documentation
12-2 Steps for Documentation
12-3 PLC Documentation Systems
12-4 Conclusion
Section Four - PLC Process Applications
Chapter 13 Data Measurements and Transducers
13-1 Basic Measurement Concepts
13-2 Interpreting Errors in Measurements
13-3 Transducer Measurements
13-4 Thermal Transducers
13-5 Displacement Transducers
13-6 Pressure Transducers
13-7 Flow Transducers
13-8 Vibration Transducers
13-9 Summary
Chapter 14 Process Responses and Transfer Functions
14-1 Process Control Basics
14-2 Control System Parameters
14-3 Process Dynamics
14-4 Laplace Transform Basics
14-5 Dead Time Responses in Laplace Form
14-6 Lag Responses in Laplace Form
Chapter 15 Process Controllers and Loop tuning
15-1 Introduction
15-2 Controller Actions
15-3 Discrete-Mode Controllers
15-4 Continuous-Mode Controllers
15-5 Proportional Controllers (PMode)
15-6 Integral Controllers (I Mode)
15-7 Proportional-Integral Controllers (PI Mode)
15-8 Derivative Controllers (D Mode)
15-9 Proportional-Derivative Controllers (PD Mode)
15-10 Proportional-Integral-Derivative Controllers (PID Mode)
15-11 Advanced Control Systems
15-12 Controller Loop Tuning
15-13 Summary
Section Five - Advanced PLC Topics and Networks
Chapter 16 Artificial Intelligence and PLC Systems
16-1 Introduction to AI Systems
16-2 Types of AI Systems
16-3 Organizational Structure of an AI System
16-4 Knowledge Representation
16-5 Knowledge Inference
16-6 AI Fault Diagnostics Application
Chapter 17 Fuzzy Logic
17-1 Introduction to Fuzzy Logic
17-2 History of Fuzzy Logic
17-3 Fuzzy Logic Operation
17-4 Fuzzy Logic Control Components
17-5 Fuzzy Logic Control Example
17-6 Fuzzy Logic Design Guidelines
Chapter 18 Local Area Networks
18-1 History of Local Area Networks
18-2 Principles of Local Area Networks
18-3 Network Topologies
18-4 Network Access Methods
18-5 Communication Media
18-6 Understanding Network Specifications
18-7 Network Protocols
18-8 Network Testing and Troubleshooting
18-9 Network Comparison and Selection Criteria
Chapter 19 I/O Bus Networks
19-1 Introduction to I/O Bus Networks
19-2 Types of I/O Bus Networks
19-3 Advantages of I/O Bus Networks
19-4 Device Bus Networks
19-5 Process Bus Networks
19-6 I/O Bus Installation and Wiring Connections
19-7 Summary of I/O Bus Networks
Section Six - Installation and Start-Up
Chapter 20 PLC Start-Up and Maintenance
20-1 PLC System Layout
20-2 Power Requirements and Safety Circuitry
20-3 Noise, Heat, and Voltage Requirements
20-4 I/O Installation, Wiring, and Precautions
20-5 PLC Start-Up and Checking Procedures
20-6 PLC System Maintenance
20-7 Troubleshooting the PLC System
Chapter 21 System Selection Guidelines
21-1 Introduction to PLC System Selection
21-2 PLC Sizes and Scopes of Applications
21-3 Process Control System Definition
21-4 Other Considerations
21-5 Summary
Appendices
Appendix A: Logic Symbols, Truth Tables, and Equivalent Ladder Logic Diagrams
Appendix B: ASCII Reference
Appendix C: Electrical Relay Diagram Symbols
Appendix D: P&ID Symbols
Appendix E: Equation of a Line and Number Tables
Appendix F: Abbreviations and Acronyms
Appendix G: Voltage-Current Laplace Transfer Function Relationships
Glossary
Index
Programmable Controllers
Theory and Implementation
Second Edition
L.A. Bryan
E.A. Bryan
PROGRAMMABLE
CONTROLLERS
THEORY AND IMPLEMENTATION
Second Edition
L. A. Bryan
E. A. Bryan
An Industrial Text Company Publication
Atlanta • Georgia • USA
© 1988, 1997 by Industrial Text Company
Published by Industrial Text Company
All rights reserved
First edition 1988. Second edition 1997
Printed and bound in the United States of America
03 02 01 00 99 98 97 10 9 8 7 6 5 4 3 2
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Reproduction or translation of any part of this work beyond
that permitted by Sections 107 and 108 of the 1976 United
States Copyright act are unlawful.
Requests for permission, accompanying workbooks, or
further information should be addressed to:
Industrial Text and Video Company
1950 Spectrum Circle
Tower A-First Floor
Marietta, Georgia 30067
(770) 240-2200
(800) PLC-TEXT
Library of Congress Cataloging-in-Publication Data
Bryan, L.A.
Programmable controllers: theory and implementation/L.A. Bryan,
E.A. Bryan.—2nd ed.
p. cm.
Includes index.
ISBN 0-944107-32-X
1. Programmable controllers. I. Bryan, E.A. II. Title.
TJ223.P76B795 1997
629.8'9—dc21 96-49350
CIP
Due to the nature of this publication and because of the different applications of
programmable controllers, the readers or users and those responsible for applying the
information herein contained must satisfy themselves to the acceptability of each
application and the use of equipment therein mentioned. In no event shall the publisher
and others involved in this publication be liable for direct, indirect, or consequential
damages resulting from the use of any technique or equipment herein mentioned.
The illustrations, charts, and examples in this book are intended solely to illustrate the
methods used in each application example. The publisher and others involved in this
publication cannot assume responsibility or liability for actual use based on the
illustrative uses and applications.
No patent liability is assumed with respect to use of information, circuits, illustrations,
equipment, or software described in this text.
Industrial Text & Video Company 1-800-752-8398
www.industrialtext.com
CONTENTS
Contents
Preface ..................................................................................................... ix
About the Authors .................................................................................... x
How to Use this Book ............................................................................. xi
SECTION 1 INTRODUCTORY CONCEPTS
Chapter 1 Introduction to Programmable Controllers
1-1 Definition ................................................................................................. 4
1-2 A Historical Background .......................................................................... 5
1-3 Principles of Operation........................................................................... 10
1-4 PLCs Versus Other Types of Controls ................................................... 13
1-5 PLC Product Application Ranges .......................................................... 22
1-6 Ladder Diagrams and the PLC ............................................................... 24
1-7 Advantages of PLCs ............................................................................... 26
Chapter 2 Number Systems and Codes
2-1 Number Systems .................................................................................... 34
2-2 Number Conversions .............................................................................. 41
2-3 One’s and Two’s Complement ............................................................... 43
2-4 Binary Codes .......................................................................................... 46
2-5 Register Word Formats .......................................................................... 50
Chapter 3 Logic Concepts
3-1 The Binary Concept ............................................................................... 56
3-2 Logic Functions ...................................................................................... 57
3-3 Principles of Boolean Algebra and Logic .............................................. 64
3-4 PLC Circuits and Logic Contact Symbology ......................................... 68
SECTION 2 COMPONENTS AND SYSTEMS
Chapter 4 Processors, the Power Supply, and Programming Devices
4-1 Introduction ............................................................................................ 82
4-2 Processors ............................................................................................... 84
4-3 Processor Scan........................................................................................ 86
4-4 Error Checking and Diagnostics ............................................................ 92
4-5 The System Power Supply ..................................................................... 98
4-6 Programming Devices .......................................................................... 104
Chapter 5 The Memory System and I/O Interaction
5-1 Memory Overview ............................................................................... 110
5-2 Memory Types ..................................................................................... 111
5-3 Memory Structure and Capacity .......................................................... 115
5-4 Memory Organization and I/O Interaction ........................................... 119
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Contents
5-5 Configuring the PLC Memory—I/O Addressing ................................. 127
5-6 Summary of Memory, Scanning, and I/O Interaction .......................... 132
5-7 Memory Considerations ....................................................................... 133
Chapter 6 The Discrete Input/Output System
6-1 Introduction to Discrete I/O Systems ................................................... 138
6-2 I/O Rack Enclosures and Table Mapping ............................................ 139
6-3 Remote I/O Systems ............................................................................. 146
6-4 PLC Instructions for Discrete Inputs .................................................... 147
6-5 Types of Discrete Inputs ...................................................................... 150
6-6 PLC Instructions for Discrete Outputs ................................................. 162
6-7 Discrete Outputs ................................................................................... 165
6-8 Discrete Bypass/Control Stations ......................................................... 177
6-9 Interpreting I/O Specifications ............................................................. 178
6-10 Summary of Discrete I/O ..................................................................... 182
Chapter 7 The Analog Input/Output System
7-1 Overview of Analog Input Signals ....................................................... 186
7-2 Instructions for Analog Input Modules ................................................ 187
7-3 Analog Input Data Representation ....................................................... 189
7-4 Analog Input Data Handling ................................................................ 196
7-5 Analog Input Connections .................................................................... 199
7-6 Overview of Analog Output Signals .................................................... 201
7-7 Instructions for Analog Output Modules ............................................. 201
7-8 Analog Output Data Representation .................................................... 203
7-9 Analog Output Data Handling.............................................................. 207
7-10 Analog Output Connections ................................................................. 213
7-11 Analog Output Bypass/Control Stations .............................................. 214
Chapter 8 Special Function I/O and Serial Communication Interfacing
8-1 Introduction to Special I/O Modules .................................................... 218
8-2 Special Discrete Interfaces ................................................................... 220
8-3 Special Analog, Temperature, and PID Interfaces ............................... 224
8-4 Positioning Interfaces ........................................................................... 233
8-5 ASCII, Computer, and Network Interfaces .......................................... 248
8-6 Fuzzy Logic Interfaces ......................................................................... 255
8-7 Peripheral Interfacing ........................................................................... 260
SECTION 3 PLC PROGRAMMING
Chapter 9 Programming Languages
9-1 Introduction to Programming Languages ............................................. 276
9-2 Types of PLC Languages ..................................................................... 276
9-3 Ladder Diagram Format ....................................................................... 282
9-4 Ladder Relay Instructions .................................................................... 289
9-5 Ladder Relay Programming ................................................................. 298
9-6 Timers and Counters ............................................................................ 306
9-7 Timer Instructions ................................................................................ 308
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Contents
9-8 Counter Instructions ............................................................................. 312
9-9 Program/Flow Control Instructions ...................................................... 317
9-10 Arithmetic Instructions ......................................................................... 322
9-11 Data Manipulation Instructions ............................................................ 334
9-12 Data Transfer Instructions .................................................................... 348
9-13 Special Function Instructions ............................................................... 358
9-14 Network Communication Instructions ................................................. 363
9-15 Boolean Mnemonics ............................................................................. 369
Chapter 10 The IEC 1131 Standard and Programming Language
10-1 Introduction to the IEC 1131 ................................................................ 374
10-2 IEC 1131-3 Programming Languages .................................................. 380
10-3 Sequential Function Chart Programming ............................................. 403
10-4 Types of Step Actions .......................................................................... 419
10-5 IEC 1131-3 Software Systems ............................................................. 429
10-6 Summary .............................................................................................. 439
Chapter 11 System Programming and Implementation
11-1 Control Task Definition ....................................................................... 444
11-2 Control Strategy ................................................................................... 444
11-3 Implementation Guidelines .................................................................. 445
11-4 Programming Organization and Implementation ................................. 446
11-5 Discrete I/O Control Programming ...................................................... 465
11-6 Analog I/O Control Programming........................................................ 492
11-7 Short Programming Examples ............................................................. 521
Chapter 12 PLC System Documentation
12-1 Introduction to Documentation ............................................................ 536
12-2 Steps for Documentation ...................................................................... 537
12-3 PLC Documentation Systems............................................................... 547
12-4 Conclusion ............................................................................................ 549
SECTION 4 PLC PROCESS APPLICATIONS
Chapter 13 Data Measurements and Transducers
13-1 Basic Measurement Concepts .............................................................. 554
13-2 Interpreting Errors in Measurements.................................................... 560
13-3 Transducer Measurements.................................................................... 565
13-4 Thermal Transducers ............................................................................ 572
13-5 Displacement Transducers ................................................................... 586
13-6 Pressure Transducers ............................................................................ 588
13-7 Flow Transducers ................................................................................. 591
13-8 Vibration Transducers .......................................................................... 599
13-9 Summary .............................................................................................. 608
Chapter 14 Process Responses and Transfer Functions
14-1 Process Control Basics ......................................................................... 610
14-2 Control System Parameters .................................................................. 614
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Contents
14-3 Process Dynamics ................................................................................ 623
14-4 Laplace Transform Basics .................................................................... 632
14-5 Dead Time Responses in Laplace Form ............................................... 644
14-6 Lag Responses in Laplace Form .......................................................... 645
14-7 Types of Second-Order Responses ...................................................... 653
14-8 Summary .............................................................................................. 665
Chapter 15 Process Controllers and Loop Tuning
15-1 Introduction .......................................................................................... 670
15-2 Controller Actions ................................................................................ 671
15-3 Discrete-Mode Controllers ................................................................... 676
15-4 Continuous-Mode Controllers .............................................................. 690
15-5 Proportional Controllers (P Mode) ....................................................... 692
15-6 Integral Controllers (I Mode) ............................................................... 706
15-7 Proportional-Integral Controllers (PI Mode)........................................ 715
15-8 Derivative Controllers (D Mode) ......................................................... 725
15-9 Proportional-Derivative Controllers (PD Mode).................................. 729
15-10 Proportional-Integral-Derivative Controllers (PID Mode) .................. 736
15-11 Advanced Control Systems .................................................................. 744
15-12 Controller Loop Tuning ....................................................................... 747
15-13 Summary .............................................................................................. 766
SECTION 5 ADVANCED PLC TOPICS AND NETWORKS
Chapter 16 Artificial Intelligence and PLC Systems
16-1 Introduction to AI Systems .................................................................. 774
16-2 Types of AI Systems ............................................................................ 774
16-3 Organizational Structure of an AI System ........................................... 776
16-4 Knowledge Representation .................................................................. 778
16-5 Knowledge Inference ........................................................................... 781
16-6 AI Fault Diagnostics Application ......................................................... 788
Chapter 17 Fuzzy Logic
17-1 Introduction to Fuzzy Logic ................................................................. 798
17-2 History of Fuzzy Logic ........................................................................ 801
17-3 Fuzzy Logic Operation ......................................................................... 802
17-4 Fuzzy Logic Control Components ....................................................... 805
17-5 Fuzzy Logic Control Example ............................................................. 828
17-6 Fuzzy Logic Design Guidelines ........................................................... 835
Chapter 18 Local Area Networks
18-1 History of Local Area Networks .......................................................... 848
18-2 Principles of Local Area Networks ...................................................... 848
18-3 Network Topologies ............................................................................. 851
18-4 Network Access Methods..................................................................... 857
18-5 Communication Media ......................................................................... 860
18-6 Understanding Network Specifications ................................................ 862
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Contents
18-7 Network Protocols ................................................................................ 866
18-8 Network Testing and Troubleshooting ................................................. 874
18-9 Network Comparison and Selection Criteria ....................................... 875
Chapter 19 I/O Bus Networks
19-1 Introduction to I/O Bus Networks ........................................................ 880
19-2 Types of I/O Bus Networks .................................................................. 883
19-3 Advantages of I/O Bus Networks......................................................... 885
19-4 Device Bus Networks ........................................................................... 886
19-5 Process Bus Networks .......................................................................... 899
19-6 I/O Bus Installation and Wiring Connections ...................................... 910
19-7 Summary of I/O Bus Networks ............................................................ 916
SECTION 6 INSTALLATION AND START-UP
Chapter 20 PLC Start-Up and Maintenance
20-1 PLC System Layout ............................................................................. 922
20-2 Power Requirements and Safety Circuitry ........................................... 931
20-3 Noise, Heat, and Voltage Considerations............................................. 935
20-4 I/O Installation, Wiring, and Precautions ............................................. 942
20-5 PLC Start-Up and Checking Procedures .............................................. 948
20-6 PLC System Maintenance .................................................................... 952
20-7 Troubleshooting the PLC System ........................................................ 954
Chapter 21 System Selection Guidelines
21-1 Introduction to PLC System Selection ................................................. 962
21-2 PLC Sizes and Scopes of Applications ................................................ 962
21-3 Process Control System Definition ...................................................... 969
21-4 Other Considerations ............................................................................ 981
21-5 Summary .............................................................................................. 982
APPENDICES
Appendix A Logic Symbols, Truth Tables, and Equivalent Ladder/Logic Diagrams ..... 987
Appendix B ASCII Reference .................................................................................. 989
Appendix C Electrical Relay Diagram Symbols ...................................................... 991
Appendix D P&ID Symbols ..................................................................................... 993
Appendix E Equation of a Line and Number Tables ............................................... 995
Appendix F Abbreviations and Acronyms ............................................................... 997
Appendix G Voltage-Current Laplace Transfer Function Relationships ................. 999
Glossary .............................................................................................. 1001
Index ................................................................................................... 1025
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