- 2.1 INTRODUCTION 5
- 2.1.1 Ladder Logic 5
- 2.1.2 Programming 9
- 2.1.3 PLC Connections 12
- 2.1.4 Ladder Logic Inputs 14
- 2.1.5 Ladder Logic Outputs 14
- 2.2 A CASE STUDY 15
- 2.3 SUMMARY 16
- 2.4 PRACTICE PROBLEMS 16
- 2.5 ASSIGNMENT PROBLEMS 17
- 2.6 PRACTICE PROBLEM SOLUTIONS 19
- 3.1 INTRODUCTION 21
- 3.2 INPUTS AND OUTPUTS 22
- 3.2.1 Inputs 23
- 3.2.2 Output Modules 26
- 3.3 RELAYS 32
- 3.4 A CASE STUDY 33
- 3.5 ELECTRICAL WIRING DIAGRAMS 34
- 3.5.1 JIC Wiring Symbols 36
- 3.6 SUMMARY 39
- 3.7 PRACTICE PROBLEMS 40
- 3.8 ASSIGNMENT PROBLEMS 43
- 3.9 PRACTICE PROBLEM SOLUTIONS 45
- 4.1 INTRODUCTION 51
- 4.2 SENSOR WIRING 51
- 4.2.1 Switches 52
- 4.2.2 Transistor Transistor Logic (TTL) 52
- 4.2.3 Sinking/Sourcing 53
- 4.2.4 Solid State Relays 60
- 4.3 PRESENCE DETECTION 60
- 4.3.1 Contact Switches 61
- 4.3.2 Reed Switches 61
- 4.3.3 Optical (Photoelectric) Sensors 61
- 4.3.4 Capacitive Sensors 69
- 4.3.5 Inductive Sensors 73
- 4.3.6 Ultrasonic 75
- 4.3.7 Hall Effect 75
- 4.3.8 Fluid Flow 75
- 4.4 SUMMARY 76
- 4.5 PRACTICE PROBLEMS 76
- 4.6 ASSIGNMENT PROBLEMS 79
- 4.7 PRACTICE PROBLEM SOLUTIONS 83
- 5.1 INTRODUCTION 89
- 5.2 SOLENOIDS 89
- 5.3 VALVES 90
- 5.4 CYLINDERS 92
- 5.5 HYDRAULICS 94
- 5.6 PNEUMATICS 96
- 5.7 MOTORS 97
- 5.8 OTHERS 97
- 5.9 SUMMARY 98
- 5.10 PRACTICE PROBLEMS 98
- 5.11 ASSIGNMENT PROBLEMS 99
- 5.12 PRACTICE PROBLEM SOLUTIONS 101
- 6.1 INTRODUCTION 103
- 6.2 BOOLEAN ALGEBRA 103
- 6.3 LOGIC DESIGN 107
- 6.3.1 Boolean Algebra Techniques 114
- 6.4 COMMON LOGIC FORMS 115
- 6.4.1 Complex Gate Forms 115
- 6.4.2 Multiplexers 116
- 6.5 SIMPLE DESIGN CASES 117
- 6.5.1 Basic Logic Functions 117
- 6.5.2 Car Safety System 118
- 6.5.3 Motor Forward/Reverse 119
- 6.5.4 A Burglar Alarm 119
- 6.6 SUMMARY 122
- 6.7 PRACTICE PROBLEMS 123
- 6.8 ASSIGNMENT PROBLEMS 127
- 6.9 PRACTICE PROBLEM SOLUTIONS 129
- 7.1 INTRODUCTION 141
- 7.2 SUMMARY 144
- 7.3 PRACTICE PROBLEMS 144
- 7.4 ASSIGNMENT PROBLEMS 151
- 7.5 PRACTICE PROBLEM SOLUTIONS 153
- 8.1 INTRODUCTION 161
- 8.2 OPERATION SEQUENCE 163
- 8.2.1 The Input and Output Scans 164
- 8.2.2 The Logic Scan 164
- 8.3 PLC STATUS 165
- 8.4 MEMORY TYPES 166
- 8.5 SOFTWARE BASED PLCS 166
- 8.6 SUMMARY 167
- 8.7 PRACTICE PROBLEMS 167
- 8.8 ASSIGNMENT PROBLEMS 167
- 8.9 PRACTICE PROBLEM SOLUTIONS 169
- 9.1 INTRODUCTION 171
- 9.2 LATCHES 172
- 9.3 TIMERS 176
- 9.4 COUNTERS 184
- 9.5 MASTER CONTROL RELAYS (MCRs) 187
- 9.6 INTERNAL BITS 188
- 9.7 DESIGN CASES 190
- 9.7.1 Basic Counters And Timers 190
- 9.7.2 More Timers And Counters 191
- 9.7.3 Deadman Switch 192
- 9.7.4 Conveyor 193
- 9.7.5 Accept/Reject Sorting 194
- 9.7.6 Shear Press 195
- 9.8 SUMMARY 197
- 9.9 PRACTICE PROBLEMS 197
- 9.10 ASSIGNMENT PROBLEMS 201
- 9.11 PRACTICE PROBLEM SOLUTIONS 205
- 10.1 INTRODUCTION 217
- 10.2 PROCESS SEQUENCE BITS 218
- 10.3 TIMING DIAGRAMS 221
- 10.4 DESIGN CASES 223
- 10.5 SUMMARY 223
- 10.6 PRACTICE PROBLEMS 223
- 10.7 ASSIGNMENT PROBLEMS 225
- 10.8 PRACTICE PROBLEM SOLUTIONS 229
- 11.1 INTRODUCTION 235
- 11.2 BLOCK LOGIC 237
- 11.3 SEQUENCE BITS 243
- 11.4 SUMMARY 246
- 11.5 PRACTICE PROBLEMS 247
- 11.6 ASSIGNMENT PROBLEMS 248
- 11.7 PRACTICE PROBLEM SOLUTIONS 251
- 12.1 INTRODUCTION 261
- 12.1.1 State Diagram Example 264
- 12.1.2 Conversion to Ladder Logic 266
- Block Logic Conversion 266
- State Equations 273
- State-Transition Equations 280
- 12.2 SUMMARY 285
- 12.3 PRACTICE PROBLEMS 285
- 12.4 ASSIGNMENT PROBLEMS 290
- 12.5 PRACTICE PROBLEM SOLUTIONS 297
- 13.1 INTRODUCTION 313
- 13.2 NUMERICAL VALUES 314
- 13.2.1 Binary 314
- Boolean Operations 317
- Binary Mathematics 318
- 13.2.2 Other Base Number Systems 321
- 13.2.3 BCD (Binary Coded Decimal) 321
- 13.3 DATA CHARACTERIZATION 322
- 13.3.1 ASCII (American Standard Code for Information Interchange) 322
- 13.3.2 Parity 325
- 13.3.3 Checksums 326
- 13.3.4 Gray Code 327
- 13.4 SUMMARY 327
- 13.5 PRACTICE PROBLEMS 328
- 13.6 ASSIGNMENT PROBLEMS 330
- 13.7 PRACTICE PROBLEM SOLUTIONS 331
- 14.1 INTRODUCTION 335
- 14.2 PROGRAM VS VARIABLE MEMORY 335
- 14.3 PROGRAMS 336
- 14.4 VARIABLES (TAGS) 337
- 14.4.1 Timer and Counter Memory 340
- 14.4.2 PLC Status Bits 342
- 14.4.3 User Function Control Memory 344
- 14.5 SUMMARY 345
- 14.6 PRACTICE PROBLEMS 345
- 14.7 ASSIGNMENT PROBLEMS 346
- 14.8 PRACTICE PROBLEM SOLUTIONS 347
- 15.1 INTRODUCTION 351
- 15.2 DATA HANDLING 353
- 15.2.1 Move Functions 353
- 15.2.2 Mathematical Functions 355
- 15.2.3 Conversions 359
- 15.2.4 Array Data Functions 360
- Statistics 360
- Block Operations 362
- 15.3 LOGICAL FUNCTIONS 364
- 15.3.1 Comparison of Values 364
- 15.3.2 Boolean Functions 368
- 15.4 DESIGN CASES 370
- 15.4.1 Simple Calculation 370
- 15.4.2 For-Next 370
- 15.4.3 Series Calculation 371
- 15.4.4 Flashing Lights 372
- 15.5 SUMMARY 373
- 15.6 PRACTICE PROBLEMS 373
- 15.7 ASSIGNMENT PROBLEMS 375
- 15.8 PRACTICE PROBLEM SOLUTIONS 377
- 16.1 INTRODUCTION 387
- 16.2 LIST FUNCTIONS 387
- 16.2.1 Shift Registers 387
- 16.2.2 Stacks 389
- 16.2.3 Sequencers 391
- 16.3 PROGRAM CONTROL 394
- 16.3.1 Branching and Looping 394
- 16.3.2 Fault Handling 398
- 16.3.3 Interrupts 400
- 16.4 INPUT AND OUTPUT FUNCTIONS 402
- 16.4.1 Immediate I/O Instructions 402
- 16.5 DESIGN TECHNIQUES 403
- 16.5.1 State Diagrams 403
- 16.6 DESIGN CASES 407
- 16.6.1 If-Then 407
- 16.6.2 Traffic Light 408
- 16.7 SUMMARY 409
- 16.8 PRACTICE PROBLEMS 409
- 16.9 ASSIGNMENT PROBLEMS 411
- 16.10 PRACTICE PROBLEM SOLUTIONS 415
- 17.1 INTRODUCTION 425
- 17.2 IEC 61131 425
- 17.3 OPEN ARCHITECTURE CONTROLLERS 427
- 17.4 SUMMARY 427
- 17.5 PRACTICE PROBLEMS 427
- 17.6 ASSIGNMENT PROBLEMS 428
- 17.7 PRACTICE PROBLEM SOLUTIONS 429
- 18.1 INTRODUCTION 431
- 18.2 THE IEC 61131 VERSION 431
- 18.3 THE ALLEN-BRADLEY VERSION 434
- 18.4 SUMMARY 438
- 18.5 PRACTICE PROBLEMS 439
- 18.6 ASSIGNMENT PROBLEMS 439
- 18.7 PRACTICE PROBLEM SOLUTIONS 441
- 19.1 INTRODUCTION 443
- 19.2 THE LANGUAGE 444
- 19.2.1 Elements of the Language 445
- 19.2.2 Putting Things Together in a Program 450
- 19.3 AN EXAMPLE 455
- 19.4 SUMMARY 457
- 19.5 PRACTICE PROBLEMS 457
- 19.6 ASSIGNMENT PROBLEMS 459
- 19.7 PRACTICE PROBLEM SOLUTIONS 461
- 20.1 INTRODUCTION 465
- 20.2 A COMPARISON OF METHODS 479
- 20.3 SUMMARY 479
- 20.4 PRACTICE PROBLEMS 479
- 20.5 ASSIGNMENT PROBLEMS 480
- 20.6 PRACTICE PROBLEM SOLUTIONS 481
- 21.1 INTRODUCTION 489
- 21.2 CREATING FUNCTION BLOCKS 491
- 21.3 DESIGN CASE 492
- 21.4 SUMMARY 493
- 21.5 PRACTICE PROBLEMS 494
- 21.6 ASSIGNMENT PROBLEMS 496
- 21.7 PRACTICE PROBLEM SOLUTIONS 497
- 22.1 INTRODUCTION 501
- 22.2 ANALOG INPUTS 502
- 22.3 ANALOG OUTPUTS 507
- 22.4 ANALOG INPUTS AND OUTPUTS WITH CONTROLLOGIX 509
- 22.4.1 ANALOG INPUTS AND OUTPUTS WITH A PLC-5 511
- 22.4.2 Pulse Width Modulation (PWM) Outputs 516
- 22.4.3 Shielding 518
- 22.5 DESIGN CASES 520
- 22.5.1 Process Monitor 520
- 22.6 SUMMARY 520
- 22.7 PRACTICE PROBLEMS 520
- 22.8 ASSIGNMENT PROBLEMS 521
- 22.9 PRACTICE PROBLEM SOLUTIONS 523
- 23.1 INTRODUCTION 527
- 23.2 INDUSTRIAL SENSORS 528
- 23.2.1 Angular Displacement 528
- Potentiometers 528
- 23.2.2 Encoders 530
- Tachometers 533
- 23.2.3 Linear Position 533
- Potentiometers 533
- Linear Variable Differential Transformers (LVDT) 534
- Moire Fringes 535
- Accelerometers 537
- 23.2.4 Forces and Moments 540
- Strain Gages 540
- Piezoelectric 543
- 23.2.5 Liquids and Gases 545
- Pressure 546
- Venturi Valves 546
- Coriolis Flow Meter 548
- Magnetic Flow Meter 548
- Ultrasonic Flow Meter 548
- Vortex Flow Meter 549
- Positive Displacement Meters 549
- Pitot Tubes 549
- 23.2.6 Temperature 549
- Resistive Temperature Detectors (RTDs) 550
- Thermocouples 550
- Thermistors 552
- Other Sensors 554
- 23.2.7 Light 554
- Light Dependant Resistors (LDR) 554
- 23.2.8 Chemical 555
- pH 555
- Conductivity 555
- 23.2.9 Others 555
- 23.3 INPUT ISSUES 555
- 23.4 SENSOR GLOSSARY 558
- 23.5 SUMMARY 559
- 23.6 REFERENCES 560
- 23.7 PRACTICE PROBLEMS 560
- 23.8 ASSIGNMENT PROBLEMS 561
- 23.9 PRACTICE PROBLEM SOLUTIONS 565
- 24.1 INTRODUCTION 567
- 24.2 ELECTRIC MOTORS 567
- 24.2.1 Basic Brushed DC Motors 569
- 24.2.2 AC Motors 573
- 24.2.3 Brushless DC Motors 580
- 24.2.4 Stepper Motors 582
- 24.2.5 Wound Field Motors 584
- 24.3 HYDRAULICS 588
- 24.4 OTHER SYSTEMS 589
- 24.5 SUMMARY 589
- 24.6 PRACTICE PROBLEMS 590
- 24.7 ASSIGNMENT PROBLEMS 590
- 24.8 PRACTICE PROBLEM SOLUTIONS 593
- 25.1 INTRODUCTION 595
- 25.2 CONTROL OF LOGICAL ACTUATOR SYSTEMS 598
- 25.3 CONTROL OF CONTINUOUS ACTUATOR SYSTEMS 599
- 25.3.1 Block Diagrams 599
- 25.3.2 Feedback Control Systems 600
- 25.3.3 Proportional Controllers 601
- 25.3.4 PID Control Systems 603
- 25.4 DESIGN CASES 607
- 25.4.1 Oven Temperature Control 607
- 25.4.2 Water Tank Level Control 608
- 25.5 SUMMARY 610
- 25.6 PRACTICE PROBLEMS 610
- 25.7 ASSIGNMENT PROBLEMS 611
- 25.8 PRACTICE PROBLEM SOLUTIONS 613
- 26.1 INTRODUCTION 617
- 26.2 COMMERCIAL CONTROLLERS 622
- 26.3 REFERENCES 622
- 26.4 SUMMARY 622
- 26.5 PRACTICE PROBLEMS 622
- 26.6 ASSIGNMENT PROBLEMS 623
- 26.7 PRACTICE PROBLEM SOLUTIONS 625
- 27.1 INTRODUCTION 627
- 27.2 SERIAL COMMUNICATIONS 628
- 27.2.1 RS-232 631
- 27.2.2 ASCII Functions 633
- 27.3 PARALLEL COMMUNICATIONS 637
- 27.4 DESIGN CASES 638
- 27.4.1 PLC Interface To a Robot 638
- 27.5 SUMMARY 639
- 27.6 PRACTICE PROBLEMS 639
- 27.7 ASSIGNMENT PROBLEMS 639
- 27.8 PRACTICE PROBLEM SOLUTIONS 641
- 28.1 INTRODUCTION 645
- 28.1.1 Topology 645
- 28.1.2 OSI Network Model 647
- 28.1.3 Networking Hardware 649
- 28.1.4 Control Network Issues 650
- 28.2 NETWORK STANDARDS 651
- 28.2.1 Devicenet 651
- 28.2.2 CANbus 655
- 28.2.3 Controlnet 656
- 28.2.4 Ethernet 657
- 28.2.5 Profibus 658
- 28.2.6 Sercos 659
- 28.3 PROPRIETARY NETWORKS 659
- 28.3.1 Data Highway 659
- 28.4 NETWORK COMPARISONS 662
- 28.5 DESIGN CASES 663
- 28.5.1 Devicenet 663
- 28.6 SUMMARY 664
- 28.7 PRACTICE PROBLEMS 665
- 28.8 ASSIGNMENT PROBLEMS 666
- 28.9 PRACTICE PROBLEM SOLUTIONS 667
- 29.1 INTRODUCTION 673
- 29.2 HMI/MMI DESIGN 674
- 29.3 SUMMARY 676
- 29.4 PRACTICE PROBLEMS 676
- 29.5 ASSIGNMENT PROBLEMS 676
- 29.6 PRACTICE PROBLEM SOLUTIONS 677
- 30.1 INTRODUCTION 679
- 30.2 ELECTRICAL WIRING DIAGRAMS 679
- 30.2.1 Selecting Voltages 683
- 30.2.2 Grounding 684
- 30.2.3 Wiring 687
- 30.2.4 Suppressors 688
- 30.2.5 PLC Enclosures 689
- 30.2.6 Wire and Cable Grouping 691
- 30.3 FAIL-SAFE DESIGN 692
- 30.4 SAFETY RULES SUMMARY 692
- 30.5 REFERENCES 694
- 30.6 SUMMARY 694
- 30.7 PRACTICE PROBLEMS 694
- 30.8 ASSIGNMENT PROBLEMS 694
- 30.9 PRACTICE PROBLEM SOLUTIONS 697
- 31.1 INTRODUCTION 699
- 31.1.1 Fail Safe Design 699
- 31.2 DEBUGGING 700
- 31.2.1 Troubleshooting 700
- 31.2.2 Forcing 701
- 31.3 PROCESS MODELING 701
- 31.4 PROGRAMMING FOR LARGE SYSTEMS 705
- 31.4.1 Developing a Program Structure 705
- 31.4.2 Program Verification and Simulation 707
- 31.5 DOCUMENTATION 708
- 31.6 COMMISIONING 716
- 31.7 SAFETY 716
- 31.7.1 IEC 61508/61511 safety standards 716
- 31.8 LEAN MANUFACTURING 717
- 31.9 REFERENCES 718
- 31.10 SUMMARY 718
- 31.11 PRACTICE PROBLEMS 718
- 31.12 ASSIGNMENT PROBLEMS 719
- 31.13 PRACTICE PROBLEM SOLUTIONS 721
- 32.1 INTRODUCTION 723
- 32.2 SPECIAL I/O MODULES 728
- 32.3 SUMMARY 731
- 32.4 PRACTICE PROBLEMS 731
- 32.5 ASSIGNMENT PROBLEMS 731
- 32.6 PRACTICE PROBLEM SOLUTIONS 733
- A.1 A 735
- A.2 B 736
- A.3 C 739
- A.4 D 743
- A.5 E 745
- A.6 F 746
- A.7 G 747
- A.8 H 748
- A.9 I 748
- A.10 J 750
- A.11 K 750
- A.12 L 751
- A.13 M 751
- A.14 N 753
- A.15 O 754
- A.16 P 755
- A.17 Q 757
- A.18 R 757
- A.19 S 759
- A.20 T 761
- A.21 U 762
- A.22 V 763
- A.23 W 763
- A.24 X 764
- A.25 Y 764
- A.26 Z 764
- B.1 SUPPLIERS 765
- B.2 PROFESSIONAL INTEREST GROUPS 766
- B.3 PLC/DISCRETE CONTROL REFERENCES 766
- C.1 PREAMBLE 771
- C.2 APPLICABILITY AND DEFINITIONS 771
- C.3 VERBATIM COPYING 772
- C.4 COPYING IN QUANTITY 773
- C.5 MODIFICATIONS 773
- C.6 COMBINING DOCUMENTS 775
- C.7 COLLECTIONS OF DOCUMENTS 775
- C.8 AGGREGATION WITH INDEPENDENT WORKS 776
- C.9 TRANSLATION 776
- C.10 TERMINATION 776
- C.11 FUTURE REVISIONS OF THIS LICENSE 776
- C.12 How to use this License for your documents 777