Automating Manufacturing Systems with PLCs V7.0 2010年版.pdf

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Automating Manufacturing Systems with PLCsVersion 7.0, April, 2010by Hugh Jack

© Copyright 1993-2010 Hugh Jack. This work is licensed under a Creative Commons Attribu-tion-Noncommercial-Share Alike 3.0 United States License.For uses not covered under the license please contact Hugh Jack (jackh@gvsu.edu). ISBN 978-0-557-34425-3Additional materials and updates for this work will be available at http://engineeronadisk.com

iiiTABLE OF CONTENTS PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii 1.PROGRAMMABLE LOGIC CONTROLLERS . . . . . . . . . . . . . . . 11.1LADDER LOGIC 11.1.1Programming51.1.2PLC Connections71.1.3Ladder Logic Inputs81.1.4Ladder Logic Outputs91.2A CASE STUDY 101.3SUMMARY 111.4PRACTICE PROBLEMS 111.5ASSIGNMENT PROBLEMS 121.1PRACTICE PROBLEM SOLUTIONS 13 2.PLC HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152.1INPUTS AND OUTPUTS 162.1.1Inputs162.1.2Output Modules192.2RELAYS 242.3A CASE STUDY 252.4ELECTRICAL WIRING DIAGRAMS 262.4.1JIC Wiring Symbols272.5SUMMARY 292.6PRACTICE PROBLEMS 302.7ASSIGNMENT PROBLEMS 312.1PRACTICE PROBLEM SOLUTIONS 33 3.LOGICAL SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373.1SENSOR WIRING 373.1.1Switches373.1.2Transistor Transistor Logic (TTL)383.1.3Sinking/Sourcing393.1.4Solid State Relays453.2PRESENCE DETECTION 453.2.1Contact Switches453.2.2Reed Switches453.2.3Optical (Photoelectric) Sensors463.2.4Capacitive Sensors513.2.5Inductive Sensors553.2.6Ultrasonic563.2.7Hall Effect573.2.8Fluid Flow573.3SUMMARY 573.4PRACTICE PROBLEMS 583.5ASSIGNMENT PROBLEMS 603.1PRACTICE PROBLEM SOLUTIONS 63 4.LOGICAL ACTUATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 674.1SOLENOIDS 674.2VALVES 674.3CYLINDERS 69

iv4.4HYDRAULICS 714.5PNEUMATICS 724.6MOTORS 734.7OTHERS 734.8SUMMARY 744.9PRACTICE PROBLEMS 744.10ASSIGNMENT PROBLEMS 744.1PRACTICE PROBLEM SOLUTIONS 77 5.BOOLEAN LOGIC DESIGN . . . . . . . . . . . . . . . . . . . . . . . . . . . . 795.1LOGIC DESIGN 835.1.1Boolean Algebra Techniques885.2COMMON LOGIC FORMS 895.2.1Complex Gate Forms895.2.2Multiplexers905.3SIMPLE DESIGN CASES 915.3.1Basic Logic Functions915.3.2Car Safety System925.3.3Motor Forward/Reverse925.3.4A Burglar Alarm925.4SUMMARY 955.5PRACTICE PROBLEMS 955.6ASSIGNMENT PROBLEMS 995.1PRACTICE PROBLEM SOLUTIONS 101 6.KARNAUGH MAPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1096.1SUMMARY 1126.2PRACTICE PROBLEMS 1126.3ASSIGNMENT PROBLEMS 1176.1PRACTICE PROBLEM SOLUTIONS 119 7.PLC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1257.1OPERATION SEQUENCE 1267.1.1The Input and Output Scans1277.1.2The Logic Scan1277.2PLC STATUS 1287.3MEMORY TYPES 1297.4SOFTWARE BASED PLCS 1297.5SUMMARY 1307.6PRACTICE PROBLEMS 1307.7ASSIGNMENT PROBLEMS 1307.1PRACTICE PROBLEM SOLUTIONS 131 8.LATCHES, TIMERS, COUNTERS AND MORE . . . . . . . . . . . 1338.1LATCHES 1338.2TIMERS 1378.3COUNTERS 1448.4MASTER CONTROL RELAYS (MCRs) 1468.5INTERNAL BITS 1478.6DESIGN CASES 1498.6.1Basic Counters And Timers1498.6.2More Timers And Counters1498.6.3Deadman Switch150

v8.6.4Conveyor1518.6.5Accept/Reject Sorting1528.6.6Shear Press1538.7SUMMARY 1548.8PRACTICE PROBLEMS 1548.9ASSIGNMENT PROBLEMS 1578.1PRACTICE PROBLEM SOLUTIONS 161 9.STRUCTURED LOGIC DESIGN . . . . . . . . . . . . . . . . . . . . . . . . 1719.1PROCESS SEQUENCE BITS 1729.2TIMING DIAGRAMS 1759.3SUMMARY 1769.4PRACTICE PROBLEMS 1779.5ASSIGNMENT PROBLEMS 1789.1PRACTICE PROBLEM SOLUTIONS 181 10.FLOWCHART BASED DESIGN . . . . . . . . . . . . . . . . . . . . . . . . 18710.1BLOCK LOGIC 18810.2SEQUENCE BITS 19410.3SUMMARY 19710.4PRACTICE PROBLEMS 19710.5ASSIGNMENT PROBLEMS 19910.1PRACTICE PROBLEM SOLUTIONS 201 11.STATE BASED DESIGN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21111.1LADDER LOGIC BY DESIGN 21311.1.1State Diagram Example21311.1.2Conversion to Ladder Logic215Block Logic Conversion215State Equations222State-Transition Equations22811.2SUMMARY 23211.3PRACTICE PROBLEMS 23211.4ASSIGNMENT PROBLEMS 23611.1PRACTICE PROBLEM SOLUTIONS 243 12.NUMBERS AND DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25712.1NUMERICAL VALUES 25812.1.1Binary258Boolean Operations260Binary Mathematics26112.1.2Other Base Number Systems26312.1.3BCD (Binary Coded Decimal)26412.2DATA CHARACTERIZATION 26412.2.1ASCII (American Standard Code for Information Interchange)26412.2.2Parity26712.2.3Checksums26812.2.4Gray Code26812.3SUMMARY 26912.4PRACTICE PROBLEMS 26912.5ASSIGNMENT PROBLEMS 27112.1PRACTICE PROBLEM SOLUTIONS 273 13.PLC MEMORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275

vi13.1PROGRAM VS VARIABLE MEMORY 27513.2PROGRAMS 27613.3VARIABLES (TAGS) 27713.3.1Timer and Counter Memory27913.3.2PLC Status Bits28113.3.3User Function Control Memory28313.4SUMMARY 28413.5PRACTICE PROBLEMS 28413.6ASSIGNMENT PROBLEMS 28413.1PRACTICE PROBLEM SOLUTIONS 285 14.LADDER LOGIC FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . 28714.1DATA HANDLING 28814.1.1Move Functions28814.1.2Mathematical Functions28914.1.3Conversions29414.1.4Array Data Functions295Statistics295Block Operations29614.2LOGICAL FUNCTIONS 29814.2.1Comparison of Values29814.2.2Boolean Functions30214.3DESIGN CASES 30314.3.1Simple Calculation30314.3.2For-Next30414.3.3Series Calculation30414.3.4Flashing Lights30514.4SUMMARY 30614.5PRACTICE PROBLEMS 30614.6ASSIGNMENT PROBLEMS 30814.1PRACTICE PROBLEM SOLUTIONS 309 15.ADVANCED LADDER LOGIC FUNCTIONS . . . . . . . . . . . . . 31715.1LIST FUNCTIONS 31715.1.1Shift Registers31715.1.2Stacks31915.1.3Sequencers32015.2PROGRAM CONTROL 32315.2.1Branching and Looping32315.2.2Fault Handling32715.2.3Interrupts32815.3INPUT AND OUTPUT FUNCTIONS 32915.3.1Immediate I/O Instructions32915.4DESIGN TECHNIQUES 33115.4.1State Diagrams33115.5DESIGN CASES 33415.5.1If-Then33415.5.2Traffic Light33515.6SUMMARY 33615.7PRACTICE PROBLEMS 33615.8ASSIGNMENT PROBLEMS 33715.1PRACTICE PROBLEM SOLUTIONS 339 16.OPEN CONTROLLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347

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