Programmable logic controllerWord下载.docx
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Programmable logic controllerWord下载.docx
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powersupply,controller,relayunitsforin-andoutput.ThemaindifferencefromothercomputersisthatPLCsarearmoredforsevereconditions(suchasdust,moisture,heat,cold)andhavethefacilityforextensiveinput/output(I/O)arrangements.TheseconnectthePLCtosensorsandactuators.PLCsreadlimitswitches,analogprocessvariables(suchastemperatureandpressure),andthepositionsofcomplexpositioningsystems.Someusemachinevision.Ontheactuatorside,PLCsoperateelectricmotors,pneumaticorhydrauliccylinders,magneticrelays,solenoids,oranalogoutputs.Theinput/outputarrangementsmaybebuiltintoasimplePLC,orthePLCmayhaveexternalI/OmodulesattachedtoacomputernetworkthatplugsintothePLC.
1.2Systemscale
AsmallPLCwillhaveafixednumberofconnectionsbuiltinforinputsandoutputs.Typically,expansionsareavailableifthebasemodelhasinsufficientI/O.
ModularPLCshaveachassis(alsocalledarack)intowhichareplacedmoduleswithdifferentfunctions.TheprocessorandselectionofI/Omodulesiscustomisedfortheparticularapplication.Severalrackscanbeadministeredbyasingleprocessor,andmayhavethousandsofinputsandoutputs.AspecialhighspeedserialI/Olinkisusedsothatrackscanbedistributedawayfromtheprocessor,reducingthewiringcostsforlargeplants.
1.3Userinterface
PLCsmayneedtointeractwithpeopleforthepurposeofconfiguration,alarmreportingoreverydaycontrol.
AHuman-MachineInterface(HMI)isemployedforthispurpose.HMIsarealsoreferredtoasMMIs(ManMachineInterface)andGUI(GraphicalUserInterface).
Asimplesystemmayusebuttonsandlightstointeractwiththeuser.Textdisplaysareavailableaswellasgraphicaltouchscreens.Morecomplexsystemsuseaprogrammingandmonitoringsoftwareinstalledonacomputer,withthePLCconnectedviaacommunicationinterface.
2Communications
PLCshavebuiltincommunicationsportsusually9-PinRS232,andoptionallyforRS485andEthernet.Modbus,BACnetorDF1isusuallyincludedasoneofthecommunicationsprotocols.Others'
optionsincludevariousfieldbusessuchasDeviceNetorProfibus.OthercommunicationsprotocolsthatmaybeusedarelistedintheListofautomationprotocols.
MostmodernPLCscancommunicateoveranetworktosomeothersystem,suchasacomputerrunningaSCADA(SupervisoryControlAndDataAcquisition)systemorwebbrowser.
PLCsusedinlargerI/Osystemsmayhavepeer-to-peer(P2P)communicationbetweenprocessors.Thisallowsseparatepartsofacomplexprocesstohaveindividualcontrolwhileallowingthesubsystemstoco-ordinateoverthecommunicationlink.ThesecommunicationlinksarealsooftenusedforHMIdevicessuchaskeypadsorPC-typeworkstations.Someoftoday'
sPLCscancommunicateoverawiderangeofmediaincludingRS-485,Coaxial,andevenEthernet.
3PLCcomparedwithothercontrolsystems
PLCsarewell-adaptedtoarangeofautomationtasks.Thesearetypicallyindustrialprocessesinmanufacturingwherethecostofdevelopingandmaintainingtheautomationsystemishighrelativetothetotalcostoftheautomation,andwherechangestothesystemwouldbeexpectedduringitsoperationallife.PLCscontaininputandoutputdevicescompatiblewithindustrialpilotdevicesandcontrols;
littleelectricaldesignisrequired,andthedesignproblemcentersonexpressingthedesiredsequenceofoperationsinladderlogic(orfunctionchart)notation.PLCapplicationsaretypicallyhighlycustomizedsystemssothecostofapackagedPLCislowcomparedtothecostofaspecificcustom-builtcontrollerdesign.Ontheotherhand,inthecaseofmass-producedgoods,customizedcontrolsystemsareeconomicduetothelowercostofthecomponents,whichcanbeoptimallychoseninsteadofa"
generic"
solution,andwherethenon-recurringengineeringchargesarespreadoverthousandsormillionsofunits.
Forhighvolumeorverysimplefixedautomationtasks,differenttechniquesareused.Forexample,aconsumerdishwasherwouldbecontrolledbyanelectromechanicalcamtimercostingonlyafewdollarsinproductionquantities.
Amicrocontroller-baseddesignwouldbeappropriatewherehundredsorthousandsofunitswillbeproducedandsothedevelopmentcost(designofpowersuppliesandinput/outputhardware)canbespreadovermanysales,andwheretheend-userwouldnotneedtoalterthecontrol.Automotiveapplicationsareanexample;
millionsofunitsarebuilteachyear,andveryfewend-usersaltertheprogrammingofthesecontrollers.However,somespecialtyvehiclessuchastransitbusseseconomicallyusePLCsinsteadofcustom-designedcontrols,becausethevolumesarelowandthedevelopmentcostwouldbeuneconomic.
Verycomplexprocesscontrol,suchasusedinthechemicalindustry,mayrequirealgorithmsandperformancebeyondthecapabilityofevenhigh-performancePLCs.Veryhigh-speedorprecisioncontrolsmayalsorequirecustomizedsolutions;
forexample,aircraftflightcontrols.
Programmablecontrollersarewidelyusedinmotioncontrol,positioningcontrolandtorquecontrol.SomemanufacturersproducemotioncontrolunitstobeintegratedwithPLCsothatG-code(involvingaCNCmachine)canbeusedtoinstructmachinemovements.
PLCsmayincludelogicforsingle-variablefeedbackanalogcontrolloop,a"
proportional,integral,derivative"
or"
PIDcontroller."
APIDloopcouldbeusedtocontrolthetemperatureofamanufacturingprocess,forexample.HistoricallyPLCswereusuallyconfiguredwithonlyafewanalogcontrolloops;
whereprocessesrequiredhundredsorthousandsofloops,adistributedcontrolsystem(DCS)wouldinsteadbeused.AsPLCshavebecomemorepowerful,theboundarybetweenDCSandPLCapplicationshasbecomelessdistinct.
PLCshavesimilarfunctionalityasRemoteTerminalUnits.AnRTU,however,usuallydoesnotsupportcontrolalgorithmsorcontrolloops.Ashardwarerapidlybecomesmorepowerfulandcheaper,RTUs,PLCsandDCSsareincreasinglybeginningtooverlapinresponsibilities,andmanyvendorssellRTUswithPLC-likefeaturesandviceversa.TheindustryhasstandardizedontheIEC61131-3functionalblocklanguageforcreatingprogramstorunonRTUsandPLCs,althoughnearlyallvendorsalsoofferproprietaryalternativesandassociateddevelopmentenvironments.
4Digitalandanalogsignals
Digitalordiscretesignalsbehaveasbinaryswitches,yieldingsimplyanOnorOffsignal(1or0,TrueorFalse,respectively).Pushbuttons,limitswitches,andphotoelectricsensorsareexamplesofdevicesprovidingadiscretesignal.Discretesignalsaresentusingeithervoltageorcurrent,whereaspecificrangeisdesignatedasOnandanotherasOff.Forexample,aPLCmightuse24VDCI/O,withvaluesabove22VDCrepresentingOn,valuesbelow2VDCrepresentingOff,andintermediatevaluesundefined.Initially,PLCshadonlydiscreteI/O.
Analogsignalsarelikevolumecontrols,witharangeofvaluesbetweenzeroandfull-scale.Thesearetypicallyinterpretedasintegervalues(counts)bythePLC,withvariousrangesofaccuracydependingonthedeviceandthenumberofbitsavailabletostorethedata.AsPLCstypicallyuse16-bitsignedbinaryprocessors,theintegervaluesarelimitedbetween-32,768and+32,767.Pressure,temperature,flow,andweightareoftenrepresentedbyanalogsignals.Analogsignalscanusevoltageorcurrentwithamagnitudeproportionaltothevalueoftheprocesssignal.Forexample,ananalog4-20mAor0-10
Vinputwouldbeconvertedintoanintegervalueof0-32767.
Currentinputsarelesssensitivetoelectricalnoise(i.e.fromweldersorelectricmotorstarts)thanvoltageinputs.
5Example
Asanexample,sayafacilityneedstostorewaterinatank.Thewaterisdrawnfromthetankbyanothersystem,asneeded,andourexamplesystemmustmanagethewaterlevelinthetank.
Usingonlydigitalsignals,thePLChastwodigitalinputsfromfloatswitches(LowLevelandHighLevel).Whenthewaterlevelisabovetheswitchitclosesacontactandpassesasignaltoaninput.ThePLCusesadigitaloutputtoopenandclosetheinletvalveintothetank.
WhenthewaterleveldropsenoughsothattheLowLevelfloatswitchisoff(down),thePLCwillopenthevalvetoletmorewaterin.OncethewaterlevelrisesenoughsothattheHighLevelswitchison(up),thePLCwillshuttheinlettostopthewaterfromoverflowing.Thisrungisanexampleofsealinlogic.Theoutputissealedinuntilsomeconditionbreaksthecircuit.
||
|LowLevelHighLevelFillValve|
|------[/]------|------[/]----------------------(OUT)---------|
|||
|FillValve||
|------[]------||
Ananalogsystemmightuseawaterpressuresensororaloadcell,andanadjustable(th
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