Automating Manufacturing Systems with PLCs

 

Version 7.0, April, 2010

 

by Hugh Jack

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

© Copyright 1993-2010 Hugh Jack. This work is licensed under a Creative Commons Attribution-Noncommercial-Share Alike 3.0 United States License.For uses not covered under the license please contact Hugh Jack (jackh@gvsu.edu).

 

 

ISBN 978-0-557-34425-3

 

 

 

 

Additional materials and updates for this work will be available at http://engineeronadisk.com

 

TABLE OF CONTENTS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PREFACE

1. PROGRAMMABLE LOGIC CONTROLLERS

LADDER LOGIC

A CASE STUDY

SUMMARY

PRACTICE PROBLEMS

ASSIGNMENT PROBLEMS

PRACTICE PROBLEM SOLUTIONS

2. PLC HARDWARE

INPUTS AND OUTPUTS

RELAYS

A CASE STUDY

ELECTRICAL WIRING DIAGRAMS

SUMMARY

PRACTICE PROBLEMS

ASSIGNMENT PROBLEMS

PRACTICE PROBLEM SOLUTIONS

3. LOGICAL SENSORS

SENSOR WIRING

PRESENCE DETECTION

SUMMARY

PRACTICE PROBLEMS

ASSIGNMENT PROBLEMS

PRACTICE PROBLEM SOLUTIONS

4. LOGICAL ACTUATORS

SOLENOIDS

VALVES

CYLINDERS

HYDRAULICS

PNEUMATICS

MOTORS

OTHERS

SUMMARY

PRACTICE PROBLEMS

ASSIGNMENT PROBLEMS

PRACTICE PROBLEM SOLUTIONS

5. BOOLEAN LOGIC DESIGN

LOGIC DESIGN

COMMON LOGIC FORMS

SIMPLE DESIGN CASES

SUMMARY

PRACTICE PROBLEMS

ASSIGNMENT PROBLEMS

PRACTICE PROBLEM SOLUTIONS

6. KARNAUGH MAPS

SUMMARY

PRACTICE PROBLEMS

ASSIGNMENT PROBLEMS

PRACTICE PROBLEM SOLUTIONS

7. PLC OPERATION

OPERATION SEQUENCE

PLC STATUS

MEMORY TYPES

SOFTWARE BASED PLCS

SUMMARY

PRACTICE PROBLEMS

ASSIGNMENT PROBLEMS

PRACTICE PROBLEM SOLUTIONS

8. LATCHES, TIMERS, COUNTERS AND MORE

LATCHES

TIMERS

COUNTERS

MASTER CONTROL RELAYS (MCRs)

INTERNAL BITS

DESIGN CASES

SUMMARY

PRACTICE PROBLEMS

ASSIGNMENT PROBLEMS

PRACTICE PROBLEM SOLUTIONS

9. STRUCTURED LOGIC DESIGN

PROCESS SEQUENCE BITS

TIMING DIAGRAMS

SUMMARY

PRACTICE PROBLEMS

ASSIGNMENT PROBLEMS

PRACTICE PROBLEM SOLUTIONS

10. FLOWCHART BASED DESIGN

BLOCK LOGIC

SEQUENCE BITS

SUMMARY

PRACTICE PROBLEMS

ASSIGNMENT PROBLEMS

PRACTICE PROBLEM SOLUTIONS

11. STATE BASED DESIGN

LADDER LOGIC BY DESIGN

SUMMARY

PRACTICE PROBLEMS

ASSIGNMENT PROBLEMS

PRACTICE PROBLEM SOLUTIONS

12. NUMBERS AND DATA

NUMERICAL VALUES

DATA CHARACTERIZATION

SUMMARY

PRACTICE PROBLEMS

ASSIGNMENT PROBLEMS

PRACTICE PROBLEM SOLUTIONS

13. PLC MEMORY

PROGRAM VS VARIABLE MEMORY

PROGRAMS

VARIABLES (TAGS)

SUMMARY

PRACTICE PROBLEMS

ASSIGNMENT PROBLEMS

PRACTICE PROBLEM SOLUTIONS

14. LADDER LOGIC FUNCTIONS

DATA HANDLING

LOGICAL FUNCTIONS

DESIGN CASES

SUMMARY

PRACTICE PROBLEMS

ASSIGNMENT PROBLEMS

PRACTICE PROBLEM SOLUTIONS

15. ADVANCED LADDER LOGIC FUNCTIONS

LIST FUNCTIONS

PROGRAM CONTROL

INPUT AND OUTPUT FUNCTIONS

DESIGN TECHNIQUES

DESIGN CASES

SUMMARY

PRACTICE PROBLEMS

ASSIGNMENT PROBLEMS

PRACTICE PROBLEM SOLUTIONS

16. OPEN CONTROLLERS

IEC 61131

OPEN ARCHITECTURE CONTROLLERS

SUMMARY

PRACTICE PROBLEMS

ASSIGNMENT PROBLEMS

PRACTICE PROBLEM SOLUTIONS

17. INSTRUCTION LIST PROGRAMMING

THE IEC 61131 VERSION

THE ALLEN-BRADLEY VERSION

SUMMARY

ASSIGNMENT PROBLEMS

18. STRUCTURED TEXT PROGRAMMING

THE LANGUAGE

AN EXAMPLE

SUMMARY

PRACTICE PROBLEMS

ASSIGNMENT PROBLEMS

PRACTICE PROBLEM SOLUTIONS

19. SEQUENTIAL FUNCTION CHARTS

A COMPARISON OF METHODS

SUMMARY

PRACTICE PROBLEMS

ASSIGNMENT PROBLEMS

PRACTICE PROBLEM SOLUTIONS

20. FUNCTION BLOCK PROGRAMMING

CREATING FUNCTION BLOCKS

DESIGN CASE

SUMMARY

PRACTICE PROBLEMS

ASSIGNMENT PROBLEMS

PRACTICE PROBLEM SOLUTIONS

21. ANALOG INPUTS AND OUTPUTS

ANALOG INPUTS

ANALOG OUTPUTS

CONTROLLOGIX HARDWARE

PLC-5 HARDWARE

DESIGN CASES

SUMMARY

PRACTICE PROBLEMS

ASSIGNMENT PROBLEMS

PRACTICE PROBLEM SOLUTIONS

22. CONTINUOUS SENSORS

INDUSTRIAL SENSORS

INPUT ISSUES

SENSOR GLOSSARY

SUMMARY

PRACTICE PROBLEMS

ASSIGNMENT PROBLEMS

PRACTICE PROBLEM SOLUTIONS

23. CONTINUOUS ACTUATORS

ELECTRIC MOTORS

HYDRAULICS

OTHER SYSTEMS

SUMMARY

PRACTICE PROBLEMS

ASSIGNMENT PROBLEMS

PRACTICE PROBLEM SOLUTIONS

24. CONTINUOUS CONTROL

CONTROL OF LOGICAL ACTUATOR SYSTEMS

CONTROL OF CONTINUOUS ACTUATOR SYSTEMS

DESIGN CASES

SUMMARY

PRACTICE PROBLEMS

ASSIGNMENT PROBLEMS

PRACTICE PROBLEM SOLUTIONS

25. FUZZY LOGIC

COMMERCIAL CONTROLLERS

SUMMARY

ASSIGNMENT PROBLEMS

26. SERIAL COMMUNICATION

SERIAL COMMUNICATIONS

PARALLEL COMMUNICATIONS

DESIGN CASES

SUMMARY

PRACTICE PROBLEMS

ASSIGNMENT PROBLEMS

PRACTICE PROBLEM SOLUTIONS

27. NETWORKING

TOPOLOGY

OSI NETWORK MODEL

NETWORKING HARDWARE

NETWORK CONTROLS

NETWORK STANDARDS

PROPRIETARY NETWORKS

NETWORK COMPARISONS

DESIGN CASES

SUMMARY

PRACTICE PROBLEMS

ASSIGNMENT PROBLEMS

PRACTICE PROBLEM SOLUTIONS

28. HUMAN MACHINE INTERFACES (HMI)

HMI/MMI DESIGN

SUMMARY

29. ELECTRICAL DESIGN AND CONSTRUCTION

ELECTRICAL WIRING DIAGRAMS

FAIL-SAFE DESIGN

SAFETY RULES SUMMARY

SUMMARY

PRACTICE PROBLEMS

ASSIGNMENT PROBLEMS

PRACTICE PROBLEM SOLUTIONS

30. SOFTWARE ENGINEERING

FAIL SAFE DESIGN

DEBUGGING

PROCESS MODELING

PROGRAMMING FOR LARGE SYSTEMS

DOCUMENTATION

COMMISIONING

SAFETY

LEAN MANUFACTURING

SUMMARY

PRACTICE PROBLEMS

ASSIGNMENT PROBLEMS

PRACTICE PROBLEM SOLUTIONS

31. SELECTING A PLC

SPECIAL I/O MODULES

SUMMARY

ASSIGNMENT PROBLEMS

A. PLC REFERENCES

B. COMBINED GLOSSARY OF TERMS

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

S

T

U

V

W

X

Y

Z