Automating Manufacturing Systems with PLCs by Hugh Jack

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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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