Automating Manufacturing Systems with PLCs by Hugh Jack
Contents of Automating Manufacturing Systems
- PROGRAMMABLE LOGIC CONTROLLERS
- INTRODUCTION
- Ladder Logic
- Programming
- PLC Connections
- Ladder Logic Inputs
- Ladder Logic Outputs
- A CASE STUDY
- SUMMARY
- PRACTICE PROBLEMS
- PRACTICE PROBLEM SOLUTIONS
- ASSIGNMENT PROBLEMS
- PLC HARDWARE
- INTRODUCTION
- INPUTS AND OUTPUTS
- Inputs
- Output Modules
- RELAYS
- A CASE STUDY
- ELECTRICAL WIRING DIAGRAMS
- JIC Wiring Symbols
- SUMMARY
- PRACTICE PROBLEMS
- PRACTICE PROBLEM SOLUTIONS
- ASSIGNMENT PROBLEMS
- LOGICAL SENSORS
- INTRODUCTION
- SENSOR WIRING
- Switches
- Transistor Transistor Logic (TTL)
- Sinking/Sourcing
- Solid State Relays
- PRESENCE DETECTION
- Contact Switches
- Reed Switches
- Optical (Photoelectric) Sensors
- Capacitive Sensors
- Inductive Sensors
- Ultrasonic
- Hall Effect
- Fluid Flow
- SUMMARY
- PRACTICE PROBLEMS
- PRACTICE PROBLEM SOLUTIONS
- ASSIGNMENT PROBLEMS
- LOGICAL ACTUATORS
- INTRODUCTION
- SOLENOIDS
- VALVES
- CYLINDERS
- HYDRAULICS
- PNEUMATICS
- MOTORS
- OTHERS
- SUMMARY
- PRACTICE PROBLEMS
- PRACTICE PROBLEM SOLUTIONS
- ASSIGNMENT PROBLEMS
- BOOLEAN LOGIC DESIGN
- INTRODUCTION
- BOOLEAN ALGEBRA
- LOGIC DESIGN
- Boolean Algebra Techniques
- COMMON LOGIC FORMS
- Complex Gate Forms
- Multiplexers
- SIMPLE DESIGN CASES
- Basic Logic Functions
- Car Safety System
- Motor Forward/Reverse
- A Burglar Alarm
- SUMMARY
- PRACTICE PROBLEMS
- PRACTICE PROBLEM SOLUTIONS
- ASSIGNMENT PROBLEMS
- KARNAUGH MAPS
- INTRODUCTION
- SUMMARY
- PRACTICE PROBLEMS
- PRACTICE PROBLEM SOLUTIONS
- ASSIGNMENT PROBLEMS
- PLC OPERATION
- INTRODUCTION
- OPERATION SEQUENCE
- The Input and Output Scans
- The Logic Scan
- PLC STATUS
- MEMORY TYPES
- SOFTWARE BASED PLCS
- SUMMARY
- PRACTICE PROBLEMS
- PRACTICE PROBLEM SOLUTIONS
- ASSIGNMENT PROBLEMS
- LATCHES, TIMERS, COUNTERS AND MORE
- INTRODUCTION
- LATCHES
- TIMERS
- COUNTERS
- MASTER CONTROL RELAYS (MCRs)
- INTERNAL BITS
- DESIGN CASES
- Basic Counters And Timers
- More Timers And Counters
- Deadman Switch
- Conveyor
- Accept/Reject Sorting
- Shear Press
- SUMMARY
- PRACTICE PROBLEMS
- PRACTICE PROBLEM SOLUTIONS
- ASSIGNMENT PROBLEMS
- STRUCTURED LOGIC DESIGN
- INTRODUCTION
- PROCESS SEQUENCE BITS
- TIMING DIAGRAMS
- DESIGN CASES
- SUMMARY
- PRACTICE PROBLEMS
- PRACTICE PROBLEM SOLUTIONS
- ASSIGNMENT PROBLEMS
- FLOWCHART BASED DESIGN
- INTRODUCTION
- BLOCK LOGIC
- SEQUENCE BITS
- SUMMARY
- PRACTICE PROBLEMS
- PRACTICE PROBLEM SOLUTIONS
- ASSIGNMENT PROBLEMS
- STATE BASED DESIGN
- INTRODUCTION
- State Diagram Example
- Conversion to Ladder Logic
- Block Logic Conversion
- State Equations
- State-Transition Equations
- SUMMARY
- PRACTICE PROBLEMS
- PRACTICE PROBLEM SOLUTIONS
- ASSIGNMENT PROBLEMS
- NUMBERS AND DATA
- INTRODUCTION
- NUMERICAL VALUES
- Binary
- Boolean Operations
- Binary Mathematics
- Other Base Number Systems
- BCD (Binary Coded Decimal)
- DATA CHARACTERIZATION
- ASCII (American Standard Code for Information Interchange)
- Parity
- Checksums
- Gray Code
- SUMMARY
- PRACTICE PROBLEMS
- PRACTICE PROBLEM SOLUTIONS
- ASSIGNMENT PROBLEMS
- PLC MEMORY
- INTRODUCTION
- PROGRAM VS VARIABLE MEMORY
- PROGRAMS
- VARIABLES (TAGS)
- Timer and Counter Memory
- PLC Status Bits
- User Function Control Memory
- SUMMARY
- PRACTICE PROBLEMS
- PRACTICE PROBLEM SOLUTIONS
- ASSIGNMENT PROBLEMS
- LADDER LOGIC FUNCTIONS
- INTRODUCTION
- DATA HANDLING
- Move Functions
- Mathematical Functions
- Conversions
- Array Data Functions
- Statistics
- Block Operations
- LOGICAL FUNCTIONS
- Comparison of Values
- Boolean Functions
- DESIGN CASES
- Simple Calculation
- For-Next
- Series Calculation
- Flashing Lights
- SUMMARY
- PRACTICE PROBLEMS
- PRACTICE PROBLEM SOLUTIONS
- ASSIGNMENT PROBLEMS
- ADVANCED LADDER LOGIC FUNCTIONS
- INTRODUCTION
- LIST FUNCTIONS
- Shift Registers
- Stacks
- Sequencers
- PROGRAM CONTROL
- Branching and Looping
- Fault Handling
- Interrupts
- INPUT AND OUTPUT FUNCTIONS
- Immediate I/O Instructions
- DESIGN TECHNIQUES
- State Diagrams
- DESIGN CASES
- If-Then
- Traffic Light
- SUMMARY
- PRACTICE PROBLEMS
- PRACTICE PROBLEM SOLUTIONS
- ASSIGNMENT PROBLEMS
- OPEN CONTROLLERS
- INTRODUCTION
- IEC
- OPEN ARCHITECTURE CONTROLLERS
- SUMMARY
- PRACTICE PROBLEMS
- PRACTICE PROBLEM SOLUTIONS
- ASSIGNMENT PROBLEMS
- INSTRUCTION LIST PROGRAMMING
- INTRODUCTION
- THE IEC VERSION
- THE ALLEN-BRADLEY VERSION
- SUMMARY
- PRACTICE PROBLEMS
- PRACTICE PROBLEM SOLUTIONS
- ASSIGNMENT PROBLEMS
- STRUCTURED TEXT PROGRAMMING
- INTRODUCTION
- THE LANGUAGE
- Elements of the Language
- Putting Things Together in a Program
- AN EXAMPLE
- SUMMARY
- PRACTICE PROBLEMS
- PRACTICE PROBLEM SOLUTIONS
- ASSIGNMENT PROBLEMS
- SEQUENTIAL FUNCTION CHARTS
- INTRODUCTION
- A COMPARISON OF METHODS
- SUMMARY
- PRACTICE PROBLEMS
- PRACTICE PROBLEM SOLUTIONS
- ASSIGNMENT PROBLEMS
- FUNCTION BLOCK PROGRAMMING
- INTRODUCTION
- CREATING FUNCTION BLOCKS
- DESIGN CASE
- SUMMARY
- PRACTICE PROBLEMS
- PRACTICE PROBLEM SOLUTIONS
- ASSIGNMENT PROBLEMS
- ANALOG INPUTS AND OUTPUTS
- INTRODUCTION
- ANALOG INPUTS
- Analog Inputs With a PLC-
- ANALOG OUTPUTS
- Analog Outputs With A PLC-
- Pulse Width Modulation (PWM) Outputs
- Shielding
- DESIGN CASES
- Process Monitor
- SUMMARY
- PRACTICE PROBLEMS
- PRACTICE PROBLEM SOLUTIONS
- ASSIGNMENT PROBLEMS
- CONTINUOUS SENSORS
- INTRODUCTION
- INDUSTRIAL SENSORS
- Angular Displacement
- Potentiometers
- Encoders
- Tachometers
- Linear Position
- Potentiometers
- Linear Variable Differential Transformers (LVDT)
- Moire Fringes
- Accelerometers
- Forces and Moments
- Strain Gages
- Piezoelectric
- Liquids and Gases
- Pressure
- Venturi Valves
- Coriolis Flow Meter
- Magnetic Flow Meter
- Ultrasonic Flow Meter
- Vortex Flow Meter
- Positive Displacement Meters
- Pitot Tubes
- Temperature
- Resistive Temperature Detectors (RTDs)
- Thermocouples
- Thermistors
- Other Sensors
- Light
- Light Dependant Resistors (LDR)
- Chemical
- pH
- Conductivity
- Others
- INPUT ISSUES
- SENSOR GLOSSARY
- SUMMARY
- REFERENCES
- PRACTICE PROBLEMS
- PRACTICE PROBLEM SOLUTIONS
- ASSIGNMENT PROBLEMS
- CONTINUOUS ACTUATORS
- INTRODUCTION
- ELECTRIC MOTORS
- Basic Brushed DC Motors
- AC Motors
- Brushless DC Motors
- Stepper Motors
- Wound Field Motors
- HYDRAULICS
- OTHER SYSTEMS
- SUMMARY
- PRACTICE PROBLEMS
- PRACTICE PROBLEM SOLUTIONS
- ASSIGNMENT PROBLEMS
- CONTINUOUS CONTROL
- INTRODUCTION
- CONTROL OF LOGICAL ACTUATOR SYSTEMS
- CONTROL OF CONTINUOUS ACTUATOR SYSTEMS
- Block Diagrams
- Feedback Control Systems
- Proportional Controllers
- PID Control Systems
- DESIGN CASES
- Oven Temperature Control
- Water Tank Level Control
- Position Measurement
- SUMMARY
- PRACTICE PROBLEMS
- PRACTICE PROBLEM SOLUTIONS
- ASSIGNMENT PROBLEMS
- FUZZY LOGIC
- INTRODUCTION
- COMMERCIAL CONTROLLERS
- REFERENCES
- SUMMARY
- PRACTICE PROBLEMS
- PRACTICE PROBLEM SOLUTIONS
- ASSIGNMENT PROBLEMS
- SERIAL COMMUNICATION
- INTRODUCTION
- SERIAL COMMUNICATIONS
- RS-
- ASCII Functions
- PARALLEL COMMUNICATIONS
- DESIGN CASES
- PLC Interface To a Robot
- SUMMARY
- PRACTICE PROBLEMS
- PRACTICE PROBLEM SOLUTIONS
- ASSIGNMENT PROBLEMS
- NETWORKING
- INTRODUCTION
- Topology
- OSI Network Model
- Networking Hardware
- Control Network Issues
- NETWORK STANDARDS
- PROPRIETARY NETWORKS
- Data Highway
- NETWORK COMPARISONS
- DESIGN CASES
- Devicenet
- SUMMARY
- PRACTICE PROBLEMS
- PRACTICE PROBLEM SOLUTIONS
- ASSIGNMENT PROBLEMS
- INTERNET
- INTRODUCTION
- Computer Addresses
- IPV
- Phone Lines
- Mail Transfer Protocols
- FTP – File Transfer Protocol
- HTTP – Hypertext Transfer Protocol
- Novell
- Security
- Firewall
- IP Masquerading
- HTML – Hyper Text Markup Language
- URLs
- Encryption
- Compression
- Clients and Servers
- Java
- Javascript
- CGI
- ActiveX
- Graphics
- DESIGN CASES
- Remote Monitoring System
- SUMMARY
- PRACTICE PROBLEMS
- PRACTICE PROBLEM SOLUTIONS
- ASSIGNMENT PROBLEMS
- HUMAN MACHINE INTERFACES (HMI)
- INTRODUCTION
- HMI/MMI DESIGN
- DESIGN CASES
- SUMMARY
- PRACTICE PROBLEMS
- PRACTICE PROBLEM SOLUTIONS
- ASSIGNMENT PROBLEMS
- ELECTRICAL DESIGN AND CONSTRUCTION
- INTRODUCTION
- ELECTRICAL WIRING DIAGRAMS
- Selecting Voltages
- Grounding
- Wiring
- Suppressors
- PLC Enclosures
- Wire and Cable Grouping
- FAIL-SAFE DESIGN
- SAFETY RULES SUMMARY
- REFERENCES
- SUMMARY
- PRACTICE PROBLEMS
- PRACTICE PROBLEM SOLUTIONS
- ASSIGNMENT PROBLEMS
- SOFTWARE ENGINEERING
- INTRODUCTION
- Fail Safe Design
- DEBUGGING
- Troubleshooting
- Forcing
- PROCESS MODELLING
- PROGRAMMING FOR LARGE SYSTEMS
- Developing a Program Structure
- Program Verification and Simulation
- DOCUMENTATION
- COMMISIONING
- SAFETY
- IEC / safety standards
- LEAN MANUFACTURING
- REFERENCES
- SUMMARY
- PRACTICE PROBLEMS
- PRACTICE PROBLEM SOLUTIONS
- ASSIGNMENT PROBLEMS
- SELECTING A PLC
- INTRODUCTION
- SPECIAL I/O MODULES
- SUMMARY
- PRACTICE PROBLEMS
- PRACTICE PROBLEM SOLUTIONS
- ASSIGNMENT PROBLEMS
- FUNCTION REFERENCE
- FUNCTION DESCRIPTIONS
- General Functions
- Program Control
- Timers and Counters
- Compare
- Calculation and Conversion
- Logical
- Move
- File
- List
- Program Control
- Advanced Input/Output
- String
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