You are on page 1of 109

Handling Machining Assembly Control

M M M

Pneumatics Electronics Mechanics Sensorics Software

Plagemann IPC recipe book

Chinese English French German Russian Spanish Blue Digest on Automation


053 627

Plagemann IPC recipe book

Control Electronics

Plagemann

IPC recipe book

Blue Digest on Automation

Blue Digest on Automation 2004 by Festo AG & Co. Ruiter Strasse 82 D-73734 Esslingen Federal Republic of Germany Tel. (0711) 347-0 Fax. (0711) 347-2155 All texts, representations, illustrations and drawings included in this book are the intellectual property of Festo AG & Co., and are protected by copyright law. All rights reserved, including translation rights. No part of this publication may be reproduced or transmitted in any form or by any means, electronic, mechanical, photocopying or otherwise, without the prior written permission of Festo AG & Co.

Preface

A few years ago it was still a topic of discussion as to whether industrial PCs and programmable logic controllers were in competition with each other or were complementary. Today, both systems have their place and are used as a matter of course. The focus of discussion and development has now shifted towards network technology instead. Decentralized automation technology is once again the hot topic in automation. The Ethernet network an age-old fixture in the PC world but entirely new in the field of automation has made decentralized automation manageable. The use of fieldbusses for decentralizing the input/output level has led to experts in automation technology becoming familiar with the terminology and techniques of networking and serial data transmission. This knowledge is now being combined with the experience of the network engineers. As a result, integrating automation technology into the networks used in manufacturing and administration is at last becoming so easy that the technology can be put to widespread use. For almost two decades now, Beck IPC GmbH, a subsidiary of Festo AG & Co, has been developing industrial control technology based on PC technology. In order to make the grade, every new development has had to meet certain requirements. Each one must be: _ _ _ _ _ small and maintenance-free, to allow smaller control cabinets to be used PC-based, to enable users to respond flexibly to widely differing demands modular and/or part of a complete family of hardware and software programmable as a PC or a PLC network-capable with Ethernet

This book describes examples of applications using the controllers from Beck and Festo. We trust you enjoy browsing and reading through the book, and hope that the descriptions might give you some ideas for new solutions of your own. Wetzlar, October 15, 2000 Bernhard Plagemann b.plagemann@beck-ipc.com http://www.beck-ipc.com http://www.festo.com

Preface..............................................................................................................................5 Contents Control and handling technology ..............................................................................9 The Boxer opens cardboard boxes..................................................................................10 From a handling device to a gateway..............................................................................12 Fully automatic welding in giant containers....................................................................14 Feeding, checking and sorting small parts with the Checkbox ......................................16 Making beautiful clothes in Denmark ..............................................................................18 Storing grain .....................................................................................................................20 Controlling mobile road tarring machines ........................................................................21 Sending electronic devices from the clean room for testing ...........................................22 Manufacture of MKP-SI capacitors ..................................................................................24 Production of spray cans .................................................................................................26 Sawing up thick tree trunks..............................................................................................28 Controlling at random .......................................................................................................30 Excursion: Programming with FST...............................................................................32 Networking and remote maintenance ......................................................................35 Pad printing on a network................................................................................................36 Securing pedestrian precincts .........................................................................................38 Recording process data and arranging for essential repairs ...........................................40 Data backup on the network.............................................................................................42 Modernisation of a high-bay warehouse ..........................................................................44 Calling the emergency repair service ..............................................................................45 Calling the machine .........................................................................................................46 Control and operation via the Internet ..............................................................................47 Excursion: Programming in line with IEC 6 1131-3 with MULTIPROG........................48 Measurement technology, data processing and quality assurance..................51 Collecting and processing environmental data ...............................................................52 Observation of historical buildings and structures..........................................................54 Compressed-air filling station for tyres ............................................................................56 Automated soil examination ............................................................................................57 Testing Tipptronic system modules................................................................................58 Testing Checkbox modules.............................................................................................60 Monitoring welding data ...................................................................................................62 Optimisation of a gas-fired power station ........................................................................63 Quality assurance in cylinder manufacture.....................................................................64 Acquisition of measured data and controlling an aerial in a measuring balloon.....................................................................................................65 Examination of rubber compounds ..................................................................................66 Testing CAN valves.........................................................................................................68 Measuring soot content in the air.....................................................................................70 Monitoring a radio station's high-frequency band ............................................................71 Excursion: Programming in C/C++................................................................................72

Process control systems, lab. technology and hydr. engineering...................73 Water treatment ................................................................................................................74 Ensuring cleanliness in cheese production ....................................................................79 Statistical process control in the manufacture of thermocylinders .................................80 Data acquisition in sewage treatment plants...................................................................81 Controlling a biological trickling filter scrubber ...............................................................82 Determining the cell state of microorganisms ................................................................84 Filling up with liquefied natural gas.................................................................................86 Providing for clean water..................................................................................................88 Edutainment and simulation.......................................................................................91 Discoveries on the high seas ..........................................................................................92 Keepers in the wild...........................................................................................................94 Learning to use modern automation technology..............................................................95 Applications with the IPC@CHIP ................................................................................97 Ethernet - CAN gateway ...................................................................................................98 Controlling with the IPC@CHIP........................................................................................99 Learning with the IPC@CHIP .........................................................................................100 Monitoring with the IPC@CHIP ......................................................................................101 Excursion: Hardware ...................................................................................................102 Index..............................................................................................................................105

Control and handling technology

It is certainly a pleasure to fold open a cardboard box and lovingly to pack it with carefully chosen Christmas presents for someone close to your heart. It is hard, tiring work to open not one cardboard box but several hundred a day so that they can be filled with goods. This is where a combination of mechanical systems and control technology is called for. This is where pneumatic components are used for the drive units, in conjunction with small, fastacting controllers.

Starting from "little" tasks such as these right through to assembly stations, they are still out there today: systems and installations which need control technology, using Boolean algebra, AND and OR, steps for organising the working sequence all this helps get the job done. Even if public discussion tends more to focus on the networks, the operating philosophy and many other things, there are still millions of relays switching motors on and off, and millions of valves letting cylinders travel back and forth. The modular system of the IPC PS1 with its multiplicity of different input and output modules and the modules for controlling stepping motors, servoelectric and servopneumatic axes is ideally suited to mastering these tasks. And the mini controllers of the Front End Controller family feel most at home in small-scale applications, where there is always call for fast and flexible automation technology that boosts productivity. In this section you will find a number of examples in which the main focus is on control technology. Enjoy your read.

Control and handling technology

The Boxer opens cardboard boxes

As explained in the introduction to this section, folding open hundreds of cardboard boxes is laborious and tedious work. All the same, every day more and more boxes have to be opened, taped, filled, closed, addressed Mail-order business is growing and every time an order is placed, a new box is needed. Automating a task like this calls for a great deal of know-how. Because although cardboard boxes are sturdy, they are certainly not stiff. The box gives way, moves, is never precisely the same size, and appears in an infinite number of variants. With the aid of a sophisticated mechanical system in conjunction with pneumatic drives and vacuum suction devices, boxes of different sizes and different strengths can be opened and set up automatically, and the base taped ready for the box to be filled. The Boxer from the Rembrandt Packaging company in Holland is one such device that assembles not just one but hundreds of cardboard boxes a day, and also tapes up the base. The boxes can then be filled, sealed and dispatched. As easy as it may sound to "open a cardboard box", the solution is equally elaborate and complex. This is because a system has to be constructed that is very costeffective (cardboard boxes should of course cost nothing they are "only" the packaging) yet at the same time highly flexible. Depending on the products being packed, the boxes have to be larger or smaller, thicker or thinner walled, stiffer or more pliable. Not only that, no-one really has space for a Boxer, so the machine must be compact and offer very flexible installation options for operation from the left or the right, or any other variant you care to think of. Rembrandt has therefore constructed the Boxer from individual modules which can be assembled to suit the customer's specific requirements.

Cooperation between Festo and Rembrandt has helped to make the Boxer flexible and fast in production. Festo in Holland manufactures the entire control cabinet with the

10

Control and handling technology

controller, valve terminals and all connecting cables and connection tubes. The cables and tubes are supplied by Festo ready cut to the correct length. The controller is fully programmed and tested. When the control cabinet is delivered, the assembly team at Rembrandt needs just another two hours to place the Boxer at the company's disposal, ready installed and tested. The only thing that is faster is assembling the cardboard boxes with the Boxer ... Hardware Software IPC FEC FC20 Mini controller with flash memory for the application. FST With FST a system of this type can be programmed in double-quick time, because the process being controlled is a sequence of movements which are ideal for programming with the STEP command in FST.

Keywords

Packaging technology, cardboard box, sequence control

Control and handling technology

11

From a handling device to a gateway

Handling devices, being special-purpose robots, are always tied to a particular type of machine. Nevertheless, they must be designed in such a way that they can be adapted to a range of different machine variants. As far as controlling a handling device is concerned, this means that for example the stroke lengths, slewing angles of the shafts and interlocking times have to be adjustable. Simple handling devices have often developed into complex process interfaces or gateways, which in addition to their handling functions also have roles to play in production data acquisition and networking. This is an area where using an industrial PC is very much the obvious choice. A major German manufacturer of handling devices for injection moulding machines was also faced with this task, because the family of devices covers precisely this range from simple gantry robots to process interfaces. The company decided to go for the PS1 system across the board. Not only does this make stockkeeping easier, it also means that staff training can be limited to one type of control electronics. One reason why this decision also has a positive effect on development times is that the system is very simple to program, like a PLC. This can be illustrated using the example of a sprue removal device.

Sprue removal device

The device can be mounted on any injection moulding machine. After the injection process, the device takes hold of the sprue part in the area of the opened mould and transfers it to a container. The injection moulded part itself is separated automatically from the sprue and drops into a different container. Within the production process, the removal operation not only represents an unproductive length of time, it is also linked to energy loss, because the open mould quickly cools down. The shorter the time taken for removal, the lower the energy loss and the more productive the plant is in operation. The electronics hardware can meet this requirement without any difficulty. The challenge in this case is for the pneumatic components. But the control program,

12

Control and handling technology

too, has to take account of this. It must not be permitted to operate with generously dimensioned waiting times. The key components of the handling system are the following: _ The x-axis, which runs parallel to the ejector on the injection moulding machine. It is implemented with two short-stroke pneumatic cylinders which allow a maximum travel of 50 mm. _ The y-axis is arranged perpendicular to the ejection system; a pneumatic linear drive with a maximum stroke of 500 mm was used for this. The z-axis is in the form of a rotation axis with a slewing angle of 90. The gripping tool is a pair of tongs mounted on one end of the y-axis cylinder. All of the axis cylinders and the tongs are driven via 5/2-way valves. The requirements that need to be met by the control system of an arrangement of this nature are satisfied by the PS1 system in the best possible way. All control tasks can be mastered with the central processing unit and the digital input/output options. As well as this, the IPC fits into the gap in the switchbox which all of the other components leave free. Program language One fundamental prerequisite for the choice of hardware was simple programmability. The FST software makes the programming of step-by-step sequences easier thanks to the STEP operation and the ability to easily administer up to 64 different programs/tasks. The control program is modular and therefore its structure means it is easy to maintain. The plant functions are implemented in two modules: the key interrogation part establishes the connection to the operating personnel, while control of the handling components is dealt with in the main program. The FST programming software supports step control in that the steps are managed by the system and the programmer is relieved of the task of setting up a step variable and interrogating it. BP11 HC16-F IM10 OM10 3-slot busboard PC/CHIP CPU with FST kernel 16-bit digital input module 16-bit digital output module

Hardware

Of the 16 digital output signals which the OM10 module makes available, 4 are used to send commands to the injection moulding machine (ejector, mould closure and core puller). Keywords Handling system, injection moulding, step programming, positioning

Control and handling technology

13

Fully automatic welding in giant containers

Huge storage containers are used for storing foodstuffs, grain, chemicals, viscose in fact raw materials of a great variety of types. That is nothing unusual. But the larger these containers are, the more expensive and difficult they are to build and, later, to repair or replace as necessary. And it is here, in the repair or complete overhaul of such containers, that the Swedish company Uddcomb comes into its own. They have developed a procedure by means of which existing containers which have become brittle or have developed a leak are lined from the inside with a new steel container. This sounds very simple, because it is a kind of pot in a pot. Actually carrying this out, though, is not so easy, because the new internal container cannot simply be inserted inside the old one. No, it has to be welded together from individual metal plates inside the container. This is the only way of ensuring that the new internal container is precisely matched to the existing container.

In principle, the yards and yards of seams can also be welded by hand, but in most cases this would make complete renewal uneconomic. Uddcomb has developed a welding machine which automatically moves along the welds inside the container in a suspended position. The welding machine is moved with the aid of stepping motors, and the welding current is used as a measure of the correct distance for the welding wire. The control system needed for such an unusual welding machine has to be extremely flexible. As well as this it should be small, because the entire system is forever having to be transported from place to place. The containers that need to be repaired do not come to Uddcomb, instead the refurbishment team always has to travel to wherever

14

Control and handling technology

there is another container waiting for a new interior lining. Being constantly on the road is not the normal operational situation for a machine control system. With the IPC PS1, this works. Hardware BP50 HC16-F 2 x AM11 IO10 OM21 5-slot busboard with power supply PC/CHIP CPU, EPROM, RAM, flash Stepping motor module 8 x analog input module Digital input/output module each 8-bit

Software

FST was chosen as the programming language; it is simple and quickly adaptable, supports the positioning task and is very well known to the people putting the project into practice. Welding, stepping motor, positioning, mobile application

Keywords

Control and handling technology

15

Feeding, checking and sorting small parts with the Checkbox

Feeding small parts such as screws, rings, springs, perfume bottles, nuts, toothbrush heads and a myriad of other parts in the proper orientation is an age-old problem in automated production. There are countless applications that use shaker conveyors, which have all sorts of elaborate mechanical "chicanery" to make sure that the parts are always fed in precisely the orientation required by the next stage of production. The Checkbox takes a new approach. In this case, no mechanical obstacles are used but instead a camera is used to check the orientation. In a teach-in process, the control system is taught what the "correct" part should look like. The computer compares the captured image with the stored image and issues a command to blow out or eject those parts that are not positioned correctly.

The particular advantage of this method is that the Checkbox is highly flexible in use. The teach-in process takes a matter of a few minutes. The correctly oriented part has to be passed beneath the camera several times, the computer saves the image that's all. In contrast, setting up a mechanical obstacle course can be a matter of hours or sometimes even days. The second advantage of the Checkbox is that not only can the parts be checked that they are fed in the proper orientation, they can also be examined for entirely different properties, such as their shape, colour, material etc. In this way, the Checkbox can also be used for sorting, not only feeding.

16

Control and handling technology

The centrepiece of the Checkbox is the camera and its associated image processor. The image processor has been developed by the Checkbox team, and in technical terms is quite a gem. This is because with the Checkbox, as is always the case in automated production, what matters is speed: thousands of parts per minute are supposed to pass through the system. This is only possible if the CPU is designed exclusively for the purpose of image processing (image capture, image comparison) and the response to evaluation of the image. The Checkbox team used the IPC PS1 Professional as the basis for its design. The busboard and the input/output modules are original PS1 components, while the CPU is a Checkbox development. Hardware Example configuration BP50 5-slot busboard with power supply OM21 Input/output module each 8-bit Checkbox image processor C/C++ is the right programming language for a task such as this. Image processing, shaker, Checkbox

Software Keywords

Control and handling technology

17

Making beautiful clothes in Denmark

Brandtex A/S was founded in Denmark in 1935, and is today one of the largest textile companies in Scandinavia. The various subsidiaries of the Brandtex group produce all types of textiles, ranging from children's clothes, jeans, young fashion and swimwear to knitwear and men's wear and ladies' wear. Around 2,000 staff are employed around the world in the design, production and sale of textiles. Particularly in the textile sector, international competition is extremely tough. For a company based in Europe, impeccable automation technology is vitally necessary in order to be able to sell textiles in accordance with market conditions: in this case this means on the one hand offering value for money, but much more than this, being flexible. Setting fashion trends means offering high-quality designs and converting them very quickly into real products. Following fashion trends means converting the standards set by fashion into products in double-quick time. It is at this interface between fashion and automation technology that Brandtex and Festo come together. Recently Brandtex began operation with a new generation of automatic sewing machines, for sewing trousers and skirts. The installation is controlled by an IPC PS1. Of course it is not a problem to build automatic sewing machines. These are available in a great variety of designs and versions. As far as Brandtex was concerned, it was not simply a matter of a sewing machine but rather of high performance in conjunction with low investment optimised for the task in hand. The control system to be used as well as the chosen pneumatics therefore also had to be subjected to the dictates of rigorous cost control. A number of components played their part in keeping the costs of the sewing machine down. Firstly there is the activation of the positioning system required for the sewing process. The power section for a stepping motor is activated directly from the inputs/outputs of the CPU. All of the parameters for the stepping motor, such as the position, speed, starting ramp and brake ramp etc., are entered in a module in the FST software. The outputs specify the frequency and direction for the stepping motor directly. The inputs read directly from the sensors on the shaft. There is no need for a separate stepping motor controller. Then there is the CPU and the entire IPC PS1 system. The HC01 CPU is specifically designed for small- to medium-sized autonomous plants, and in terms of its price fits very well into a project as critical as this. Thirdly there is the programming software that is used. With the FST software, the programming process is adapted to the way that the engineers think.

18

Control and handling technology

Fourthly we come to the Festo valve terminals used in this system, which enable the pneumatic power section to be activated quickly and easily, and are also extremely compact. One particularly important factor regarding the use of an automatic sewing machine is also that the operating personnel do not usually have much idea of electronics or computers. The necessary operator actions must therefore be kept simple, clear and uncomplicated. At Brandtex they use an EXOR terminal for the purpose of operator control. This terminal is itself equipped with a computer, so it can access the control system independently. Clear and uncluttered software allows the data and communication rules to be entered in the simplest possible way.

Hardware

BP31 PS10 HC01 2 x IM11 2 x OM11

8-slot busboard Power supply unit CPU with 8 bidirectional I/Os 16-bit digital inputs 16-bit digital outputs

Keywords

HC01, positioning, stepping motor, EXOR display, valve terminals, FST, textile industry

Control and handling technology

19

Storing grain

When Grandmother tells stories of how the barley used to be harvested and stored, old memories are aroused and a picture is painted of manual farming in a natural idyll. When the grain harvested today's agricultural reality is put in central storage in order to be able to supply a major city with flour for an entire year, what is needed are huge silos which can be filled and emptied fully automatically. In Australia there is an industrial park comprising silos, conveyor belts, grain hoists and access roads for the trucks bringing or fetching the grain. The system includes a total of 16 silos, two hoists and 6 conveyor belts, and depending on requirements it has to be persuaded to put grain in storage, release it from stock, relocate the valuable goods within the system or carry out a number of similar tasks. Festo Australia has used an IPC PS1 Professional for this purpose, which can be operated in its entirety from two locations with the aid of EXOR ECT touch panels. On either of these two panels the operator can enter whether grain is to be stored, relocated or released, and from where to where this is to be done. The precise route through the labyrinth of conveyors and containers is found by the control system itself. Two jobs can be processed simultaneously, so it is impossible for the two operators working at the panels to get in each other's way. On its route through the containers, the grain is steered with pneumatic cylinders which report back their position to the control system with the aid of an integrated displacement measurement facility. The speed with which the grain flows is controlled by the opening angle of the gates. The valves for triggering the pneumatics are grouped on three sets of Festo valve terminals, which in turn are connected to the control system via the Festo fieldbus. This has the effect of considerably reducing the cost of installing the system. BP40 PS10 HC16-F CP30 CP61 3 x IM10 3 x OM10 3 x IO12 3 x IFB1 03 2 x ECT-16 14-slot busboard Power supply unit PC/CHIP CPU, EPROM, RAM, flash RS232c interface Festo fieldbus master 16-bit digital input module 16-bit digital output module 8 x analog input module Type III valve terminals with Festo fieldbus node EXOR touch display

Hardware

Software

The programming makes use of the multitasking system provided by the FST software and, in addition, the MultiCI driver, which ensures that the touch panels have direct access to all variables in the control system. Agriculture, silo, pneumatic cylinder position detection, touch panel

Keywords

20

Control and handling technology

Controlling mobile road tarring machines

In the fully automatic high-performance road tarring machines that are used around the world, machines which can lay up to 90m of asphalt per minute, a rugged control system is needed in order to perform a varied set of tasks. These include: _ Controlling every aspect of the vehicle hydraulics _ Operator prompting via a graphics monitor for the driver _ On larger vehicles, networking via a CAN fieldbus to the control console for the tarring machine operator. _ On special vehicles, networking to a hand-held terminal for personnel accompanying the vehicle on foot _ Complete recipe management and control of the mixtures of tar, chippings and colouring The complexity of the tasks calls for programming in a high-level language in this example it is in C in a modular system environment. The IPC PS1 is particularly well suited to this application. It is compact, robust, modular and therefore flexible, programmable in a high-level language, and the special modules are based on an open standard. A remote maintenance facility via GSM modem has been included on many vehicles. Configuration example for a small vehicle:

Hardware

BP40 PS10 HC16 4 x IM10 2 x OM10 IO12 2 x IO60

14-slot busboard Power supply unit PC/CHIP CPU, EPROM, RAM, flash 16-bit digital input module 16-bit digital output module 8 x analog input module 4 x analog output module

Optional CAN interface Software Keywords Programming in C Road tarring machines, vehicle hydraulics, operator prompting, CAN, C/C++, GSM modem, remote maintenance

Control and handling technology

21

Sending electronic devices from the clean room for testing

The production of hard disks, floppy disks, CD ROM drives or else are a minor technical miracle. For a long time now we have got used to the idea that the mass storage devices in our PCs do their job year after year. And yet each of these devices is a masterpiece of mechanical precision and miniaturisation. During operation, for example, the clearance between the read-write heads of a hard disk and the disk is only a few micrometers, far less than for instance the thickness of a human hair. Awareness of this fact alone should make it plain that production of such devices themselves have to take place in a clean room, to ensure that under no circumstances can dust, dirt or any other foreign matter be allowed to enter the device. On the other hand, eventually any part produced will have to leave the clean room, because the office where the computer will be expected to do its stuff for the customer really cannot be called a clean room.

Product ion o f mass s torage devices

Pick & Place Unit s


PP1 ... PP8

Clean Room Further production

Pick & Place Unit s


PP1 ... PP8
Points Point s Poin ts

Tes t

Tes t

Test

For reasons of cost-saving, if no other, the clean room has to be kept as small as possible. As many production stages as possible, therefore, should take place outside the clean room. One of the major manufacturers for mass storage devices produces hard disks in many Asian countries. Festo in collaboration with an engineering company has contributed to achieving a further automation of hard disk manufacture, and thus making it even more productive. This involved setting up fully automatic pick-and-place units at the end of the clean room production process; these transfer the finished disks onto a conveyor system which leaves the area of the clean room. On the opposite side, now under largely normal ambient conditions, the disks are turned over, identified by barcode readers and sent to a testing station according to type. On first impression, that sounds nothing special: transfer transport transfer transport distribute. One special feature of this application was that the automatic

22

Control and handling technology

system had to be integrated fully into an existing production facility that was previously operated by hand. The traditional procedure was for the disks to be placed on stainless steel trolleys in the clean room; these trolleys were then rolled out of the clean room, and in the testing area the disks were taken out of the trolleys again by hand and given over to testing, sorted according to type. It is also worth noting that the pick-and-place devices work on one side, inside the clean room. The entire pneumatic system therefore had to be designed in such a way as not to cause contamination in the clean room. Secondly, we can assume that the disks are not produced in a leisurely manner one after the other, but thousands of disks every day. The equipment list for merely the first of three project stages is correspondingly extensive: 26 IPC PS1 Professional modules were installed, 52 pick-and-place units with HMP cylinders, 180 type CPV pneumatic valve terminals, and a great deal more besides. The IPC PS1s for the pick-and-place units are equipped with Profibus DP master modules. The systems at the sorting gates have HC02 CPUs and digital I/O modules. All systems are fitted with Ethernet interfaces and are networked with a central PC. A Visual Basic program written especially for this application runs on this PC, monitoring all of the connected stations and issuing error messages in plain text. Among other things, these messages are based on the fact that all cylinder movements are monitored by a timeout feature. Hardware The pick-and-place units consist of the following: BP 31 8-slot busboard PS 10 Power supply unit HC16-F PC/CHIP CPU, EPROM, RAM, flash CP 14 Ethernet interface CP 62 Profibus DP master IM 11 16 x digital input module OM11 16 x digital output module 2xCP 35 Serial interface The sorting gate controllers consist of: BP 31 8-slot busboard PS 10 Power supply unit HC02-F AM186 CPU, flash, Ethernet IM 11 16 x digital input module OM11 16 x digital output module 2xCP 35 Software Serial interface All control programs are written in FST, the monitoring PC program is written in Visual Basic. Clean room, pick-and-place, handling, Visual Basic, Profibus DP, Ethernet

Keywords

Control and handling technology

23

Manufacture of MKP-SI capacitors

Metallised plastic polypropylene safety capacitors are capacitors that are made up of several thousand winding layers. The capacitor elements are packed in oil in a metal housing. The housing has a type of expansion joint to enable it to expand if the capacitor undergoes thermal expansion as a result of overload or a fault. The "SI" in the name MKP-SI capacitor refers to the property that one of the capacitor's connecting wires has a predefined break point. The connecting wire is attached in such a way that if the housing expands the wire is subjected to tension. The wire breaks at the predefined break point; in the event of a fault, therefore, the capacitor is electrically isolated and therefore harmless. The application described here is not responsible for the entire capacitor production process, "only" for the attachment of the connecting wires including the predefined break point. As is usually the case nowadays in automation technology, the primary demands made of the system were flexibility and speed while maintaining constant quality. _ Flexibility means that around 100 types of capacitor have to be produced, each with different dimensions. And flexibility in this case also means that additional type data can be added on-line at any time. A small database administers all geometric data applicable to the various types so that the machine is always prepared for every job that comes along. _ Speed means that a cycle time of less than 8 seconds per capacitor has to be maintained. _ Quality means that, along with technical functionality, the consideration of safety plays a very important part. The predefined break point in the connecting wire is a safety feature that, when the capacitor is subsequently put to use, is responsible for the safety of much larger systems and processes.

Hardware

Plmer Elektrotechnik, a company based in Berlin, is responsible for the control section. It chose the IPC PS1 Professional because it is sufficiently flexible to satisfy the various requirements that the system has to meet in terms of control technology. For the purposes of our example, this means: BP40 PS10 HC12 CP50 4 x AM11 14-slot busboard Power supply unit PC/CHIP CPU, EPROM, RAM InterBus master 2 x stepping motor module, in this case for controlling 7 stepping motor axles (Portescape motors with Nanotec power section) 16-bit digital input module 16-bit digital output module LCD display Floppy disk controller and drive, in this case as a boot drive and as storage for the customer's type database.

PS1-IM10 PS1-OM10 PS1-DIS1 PS1-FC/FD10

24

Control and handling technology

Software

Plmer Elektrotechnik decided on Pascal as the programming language for this installation. The program is divided into two groups, which can never be executed simultaneously. These are a real-time-capable control section with a cycle time of < 20 ms and use of the watchdog for monitoring run-time errors, and an operating and parameterisation section without real-time capability which allows access to the type database with the aid of the floppy disk drive. A sophisticated error monitoring function monitors every step of the control technology sequence. Every cylinder movement, for example, is monitored by a timer module. If the movement does not occur within a specified time, an error message is displayed on the DIS1 with indication of the cylinder, limit switch and valve. To the advantage of the maintenance personnel, therefore, all standard errors that may occur in the control technology are carefully monitored and are displayed in plain text. Short stoppage times are the benefit of having a monitoring program as well-devised as this.

Keywords

Capacitor manufacture, quality requirements, stepping motor, InterBus, Pascal, database, error monitoring

Control and handling technology

25

Production of spray cans

The importance of spray cans in many people's day-to-day life is huge. Although they are very rarely spoken about, their possible uses and the areas in which they are used are so varied that it is likely to be very difficult to exclude any everyday field of use. The most common contents of spray cans are cleaning agents, lubricants, oils, paints etc., which are then available for easy and convenient use. Now that CFCs have been replaced by compressed air and the can itself is usually made of recyclable metal, the discussions surrounding environmental compatibility have largely subsided. It is just that someone has to make the cans. And this is where the PS1 system helps.

The tube in the can

Most spray cans are made in such a way that inside the can a plastic tube is attached to the valve, extending down to the base of the can. This ensures that, provided the can is held upright, virtually all of the contents can be used. For many applications there is also the possibility of attaching a tube to the outside of the valve, with the aid of which the oil, cleaning agent or whatever else the can contains can be sprayed with great accuracy exactly where it is needed. It is these tubes which have particularly grabbed our attention. These days, nothing carries on as usual in the old, easy-going way. Of course it is not enough to cut a tube to length and put it in position. In the PS1-controlled plants, 650 tubes per minute are cut to length, the length is checked, and the tubes are attached and are tested in position that is one tube every 92 ms. The combination of sophisticated mechanical engineering and well thought-out control technology makes these speeds possible. The company responsible for the mechanical engineering side is Fischer in Bad Oldeslohe. A unit that from the outside looks like a CNC machine processes the tube material, cuts it to different lengths as required and inserts the tubes. The company responsible for the control technology is Dter in Hamburg. Mr. Peemller has put together a system that is made up of two separate PS1 systems.

Fast, faster, fastest

26

Control and handling technology

Hardware

The control system consists of the following: BP40 14-slot busboard PS10 Power supply unit HC27 32-bit CPU 4 x IM11 16-bit digital input module 3 x OM11 16-bit digital output module IO60 4 x analog input module CP10 2 x RS232 module Kobolt servocontroller and servoamplifier for the positioning system. A separate CPU for operator guidance - the human-machine interface - is accommodated on a second busboard: BP11 3-slot busboard HC16 PC/chip CPU, EPROM, RAM, flash BG20 Display The operator's station communicates with the control computer via an RS232c

interface. Program language The entire system is programmed in MULTIPROG, the programming package that conforms to IEC 6 1131-3.

Keywords

Spray cans, cutting to length, positioning, testing, IEC 6 1131, MULTIPROG

Control and handling technology

27

Sawing up thick tree trunks

Tree trunks: they can be thick or thin, hard or soft that's how it is with tree trunks. Boards at a DIY store or at a timber merchant may be thick or thin, long or short, best quality or not so good. But if you want boards with a thickness of 18 mm, then they should be precisely 18 mm thick, exactly like those you bought 6 weeks ago. Between your DIY store with its boards that are always exactly 18 mm thick and the tree in the forest there is a great deal of work. One of Europe's biggest manufacturers of band-saw machines for sawmills is having its band saws equipped with the IPC PS1.

The tree trunks delivered to the sawmill need to be sawn into boards to a thickness that precisely matches the details of the customers' orders. The demands imposed on board production are not so very different from the demands made on the production of items such as valves or alarm clocks: constant quality of the end product, even if the primary product the tree trunks is highly variable; high flexibility, with batch sizes alternating between just 1 and several hundred; and speed of production. Of course, the primary product has to be handled quite differently from products such as small screws. The huge trunks in some cases have diameters of over 1 metre. They are placed on trucks that remind you of railway goods wagons. There they are clamped in place and taken to the saw. There is no-one standing by the saw holding a metre rule to measure what thickness the board should have: instead, positioning is carried out with highperformance frequency-controlled three-phase motors and with hydraulic shafts. The required thickness for each order is entered at a control console, the clamping trestles on the truck clamp the trunk and guide it with an accuracy measured in millimetres to the band saw or to the double band saw, if a second, offset and separately positionable band saw is also connected. The idler wheel on the band saw alone may have a diameter of up to 1.8 m - while the IPC PS1, in contrast, is barely larger than one or other of the fixing bolts.

28

Control and handling technology

Open- and closed-loop control with a CPU

Clamping, starting, stopping, sawing etc. are all classical control tasks which can be dealt with by any PLC. The positioning of what nowadays may be up to 6 axes, on the other hand, requires a quite considerable level of computation work because the axes have to be coordinated with each other. And user guidance, with entry of the job details, log printing etc. is a typical task for a PC. In the IPC PS1, all of these tasks are brought together. A single CPU takes care of controlling, positioning and user guidance. Depending on the size of the saw machine, 12x or 20x busboards are used. Positioning is controlled with AM20 modules, and the CPUs are usually 486s. The software follows hot on the heels of the distribution of tasks: the control section is programmed in S5. The S5 operating system is embedded in a multitasking kernel, so the positioning and the user interface are written in C/C++. An ideal combination. Because the tough sawmill environment requires a simple interface to the control technology. And these days Step5 is also familiar to electricians at sawmills. User prompting and positioning, on the other hand, are reserved for the PS1 engineer. Sawmill, positioning, S5, C/C++

Hardware

Software

Keywords

Control and handling technology

29

Controlling at random

Can you imagine entrusting your application to chance, random events? Or even that it is conceivable that it is the task of a controller to work "at random"? Well, there is such an application. In order to boost the sales of products that are packed in cans, sometimes surprise gifts are included with them. A drinks manufacturer, for example, arranged to include vouchers for lavish holiday trips in the tops of their drinks cans. A customer who buys the can with the "golden nut" and actually finds the voucher and redeems it has won a valuable prize. The manufacturer of the drinks cans, or rather the manufacturer of the tops for the drinks cans, therefore has to see to it that the vouchers a prescribed number of vouchers in each production batch are included in the tops. And the inclusion of the special can tops must be done at random. To do this, a small station was developed which inserts the tops with vouchers into the production process according to a random principle. The top itself is of course functionally identical to every normal top, but it has that little something extra on board ... The IPC PS1 that controls this random insertion machine has to be able to provide precise information, however, on when tops have been inserted, how many are still left to be inserted and so on and so forth.

Networking with the office via Ethernet every CPU can do that.

In addition, the controller is integrated into the company's network, because the "golden" tops should of course only be inserted if the customer actually requires this. In collaboration with Festo Ireland, a manufacturer has developed a machine of this type, connected the controller to the central database in the company network and implemented local operator control and visualisation with an EXOR display.

Hardware

BP40 PS10 HC16-F CP61 IM11 OM11 CP14

14-slot busboard Power supply unit PC/CHIP CPU with FST kernel Festo fieldbus slave 16-bit digital input module 16-bit digital output module Ethernet interface

Software

The station is programmed in FST, because programming the automatic insertion process is quickest in FST. The dimensions of the tops differ depending on the production batch. The insertion arm is therefore positioned with a servopneumatic regulator, the SPC200 from Festo.

30

Control and handling technology

The operating terminal is programmed with the EXOR designer software, which already includes the driver for FST controllers and supports development on even complex and sophisticated operating interfaces in the simplest possible way.

The system is networked with the company's local area network and the company database via Ethernet. The Festo fieldbus slave is integrated into the system because the production master computer has a Festo fieldbus master and as a result is able to receive status messages from the station very easily. Keywords Random generator, Festo fieldbus, Ethernet, SPC200, EXOR, positioning, database, FST

Control and handling technology

31

Programming with FST

For many years now, the proportion of software costs in automation projects as compared with hardware costs has been rising almost continuously. Every new set of programming software has to try and square the circle yet again, because the demands made of good programming software are fundamentally contradictory: _ Because hundreds of thousands of mini controllers control applications on a small and even miniature scale, the software must be fast and easy to operate. For many members of staff in project departments, creating a fully finished project every day is an imperative. Complicated configuration routines would only interfere with the process. _ Because large projects, in particular, can quickly become confused and chaotic, especially if they have to be constantly changed because of endless follow-up requests, the software has to be powerful in order to support systems with thousands of input/outputs and complex task structures. _ The familiarisation time for beginners must be short or really should not be necessary at all. Everything must be self-explanatory, intuitive and simple. No programming software manages this entirely. Compromises always have to be made. The FST software approaches these compromises from a highly original angle. It allows programming to be performed in the way that you would describe a machine.

IF ... THEN OTHRW

"If a part is available here, then this cylinder should advance." This becomes: IF part_present THEN SET cylA_forward This IF ... THEN ... OTHRW structure, so familiar to programmers in high-level languages, in conjunction with the SET and RESET operations for activating and deactivating a digital output, is so neat and easy to remember that the first lines of the program can be written and understood very quickly even by beginners.

STEP

What is more, because more than 80% of all machines represent a sequence control system in automatic operation, the FST software supports the programming of such sequences by operating independently. A typical automatic handling machine, for example, has to guide the gripper through the following sequence: - lower - close - raise - move - lower - open The FST software uses the STEP operation for this purpose. This automatically forces a program into a single step, the active one.

32

Control and handling technology

STEP IF THEN STEP IF THEN STEP

Start

Lower

Close

As a result, sequences of this type lose their terrors and can be programmed in the twinkling of an eye.

Multitasking

Although the sequence is the central element for most machines, it is far from being the largest part of the program. Setting up, manual operation, error messages, organisation and many other things require a due amount of attention. To allow this, the FST software provides an easy-to-handle multitasking structure. Within each project, program 0 enjoys a special status as it constitutes the "mother" of all of the other programs and is launched on startup. A further 63 programs can be added as needed, and operate simultaneously.

Control and handling technology

33

Variables

You can never have enough of them: flags, timers, counters, input/output addresses, to name but a few. FST takes this to its logical conclusion: 10,000 flag words (that is 160,000 individually addressable bits), 256 timers and 256 counters are sufficient for even large-scale projects. Increasingly, however, today's automation projects are not merely large, they are also decentralised: a large number of small controllers, each with small projects, operate in concert. Small, clearly organised, fast, easy-to-program projects in small control systems provide in total a more easily manageable and clearly arranged whole than a single giant monster. The FST software supports the networking of controllers with the assistance of traditional fieldbusses such as Profibus DP and FMS, CAN, ASi, Festo fieldbus etc., but also now Ethernet - the fieldbus of today. With Ethernet it is possible both to exchange data between the controllers and to program the controllers. From a single Ethernet connection, direct access can be gained to all of the controllers out there on the network. Central programming of distributed controllers is the key concept here. With FST, from the mini controller to the major system, this is already reality today. No programming software can satisfy every requirement. It is only a matter of time before someone will ask for this or that feature that "my" job needs, but which "they" have forgotten about. FST has an open interface for modules and drivers. New modules can be written in C/C++, and new drivers too. In this way, FST is open to expansion, modification, and adaptation for small controllers just as much as for large ones. One example of how this open structure is used is the WEB server. A driver allows access to the I/O level of the controller via an intranet or the Internet. On the basis of the TCP/IP driver, the controller with the WEB server understands HTML code, the language of the Internet. Are you interested in FST? More information is available here: http://www.beck-ipc.com/fst http://www.festo.com/fst

Networking

Modules and drivers

WEB Server

34

Control and handling technology

Networking and remote maintenance

These days there is much philosophising about "decentralised architectures", "decentralised automation technology" and a great deal besides. Much is written about the fact that small controllers, small programs and small systems are clearer and more manageable than large and centralised systems. The theory goes that a large number of small, autonomous systems are more stable in operation than a large, centralised system.

How does it look in practice?

Well, after all is said and done, people do choose the large controller again, with many thousands of input/outputs, because it is too much trouble for them to rack their brains about the small subgroups; and because it is too much like hard work to program every single station individually; and because it is too complicated to network all stations with each other and to bring up the network in the right order; and because ... Anyone who says "decentralised" is the best option must also point out ways in which "decentralised" can be made practicable. Anyone who says "decentralised" is the way to go needs a network that actually supports decentralised structures and does not simply grind to a halt when some component or other fails. Anyone who promotes the "decentralised" theme must illustrate that programming can be carried out centrally and that troubleshooting can be performed from a central location. Networking with Ethernet, programming via Ethernet, operation via Ethernet, remote maintenance via intranet and Internet, process visualisation. In this section you will find several examples in which decentralisation is taken seriously. Enjoy reading about them.

Networking and remote maintenance

35

Pad printing on a network

They are round, and look nicest when they are colourful: toy balls. The technique of pad printing can be used for printing a huge variety of subjects which lend colour to children's play. But also ball-point pens, cigarette lighters, small packages or spectacles, in other words relatively small objects with curved or uneven surfaces, can be printed economically in large numbers in this way. To make sure that the imprint hits home, mini controllers from Beck are used together with pneumatic feed units from Festo. Not multi-coloured but with a single-colour imprint, table-tennis balls fly across the table and golf balls soar through the sky. The toy balls for children are usually larger and also more brightly coloured. The concept that Printing International has devised with its latest pad printing machine offers the solution for both variants: a modular system. Every module, in this case the print head, can print both on its own and in concert with others. If it is left on its own, just one colour is applied. Used in combination, multi-colour printing becomes possible. Advanced network technology and efficient programming tools characterise the pad printing machines from this Belgian manufacturer. The printing mechanism is pneumatically driven. Pad printing is an indirect gravure printing process in which the subject is etched into the plate; ink transfer takes place with the aid of a flexible medium, known as the pad. The printing machine consists of a vertical feed unit, a Festo cylinder. This executes the pad's printing movement. The horizontal feed unit moves the printing plate between two fixed positions, towards the pad or towards the "ink cup". This process is repeated after every imprint. Controlling the pad printing machine is fundamentally a rather simple task. If it is intended to print several colours and several subjects on a single object, the actions of the print modules must be coordinated with each other. The possibility of activating different print heads selectively is offered by the IPC FEC FC34 Front End Controller, the mini controller from Beck IPC GmbH. In a network version using Ethernet, it takes care of every aspect of control of the machine.

Pad printing brings colour into play

36

Networking and remote maintenance

Optimum networking flexible programming

With Ethernet, connections can be plugged in and disconnected without adversely affecting ongoing operation. The modules making up the printing machine can easily be checked and put into operation individually. The conversion phase for the machine as a whole is totally flexible, because the modules can be contacted as required and independently of each other. If there is a combination of several equally ranked controllers, the question always arises as to which one has the upper hand in the event of parallel access. Printing International has found an easy way of solving this conflict: as soon as at least two modules begin to interoperate, a single "head controller" is added. Here, too, the FEC shows its strength in action it directs the entire system with the aid of the FST programming system, in which the "Step" sequence operation is already integrated. Whether the ball will then find its way step by step into the goal or across the green into the hole at the moment that is still beyond the capabilities of the FEC.

Hardware Keywords

IPC FEC FC34 Pad printing, modularity, F34, Ethernet, FST

Networking and remote maintenance

37

Securing pedestrian precincts

Every modern town has one now: a pedestrian precinct. And the way they are organised is much the same everywhere: in daytime, during the usual opening times, the pedestrian precinct is supposed to be precisely what the name suggests: they are reserved exclusively for the use of pedestrians. In the early morning and the evening, though, delivery vehicles should be able to bring in goods as easily as possible, and also be able to pick up goods as necessary. But how can the observation of these regulations be monitored? Or should we simply rely on the law-abiding nature of motorised road users? In Belgium, the method used to maintain the rules is as simple as it is amazing. Retractable posts have been installed at the entrances to the pedestrian precincts. During the day, when the area is for pedestrians only, they are raised, but at night they are lowered into the ground.

Boundary between a pedestrian precinct and a road

The job of raising and retracting the posts is taken care of by pneumatic cylinders. The task of triggering the valves is the responsibility of a small controller and the neat thing about this solution is that the controller is connected to the local police headquarters by modem. The cylinders are automatically raised in the morning, and in the evening they are lowered again. Once a day the PC (the computer, not the officer!) at police headquarters polls each controller to establish whether the cylinders are up or down as they should be, and in order to synchronise the clock in the controllers. The master computer at police headquarters A car has been driven into the pedestrian precinct and the driver has forgotten the time. How can he get out? Well, the controller can be called up from the police station and in exceptional cases the post can also be retracted during the day to allow access to the road.

38

Networking and remote maintenance

Windows NT PC with Visual Basic Soft ware

Modem

Modem FE C FC30
2 Cylinder with valves

Modem FE C FC30
2 Cylinder with valves

Modem FE C FC30
2 Cylinder with valves

Modem FE C FC30
2 Cylinder w ith valves

The controller is an IPC FEC FC30. A particular advantage of this is that it has two serial interfaces. One is used for the modem, and one during commissioning and maintenance for the programming unit. The police computer is a standard Windows PC with a Visual Basic application that accesses the controllers.

Hardware

IPC FEC FC30 Pneumatic cylinders, type DNC Valves, type CPE Modem PC Windows NT Remote control, telemonitoring, modem, traffic control technology

Keywords

Networking and remote maintenance

39

Recording process data and arranging for essential repairs

TURNILS AB is a Swedish company that is one of the world's largest manufacturers of sun-shades, awnings, sun-blinds and everything related to such products. With exports making up around 80% of sales, Turnils is a global player in a market that for average, unaware consumers such as us appears relatively trivial. How many people have spent much time thinking how sun-shades are made? The experts at Turnils do a lot of new thinking every day. What makes it more difficult is that sun-shades and awnings, in much the same way as clothing, are highly dependent on fashion as far as colours are concerned. And they are purely seasonal products. If good weather is forecast in a particular area, sales rise. Persistent rain for weeks on end leaves orders in the doldrums.

Additional serial interfaces are simply plugged into the busboard.

In view of the need to be able to respond very quickly, it is particularly important to have a perfect overview of the current situation in production at all times. The production planners and machine experts have therefore integrated an IPC PS1 system into the existing manufacturing setup, to function as a data collector. The process data is gathered from 19 production robots and 17 injection moulding machines to be evaluated in a Windows PC, giving the production management team an excellent overview of the status of production whenever it needs it.

40

Networking and remote maintenance

In a further step, the IPC was fitted with a modem. If a problem occurs in production, the emergency maintenance service can be summoned via the modem. As a result it has been possible to further expand the number of unmanned shifts and reduce response times in the event of a fault. Hardware BP31 PS10 HC16-F 2 x IM11 CP31 FC/FD10 Modem 8-slot busboard Power supply unit PC/CHIP CPU, EPROM, RAM, flash 16-bit digital input module 2 x serial interface Floppy disk controller and drive

Software

FST, the universal software with file handling capability and support for serial interfaces, was once again the software used here. Modem, ghost shift, production statistics

Keywords

Networking and remote maintenance

41

Data backup on the network

In the world of automated production, the reconstruction of individual steps in production or testing after the event has become enormously important. During the 70s the concept of CIM - Computer Integrated Manufacturing - was illustrated by the example that a manager can interrogate the limit switches in the production plant from his PC. The problem was that the manager wasn't in the least interested in these limit switches, and networking technology also needed another few years of development work until this vision could be made reality. Today it is not a matter of being able to interrogate data just for the fun of having data. What is important is being able to ensure unbroken tracking of production data and testing data. When, for example, the bolts on the engine block of a new engine are tightened, it is not only important to know that a bolt has been inserted at all but also that the bolt has been tightened using the defined tightening torque and that bolting has therefore been successfully completed using the defined force. Cooper Power Tools (CPT) has developed its own bolting controller for dealing with bolting tasks of this nature. The controller is capable of carrying out conclusive checking of the bolting during the bolting process. The data arising for each individual bolt must be saved automatically, and must remain available for at least 10 years.

Bol ting server Windows NT Interface P C

Ethernet

C PT bol ting cont r oller

CPT b olting controller

CPT bol ting cont r oller

CPT b olt ing con troller

Bol t t ightener Bol t t ightener Bol t t ightener

Bol t t ightener Bol t t ightener Bol t t ightener

Bol t tigh tener Bol t tigh tener Bol t tigh tener

Bolt t ightener Bolt t ightener Bolt t ightener

CPT has therefore networked its own bolting controller with an IPC PS1 system, and in turn it has integrated the PS1 system into the customer's in-house Windows NT network. The data from the bolting controllers is stored on the IPC PS1's local hard disk; it is then transferred on a cyclical basis to the NT network, where again it is backed up on hard disk. Every day the production data is written to CD, and the CD is placed in storage. In addition, the NT network is regularly backed up as part of the general data backup procedure for the IT systems.

42

Networking and remote maintenance

In general terms, in this application the IPC PS1 Professional acts as a gateway between the bolting controller and the customer's local network. As well as the simple gateway function, though, it fulfils two other tasks. Firstly, the local hard disk acts as a buffer store. The storage facility is actually divided into two: in step with production, the data is initially stored in a battery-backed RAM, then in a cycle of a few seconds it is written to the hard disk before finally in a cycle of a few minutes being transferred to the local network. Secondly, with the aid of its input/output modules the IPC PS1 can also carry out control tasks "on the side". This feature has had the result that, in the course of time, control tasks have also been transferred to the gateway, for example for belt control, component feeding etc. In this way, a simple gateway has turned into a controlling and storing gateway. Hardware The basic equipment set generally looks like this: BP31 8-slot busboard PS10 Power supply unit HC20-50 32-bit CPU with 586 processor, Compact Flash slot HD51 2 GB hard disk IM11 16-bit digital input module 16-bit digital output module Programming is carried out in C/C++, the simplest method in a gateway optimised for the Windows network. Gateway, Windows NT, hard disk, buffer storage

OM11 Software

Keywords

Networking and remote maintenance

43

Modernisation of a high-bay warehouse

The Russian company Svetogorsk operates one of that country's largest factories for paper products of all kinds. A high-bay warehouse was built there in 1987, extending over 6 floors and with up to 20 rows, each with up to 40 pallets. In 1999 work was started on modernising the high-bay warehouse. On 3 of the 6 floors, initially, the handling equipment was replaced with vehicles driven by frequency-controlled electric motors. In addition, the data management system and control of the store system were renewed. The head controller for the system as a whole is an IPC PS1 Professional system with an HC20. HC01 CPUs are used on the modernised floors. The HC01 CPUs control the vehicles, which have to be positioned with an accuracy of 6mm within the rows, each of which are 80m long. The HC20 controller is equipped with 8 serial interfaces, some of which are in the form of RS485 bus systems. These are used for communication with the modernised floors and with the floors that have been left in their old condition for the time being. Ethernet is used for communication with the operator terminal. This is where all the data management work for the high-bay warehouse is carried out, as well as operation of the system, on a standard PC. There are a number of subcontrollers each responsible for a single vehicle. HC01 CPUs are used for this. The positioning system uses the fast counter input provided by the HC01, which picks up signals from a rotary pulse generator. In the course of the year it is intended to convert the remaining floors as well. Altogether, in the final configuration, 56 PS1 Professional systems are planned throughout the building. Head controller: BP31 8-slot busboard PS10 Power supply unit HC20-50 32-bit CPU with 586 processor, Compact Flash slot CP12 Ethernet interface 3 x CP3X Serial interface Individual controller for a number of rows in the high-bay warehouse: BP50 5-slot busboard with power supply HC01 AM186 CPU with 8 digital I/Os OM21 Digital input/output module each 8-bit

Hardware

Software

The software was developed by AKMA Ltd (e-mail: aml@akma.spb.su), a company based in St. Petersburg. AKMA has devised its own real-time kernel for DOS systems, and this is used in this application. The languages it uses are C/C++ and Assembler. An integral part of the real-time system is a monitor for troubleshooting; this allows direct access to the variables in the CPU for development work and fault finding. High-bay warehouse, Real Time, Ethernet, fieldbus

Keywords

44

Networking and remote maintenance

Calling the emergency repair service

Isabellenhtte is a company in Dillenburg, central Germany, with a tradition stretching back 500 years. This company is living proof that long-standing tradition need not lead to fossilisation but can instead very much bring about advancement and a wealth of ideas. Today the Isabellenhtte is considered one of the world's leading manufacturers in the field of electrical resistor materials whether in the form of resistors for the production of printed circuit boards or in the form of thermal wires and resistance wires. The manufacture of thermal wires and resistance wires entails first drawing ever finer wires, and then also twisting several fine and extra fine wires to produce the final wire. This process of twisting a number of extremely fine wires together is performed automatically on machines specially made for this purpose. The reels for the initial products and end products are designed so as to enable the units to operate for up to 36 hours without interruption. The operating personnel ensures that the machines run around the clock, 7 days a week human intervention is only needed in order to change the reels. What happens, though, if shortly after the new reels are put in place a fault occurs, for example a thread breaks or a reel becomes jammed? It used to be the case that the plant had to wait until help arrived more than a day later. Mr. Eichmann is the engineer responsible for the machinery at Isabellenhtte, especially for production of the special-purpose machines that the company builds and programs itself. In order to reduce the length of stoppage times in the event of faults during the "ghost shifts", Mr. Eichmann now uses a small control cabinet with an IPC PS1. The IPC PS1 receives digital fault signals from the manufacturing equipment. The fault groups are indicated with the output module. What is more important, though, is that a message is sent to the responsible emergency repair service with the aid of a modem connected to the RS232 interface. The fault is reported to the emergency repair team on a paging service (Scall) wristwatch receiver. The downtime for the machines is now reduced to the length of time that the emergency team needs to get to the factory and repair the machinery. BP11 HC15 OM20 MC10 Modem 3 x busboard with power supply PC/CHIP CPU, EPROM, RAM Digital input/output module each 8-bit PCMCIA module

Twisting thermal wires

Automatic fault detection

The PS1 system calls for help

Hardware

Software Keywords

For Mr. Eichmann, Basic is the fastest and easiest method of achieving success. Fault monitoring, ghost shift, modem, Scall receiver, Basic

Networking and remote maintenance

45

Calling the machine

As an exhibit to be used for presentation purposes at trade fairs, a device has been developed that illustrates the possibilities offered by mobile telephony in conjunction with automation technology in a particularly attractive way. A traditional type of automatic chewing gum dispenser, of which there are hundreds of thousands in use wherever it is hoped to do a trade in small sweets or gifts for a few pence, was fitted with an electric drive. Control of the drive is taken care of by an FEC FC38. This is a mini controller with an integrated GSM modem.

The GSM modem and the controller communicate via the second serial interface on the FC38, the EXT interface. As a consequence the FC38 can basically be programmed in any programming language, provided that it supports the EXT interface. As well as this, a special software package was developed, TCM-SMS, which evaluates SMS messages. This package firstly enables the controller to send an SMS message. It is also possible, however, to issue commands to the controller with the aid of SMS messages, in other words for example to switch outputs, read out inputs etc. The software was adapted for the chewing-gum dispenser in such a way that it is enough just to make a phone call to the machine. The call and the calling number are logged. In this process, though, the call is not answered (that would incur call charges for the calling mobile phone every time). The fact is merely recorded that an attempt has been made to make a call. When a call is logged, the motor is activated to enable the machine to give out a small gift. Hardware Keywords IPC FEC FC38 GSM, remote control, remote maintenance, mobile phone

46

Networking and remote maintenance

Control and operation via the Internet

Many experts are still not really happy to let the words "Internet" and "automation" pass their lips in the same sentence. The "toy" and knowledge database that is the Internet seems just too far removed from the clear and predictable (or so they should be) applications in automation technology. It is only gradually that many users are becoming aware that the technologies of the Internet offer enormous opportunities for automation: remote maintenance, remote control, visualisation and a good deal more.

As an illustration of what is possible with very simple means, a number of examples are available on the Internet. _ If you go to http://fc34demo.beck-ipc.com you will find an FC34, i.e. a real mini controller, showing that already today it can be used as a WEB server at the same time as being used as a controller. _ At http://fstdemo.beck-ipc.com you can see online on the Internet how the language of the Internet, HTML, can be used to display and change process variables. _ And at http://webdemo.beck-ipc.com the IPC@CHIP shows that it can make a small meteorological station available on the Internet. Hardware FC34 Demo

IPC FEC FC34 Mini controller DGO cylinder Linear drive CPV valve terminals BP11 HC16-F AS11 CP14 IPC@CHIP DK40 3-slot busboard with power supply PC/CHIP CPU, EPROM, RAM, flash Input/output module, each 8-bit, with pushbuttons and LED Ethernet interface The entire IPC on one chip Evaluation board

FST Demo

WEB Demo

Keywords

Internet, WEB server, FST, remote control, remote maintenance, visualisation

Networking and remote maintenance

47

Programming in line with IEC 6 1131-3 with MULTIPROG

Many programming methods used in automation technology are good, well known, simple or complicated, or they may have unique properties which enable them to tackle one task or another particularly well. Only one programming method is internationally standardised, internationally accepted, and internationally established programming in accordance with DIN IEC 6 1131-3.

The Edit Wizard and the online help ensure handling of IEC 6 1131 to be fast and easy.

This standard, actually adopted many years ago now, is the only internationally recognised method of PLC programming. Not only that, it is the only PLC programming method that is promoted, tested and distributed by an independent institution, the PLCOpen. At the same time, IEC 6 1131-3 allows the user a great deal of freedom. Five programming languages are standardised: The 5 languages of the standard The text-based languages Instruction List and Structured Text, the graphical languages Function Block Diagram and Ladder Diagram and Sequential Function Chart for organising sequential systems. The IPC systems, ranging from the FEC mini controller to the large IPC PS1 Professional system, are all programmable with MULTIPROG, one of the leading IEC 1131-3-compatible software packages. Wizards and dialog boxes MWT has not only translated the standard into practice, it has also introduced tools which simplify handling of the standard and make it user-friendly: wizards for making use of functions and function blocks as well as dialog boxes for the declaration of variables familiar to all PLC programmers as the allocation list.

48

Networking and remote maintenance

For programming and debugging via TCP/IP only the IP address is necessary.

Networks

From the very beginning, IEC 6 1131-3 has taken account of the fact that modern automation technology cannot work without networks. For this reason, MWT can manage entire networks in a single project, with dozens of CPUs. When IPC central processing units are used with Ethernet, every controller can be accessed via Ethernet from a central location with one Ethernet connection and one programming unit. Programming according to IEC 6 1131-3 has long ceased to be an exotic exception. The range extends from mini controllers to large networked systems.

Networking and remote maintenance

49

The project tree of MULTIPROG

Data types

IEC 6 1131 detaches itself from the usual data types in the PLC world. In addition to bits, bytes and words, it supports a large number of other data types. Depending on the possibilities offered by the particular hardware, INT, DINT, DWORD, UINT, REAL and STRING can be used, among others. This considerably extends the potential uses of PLC programming. MULTIPROG exploits this potential, and also offers a large number of options for converting data types. At last it is now also possible to use local and global flags in PLC programming. The name Start can be used perfectly well in several programs, and in each program it refers to a different flag and is therefore local. This makes handling flags much easier. In traditional PLCs, the number of timers or counters that a controller provides is specified. MULTIPROG may include just one block for an on-delay function, for example. The block can be called as often as the application requires (and the memory in the CPU allows). Limits are set by the application, no longer by the programming system. Todays Ladder Diagram uses NO contacts, NC contacts, coils and so on in just the same way as Ladder Diagram has since the start of PLC development. Every block, whether for example for a counter, a calculation, a flip-flop or any other subprogram, can be integrated into Ladder Diagram. These blocks look precisely the same as in Function Block Diagram. This means that the boundaries between Function Block Diagram and Ladder Diagram are disappearing; the two can be used immediately alongside each other in every program or block.

Local/global flags

Timers and counters

Ladder Diagram / Function Block Diagram

50

Networking and remote maintenance

Measurement technology, data processing and quality assurance

Sitting in your living room poring over the statistics on the discharge of pollutants from old contaminated industrial sites and the consequences for the quality of our drinking water is one thing. Gathering the data for those statistics is quite another. Writing a specification and an accompanying form for the acquisition of data on the tensile forces of wheel bolts on a car is one thing. Actually collecting the data and storing it in a meaningful way is quite another. Discussing the sense or lack of it behind catalytic converters, diesel particle filters and speed limits on roads is one thing. Obtaining the necessary data for a scientific assessment is quite another. The PC architecture underlying the entire system of IPC FEC and IPC PS1 controllers in conjunction with optimisation for minimising power consumption provides the ideal prerequisite for operation as a data collector. In this section you will find various examples which concentrate on the acquisition, storage and transmission of measurement data. Enjoy your read.

Measurement technology, data processing and quality assurance

51

Collecting and processing environmental data

To comply with environmental directives, operators of abandoned potassium mine spoil heaps are obliged to provide continuous proof of the salt loading in the neighbouring river and if necessary, if certain levels are exceeded, to initiate countermeasures. In order to monitor this type of problem, the conductivity of the water is constantly recorded at six decentralised measuring points (upstream and downstream of a potash heap in each case), and the chloride concentration is calculated from that. The IPS1 system in this case acts as a data logger. The data source, a conductivity meter, makes its measured values available at the COM2 (CP30) port face every second. The implemented software then has the task of breaking down the serial data stream into the required data components and of converting the conductivity into the chloride concentration. Over an interval of two hours the mean value is calculated and the minimum and maximum values are identified. These 3 values together with the temperature are assigned a time stamp and stored. For reasons of furnishing proof, the momentary measured values are logged every minute for a period of 30 days in a ring memory on the memory card. In the event of an incident, the data can be read out from the memory card. Five of these measuring stations are housed in a small control cabinet close to the river bank. Every conceivable type of weather experienced in central Europe is thrown at the PS1. In several months of continuous operation, the system successfully passed its test in action. On the basis of this measurement data it was possible to prove that neither fluctuations in temperature (moisture condensation) nor decidedly chilly temperatures of below -5C (even over a number of days) had resulted in any failures. The decision to choose the MC10 module with a 1MB SRAM card as the storage medium proved to be the correct one in these harsh ambient conditions. The COM1 (HC12) operates the trunked mobile radio unit. The switch output pin7 of the CGA port is used to check the radio unit into the trunked radio network at least once a day. The COM3 takes over the role of a service interface. System parameters can be visualised and modified on location with the aid of a notebook. Three of these measurement systems are located far away from civilisation. They are supplied with power from photovoltaic installations. In this instance it was important to save every possible milliampere. This is why the HC20-40 is used, with its two serial interfaces and the flash memory. Any components that are not required, such as VGA, are deactivated in the setup. This offers advantages with regard to power saving. Especially as the local fauna is unlikely to be interested in reading the measurements on a monitor. In order to make the measurement data accessible to the plant operator, at intervals of two hours it is automatically transmitted via public trunked mobile radio to a mainframe (AS/400), where it is archived. This task is dealt with by another PS1 system. It acts as a radio server, and communicates with the AS/400 via the in-house LAN topology.

52

Measurement technology, data processing and quality assurance

As far as the radio interface is concerned, a highly efficient and cost-effective means of data transmission was organised by using the MAP27 API with the SDM/EDM functions. The entire system operates autonomously. Manual access to the functionality is only necessary for the purpose of administrative procedures. In this case the decentralised measuring stations can be operated by remote control in remote mode. The infrastructure of the trunked mobile radio network means that the data can be accessed anywhere in Germany. A significant contribution to the overall stability of this highly independently operating measuring system is the watchdog function that is implemented. Every aspect of the functionality of the measuring system including the radio interface to the MAP27 API was written in C/C++. Hardware Device Number BOSCH KF-CHIP radio unit BP11 BP50 CP10 CP30 HC12 3-slot busboard 5-slot busboard Ethernet interface RS232 interface PC/CHIP CPU X X X X X X X X X X X X X X X X Radio server 1 X Measuring station 3 X Measuring station 3 X X

HC20-40 32-bit CPU, 486 processor, CF, flash LF340 WTW conductivity meter MC10 PCMCIA module SM14 ZL16 ZL31 Software Keywords TTL/RS232 adapter Zero power RAM disk 1 MB SRAM

ROM-DOS, firmware: FunkServ, LF_Val, MAP27.LIB Environmental monitoring, telemonitoring, remote maintenance, conductivity measurement, data logger, preservation of evidence, ambient conditions, power supply, public trunked mobile radio, radio server, autonomous measurement systems, C/C++, watchdog

Measurement technology, data processing and quality assurance

53

Observation of historical buildings and structures

Research work carried out at the Bauhaus University in Weimar includes the supervision of historically valuable buildings and structures such as churches and bridges. The aim is to prevent deterioration. The relevant physical quantities relating to the structure are monitored and diagnosed using mathematical models, so that if necessary a restoration plan can be drawn up in good time. The consultant engineers, ISL Ing-Bro fr Systemlsungen in Erfurt, use the IPC PS1 as a long-term data storage facility. Critical measuring points include the beams of a church tower, for example, when subject to changing wind load and the varied influences of weather. Another application is the long-term observation of the load behaviour and response to weathering of a historically valuable bridge. What needs to be done here is to document the "healing success" with data from about 1 year before, during and after the renovation of such a bridge. The hardware basis is provided by the Spider 8 measuring instrument from HBM and the PS1 system. The entire functionality of the Spider 8 is stored as an image in the PS1. The Spider 8 and PS1 communicate via the COM interface using a corresponding software protocol. Various modes are implemented on the user side: a) b) c) d) e) Direct coupling between PS1 and notebook (usually at the time of initial installation or when adjusting the measuring bridges on location) Coupling of PS1 via modem Coupling of PS1 via GSM radio unit (inaccessible terrain with no infrastructure, no 230V supply, no telephone connection) Coupling between PS1 and private mobile radio equipment Autonomous data transfer to the server (script-controlled)

In modes a) to d) the operator obtains an image of the entire system displayed on his PC/notebook. In remote mode he can parameterise the installation, configure it, balance (calibrate) sensors, define filter rates and sampling rates, etc. The measurement data is transmitted using a transfer protocol (X-modem). A formula editor is implemented which enables the integer measured value to be presented as a physically relevant measured quantity. In the subsequent expansion stages dynamic and event-controlled measurements will also be used with the assistance of HC20 or HC50 modules. As a result it will be possible, for example, to assess bridges under rapidly changing loads (trucks, trains). A major contribution to the overall stability of this autonomously operating measurement system is provided by the watchdog function that is implemented.

54

Measurement technology, data processing and quality assurance

The PS1 proved its mettle both in use in severe environmental conditions (during the building phase) and in relation to its all-weather resistance (at times in external temperatures of -5C according to the measurement data). The entire functionality of the measurement system including the transfer interface was written in C/C++. Hardware Long-term measurement BP11 3-slot busboard HC12 PC/CHIP CPU ZL16 Zero power RAM MC10 PCMCIA module ZL31 1 MB SRAM CP30 RS232 interface ZP11 Modem Spider 8 HBM Dynamic long-term measurement BP11 3-slot busboard HC20 32-bit CPU, CF, flash MC10 PCMCIA module ZL32 2 MB SRAM 2*CP30 RS232 interface Modem 4*Spider 8 HBM Software Keywords ROM-DOS, firmware: S8PS1D, S8ContrlWin, Trans_Srv Physical properties of structure, telemonitoring, remote maintenance, long-term data storage, environmental conditions, modem, radio, autonomous measurement systems, C/C++, watchdog

Measurement technology, data processing and quality assurance

55

Compressed-air filling station for tyres

When tyres are fitted they initially have to be inflated to a relatively high pressure so as to achieve a perfect fit with the wheel rim. The pressure is then reduced to the appropriate mounting pressure. Depending on the type of tyre, the initial pressure may be 5 bar, for example, and the final pressure 1 bar. Inflation and to some extent pressure reduction is carried out automatically. The difficulty with pumping air into the tyre is that air is supplied through a valve. The valve acts as a throttle. This has the effect that it is never possible to measure the pressure and pump in air at the same time. Consequently, the tyre is always inflated for only a short time, then the pressure is measured, inflated, measured... At the Swedish manufacturer, the intelligent solution produced with the IPC PS1 has reduced the time needed for inflation by 50%. To achieve this, the IPC recalculates the assumed inflation time at every inflation stage on the basis of a previous inflation process. It is only when the inflation level is calculated to have reached 90% that the inflation process is interrupted, a measurement is taken and a new calculation is performed, etc. This is therefore a self-optimising closed-loop process control function.

Hardware

PB31 PS10 HC16 IM10 OM10 I010 BG10

8-slot busboard Power supply unit PC/chip CPU, EPROM, RAM, flash 16-bit digital input module 16-bit digital output module 8 x analog input module 4-line LCD display with 4 function keys

Software

Programming is carried out in Pascal, because the emphasis is less on controlling the input/outputs than on the calculation algorithm. Self-optimising closed-loop process control, pressure measurement, Pascal

Keywords

56

Measurement technology, data processing and quality assurance

Automated soil examination

Soil tests which investigate the density or compaction of the soil are very important in agriculture. Also the question of the extent to which the tyres of a tractor compact the soil, for example, is important for assessing the possible ways in which the vehicle can be used. In Belgium a vehicle has been developed that carries out measurements of soil compaction automatically and saves the measurement results. To do this, it measures the force that is needed to enable a rod to penetrate the ground down to a specified depth.

The IPC PS1 controls two of the axes, X and Y. In the X-axis a stepping motor is used in order to obtain a series of measurement results, which are then saved. In the Y direction the measuring rod is extended and the force is recorded. The measurement data is stored in Excel format in the flash drive belonging to the CPU, and at the end of a series of measurements it is read out via RS232. In the office the data is then edited and evaluated using standard software. Hardware BP50 HC17 OM20 AM11 IO12 Pascal Soil examination, Excel, flash drive, force measurement 5-slot busboard PC/CHIP CPU, EPROM, RAM, flash Digital input/output module, each 8-bit Stepping motor module 8 x analog input module

Software Keywords

Measurement technology, data processing and quality assurance

57

Testing Tipptronic system modules

Tipptronic is a semi-automatic gear-shift system for cars. The driver selects a gear with the selection lever, and the gear is set electronically. There is no clutch for the driver to operate. The electronics also monitors whether the selected gear makes sense. Changing into reverse gear when travelling at 70 miles per hour on the motorway is therefore made impossible electronically. It goes without saying that the selection lever must always issue an unambiguous instruction to the electronics. And this instruction must precisely correspond to what the driver wants to do. Hco electronic GmbH manufactures these Tipptronic components and tests the system with the IPC PS1 Professional. The core of the Tipptronic is a curved printed circuit board with Hall sensors. The purpose of the test stand is to check whether the Hall sensors correctly signal the position of the selection lever.

The various positions of the selection lever are simulated with the aid of pneumatic cylinders, triggered by Festo valve terminals, with a magnet mounted on them. The gear selection status is output on LEDs. The state of the LEDs is picked up by photoresistors and is reported back to the testing system. What was important during the development of the test stand was that the system had to be very easy to adapt to new requirements, new shapes, and new types. From the beginning, the test cabinet was designed to allow space for expansion. A number of files are created for each component type, for example the job file, the limit value file and the CAQ file, where the measured data is stored. Altogether each measurement procedure currently amasses 37 measured values. The measurement system is operated using a standard keyboard and monitor as far as the measurement itself is concerned. The photo shows the control cabinet with the IPC PS1 together with the 14" monitor and the keyboard, as well as to the left of these the label printer. In addition the AS11 module with its 8 pushbuttons and LEDs is used in order to switch back and forth between various limit value files.

58

Measurement technology, data processing and quality assurance

Hardware

BP40 PS11 HC20-80 HD50 FC/FD10 AS11 CP30 OM70 IM12 2 x IO12 OM22 OM11

14-slot busboard built into a 19" rack Power supply unit 32-bit CPU with 486 processor with mathematical coprocessor 1 Gbyte hard disk Floppy disk controller and drive Combined 8-bit digital input/output module RS232 interface for the label printer 6 x relay output module 32-bit digital input module 8 x analog input module Digital input and output module, each 16-bit 16-bit digital output module

Software

The approach to programming was split into two: the control section including the test sequence was written in Step5, while the user interface, measured value acquisition, evaluation and data backup were written in C/C++. The two programming systems are connected via the real-time multitasking system on the basis of RT Kernel. Tipptronic, S5, C/C++, measured value acquisition, Hall sensor

Keywords

Measurement technology, data processing and quality assurance

59

Testing, testing, testing ... Testing Checkbox modules It is a fact that we are all familiar with: the more complex the module, the more elaborate the testing becomes. The Checkbox is a system for feeding correctly oriented small parts that checks the parts at the same time (see the description of the Checkbox in the section on control technology). The electronics for this are without doubt among the most demanding examples known. This is because the CPU is optimised for evaluation of the camera images and simultaneously controlling the input/outputs in the system. Apart from the in-process tests which every electronic module undergoes in the course of production, a final test is absolutely essential. In the case of the Checkbox hardware this has to be very flexible so that the test can be adapted to various versions of the CPU. Once again, the IPC PS1 was chosen as the centrepiece of the testing station, although without doubt one reason for this was that the Checkbox team were already thoroughly familiar with the IPC PS1.

An HC16 CPU, which in this case is able to concentrate entirely on testing, is quite sufficient here. A BG20 takes care of the graphical representation of the whole testing process, and input/output modules provide signals for the electronics under test, to which it has to respond.

60

Measurement technology, data processing and quality assurance

Needless to say, the test procedure also includes storage of the test data and subsequent evaluation in a database. Hardware BP50 HC16 OM22 IO10 IO60 BG20 5-slot busboard with power supply PC/CHIP CPU, EPROM, RAM, flash Digital input/output module, each 16-bit 8 x analog input module 4 x analog output module LCD display

Software

Programming is carried out in C/C++, because that is everyday routine for the Checkbox team. Electronics testing, Checkbox

Keywords

Measurement technology, data processing and quality assurance

61

Monitoring welding data

Inert-gas-shielded welding is one of the most commonly used welding techniques when producing circumferential welds for bicycle frames or similar products. As in so many cases, the testing of welds such as these is now a vital part of the manufacturing process. Where automatic test procedures are used, it makes sense to record the welding parameters while the actual welding operation is still in progress. These include the welding current, the flow of shielding gas and the welding voltage. Weber Robotertechnik GmbH has developed a system which detects the key parameters determining the quality of the welded seam independently of the welding control system. The SDC the welding data controller is integrated into the welding system and is totally transparent for the welding controller. The SDA the welding data display processes the data. In the simplest case, this includes calculation, with the result being a decision to accept or reject the weld, through to detailed graphical output on a printer or onto a network on a higher-level control desk.

Inside the SDA there is an IPC PS1 Professional beavering away, which is ideally suited to the task because it provides all of the necessary input/output modules to the SDC, the system remains small enough and programming of the PC-based system is no problem for the developers at Weber. Hardware BP50 HC12 IO10 CP70 CP31 5-slot busboard with power supply PC/CHIP CPU, EPROM, RAM, flash 8 x analog input module Printer interface 2 x serial interface

Software Keywords

Programming is carried out in C/C++. Welding, inert-gas-shielded welding

62

Measurement technology, data processing and quality assurance

Optimisation of a gasfired power station

By measuring the carbon monoxide (CO) and oxygen (O2) at the flue gas outlet header of a gas-fired power station, conclusions can be drawn as to the level of gas consumption and waste gas emissions by the power station. In order to reduce gas consumption and therefore also emissions in an existing gasfired power station in Spain, a measuring system with an IPC PS1 is installed at the flue gas outlet header; this exchanges data with another IPC in the central control room via an RS485 interface. In the control room the data is visualised and incorporated in the process control system. This feedback arrangement therefore enables process optimisation to be implemented within power station operation. The rugged and compact design of the PS1 system allows it to be used directly at the measurement location (the flue gas outlet header) under the difficult ambient conditions prevailing there for direct recording of the analog measurement signals from the gas sensors. This results in a cost-effective measurement system.

Hardware

IPC at the flue gas outlet header PS1-PB31 8-slot busboard PS1-PS10 Power supply unit HC12 PC/CHIP CPU, EPROM, RAM IM10 16-bit digital input module OM10 16-bit digital output module IO11 8-channel analog input module IPC in the process control room PS1-PB31 8-slot busboard PS1-PS10 Power supply unit PS1-HC12 PC/CHIP CPU, EPROM, RAM PS1-VM12 VGA module

Additional components: Measurement system for CO and O2 (gas sensors) Link between the two IPCs over a distance of about 200m via RS485 Software Programming was carried out in C, because in that way adaptation to the existing system was easy and flexible. Process optimisation, measurement of gas emissions, process control system, process visualisation, RS485, C/C++

Keywords

Measurement technology, data processing and quality assurance

63

Quality assurance in cylinder manufacture

A test station in which pneumatic cylinders are tested in various steps is controlled by an IPC PS1. The crucial test step is the leak test performed with the cylinder at its various operational stages (extended and retracted). The test principle used is measurement of the pressure drop. The cylinder is pressurised and hermetically sealed. The pressure drop within a defined period of time and depending on the size of the cylinder must not exceed a specified value. Various pressure levels are set with the aid of a proportional valve, depending on the type of cylinder involved. This calls for the use of a computer-controlled D/A converter. In order to be able to evaluate the test results in the central computer, the test system is connected to the company's local area network and thereby to the QA computer. After conclusion of the test phase, the program is stored in an EPROM. This means that no mass storage is required, the system is immediately ready for operation on startup and operational reliability is enhanced. Hardware PB31 PS10 HC12 IM10 OM10 CP11 IO70 DIS2 8-slot busboard Power supply unit PC/CHIP CPU, EPROM, RAM 16-bit digital input module 16-bit digital output module Ethernet interface 2 x analog output module LCD display

Software

The entire program is written in Turbo Pascal. The LAN is a Novell network, so the measuring station is a Novell client. Quality assurance, pressure regulation by proportional valve, Ethernet, Novell, Pascal

Keywords

64

Measurement technology, data processing and quality assurance

Acquisition of measured data and controlling an aerial in a measuring balloon

A research project conducted in collaboration with UNICEF is intended to provide information on, among other things, the connection between energy transfer in the atmosphere and the phenomenon known as the jetstream. The required data is collected in a balloon. In addition to the measuring instruments, the balloon also contains a telecommunications unit that operates via a satellite link. This means that the aerial alignment has to be continuously corrected in order to track the appropriate satellite. Data collection and aerial control are taken care of by an IPC. The IPC receives the digitised measured values from a device for measuring the field strength of radio waves, assigns a time stamp to the values and stores them. Because umpteen thousands of measurements are taken in the course of a flight, the data is stored on a floppy disk. The alignment of the aerial is adjusted using an electric linear drive, which is controlled from a digital output on the IPC. All of the indicating and operating options offered by the IPC system are reduced to a minimum, to keep energy consumption down. The operator actions required for starting the system are therefore performed via a key and

LED module. IPC PS1 is predestined for this application because of its PC compatibility, its rugged and compact design and the possibility of running it in energy-saving 12 V mode. Hardware PS1-BP50 PS1-HC12 PS1-AS11 PS1-OM20 PS1-FC10 PS1-FD10 5-slot busboard with power supply PC/CHIP CPU, EPROM, RAM Input/output module with 8 pushbuttons and 8 LEDs Digital input and output module, each 8-bit Controller for a floppy disk drive Floppy disk drive

Software

Programming was carried out with Quick Basic; this meant that the values taken from measuring the field strength could be transferred using a simple digital interface. Measured data acquisition, measurement of field strength of radio waves, satellite telecommunications, energy consumption, Quick Basic

Keywords

Measurement technology, data processing and quality assurance

65

Examination of rubber compounds

Rubber (caoutchouc, India rubber) and similar materials are used in an endless number of different forms and an endless number of different applications: as vibration dampers or seals, as toys or braking elements, bonded or screwed, and so on and so forth. A huge range of different requirements have to be met, depending on the particular use. And depending on these requirements, different mixtures of the parent materials have to be used. With a great deal of experience and sophisticated calculation algorithms it is possible to draw conclusions as to the composition of the material and the mixing ratio of the starting materials on the basis of stress tests. Scarabaeus is a company that has developed the know-how to perform and evaluate slow-running automated load tests. The particular skill in this connection is to match the temperature and the course of the stress tests to each other correctly, and to record the material behaviour accurately in a single series of measurements. The series of measurements with its ups and downs of material deformation and material reaction can be evaluated mathematically. The evaluation provides an indication of whether the material is suitable for the stated purpose or in what way the mixing ratios need to be changed in order to better adapt the material to the requirements.

The hardware for the control system consists of two separate IPC PS1 systems. One is responsible for controlling the stress test, and one deals with recording the measurement data. The measurement data is sent cyclically to a higher-level computer, which takes care of graphical representation and further evaluation of the data. Several versions of the entire system were programmed in C/C++, because this offers the best flexibility in dealing with data and communications. The disadvantage of this form of programming, though, is that troubleshooting in the program is relatively

66

Measurement technology, data processing and quality assurance

difficult. This is because the high-level language system always assumes that the program editor and the target system are available at the same time on one computer. In this case, however, the target system is the IPC PS1, while the programming workstation can be any Windows PC. For this reason the programming was switched to MULTIPROG. This programming system provides the possibility of dealing with the widest variety of data types, including real numbers, and performing calculations with them. The Structured Text programming language is also similar to the familiar C or Pascal environment, which meant that familiarisation went very quickly. Hardware A typical system has roughly the following components. BP50 5-slot busboard with power supply HC20-50 32-bit CPU with 586 processor, Compact Flash slot OM21 Digital input/output module, each 8-bit IO40 4 x analog input module CP30 Serial interface MULTIPROG Material test, rubber, MULTIPROG

Software Keywords

Measurement technology, data processing and quality assurance

67

Testing CAN valves

Even if it is the case that hydraulic, pneumatic, vacuum or other valves are nowadays supplied more and more often with fieldbus connections, there is barely a single product line that is produced exclusively with a fieldbus connection. The CAN bus has a particularly important part to play in the field of automobiles and trucks. This is not solely due to the fact that CAN was originally developed for car manufacture. It is also a fact that the CAN chip, in other words the hardware for CAN, is particularly inexpensive thanks to mass production, and this makes CAN interesting for large-scale applications such as cars, trucks etc. If a manufacturer intends to supply valves for this field of work, he will usually offer an existing valve series with the addition of a variant with a CAN interface. In manufacture, this additional variant imposes new requirements on the organisation of production. Above all it is necessary that the newly introduced variant should also be tested: 100% test, statistical quality control, backing up of the test data, constant, reproducible test criteria all necessary adaptations to the new variant of the valve with a CAN interface.

The Atega box on the test line

ATEGA, a company based in Vlklingen, near the Franco-German border, has developed a small test box to cope with this problem; it is simply integrated into the existing production chain. It is only when confronted by valve types with a CAN interface that the test does not apply directly to the valve solenoid but instead is run via the ATEGA test box. The box uses the CAN protocol to switch, test and check the valves. The essential advantage of this is that the manufacturer is able to retain his established production line and simply has to slip the CAN valves in between. Thanks to the PS1 system, the test box is small and manageable despite being equipped with the BG10 for operator guidance. ATEGA has also made it possible to integrate special customer-specific communication protocols in addition to the standard fieldbus protocols by means of a universal PS1 module that they have manufactured themselves. An ATEGA level converter takes care of the task of adaptation and tests the product; in all of this, production remains as flexible as before.

68

Measurement technology, data processing and quality assurance

The Atega box in development

Hardware

BP31 PS10 HC27 CP30 OM21 OM70 CP81 DK10 BG10

8-slot busboard Power supply unit CPU 486 DX25 RS232 interface 8-bit digital input and output module 6-bit digital relay output module, 8A CAN interface Blank module with the ATEGA adaptation Operating terminal

Software

All of the programming is done in C++. For this, ATEGA uses a developer CPU equipped with a hard disk for code development, debugging and compiling. The finished EXE file can then run in a CPU with a smaller hard disk. Fieldbus, CAN, flexible testing, quality control, C++

Keywords

Measurement technology, data processing and quality assurance

69

Measuring soot content in the air

Soot content why do we need to know about that? Now that emissions of sulphur and nitrogen oxides are not as significant as they once were, because flue gas desulphurisation in power stations and catalytic converters in cars are taking effect, measuring soot content is becoming more and more important. What this means, though, is not measuring the soot that you can knock off the washing hanging in the garden, as was still common in the vicinity of coal-fired power stations or steelworks some 30 years ago. This is about measuring extremely fine soot particles which are respirable and which have adsorbed pollutants on their surface. These particles are produced in internal combustion engines. Soot of this size can be measured with an Aethalometer, anywhere from the Antarctic to the centre of Frankfurt. And the IPC PS1 is always there as well. Software that was developed at an American university, the computer technology of IPC PS1 Professional, production technology honed in a Slovenian high-tech workshop, marketing capacity provided by an expert in Bad Homburg all of this combined produced the Aethalometer, an automatic measuring instrument used in environmental protection. The air is directed through an optically homogeneous quartz paper. A sophisticated system of sensors detects changes in the colour of the paper. The computer calculates the soot content in the air from the rate of change of the blackness of the paper and the flow of air through the paper. The data is time-stamped and saved. Depending on the particular application, the data is temporarily stored in the system, fed directly into a network or retrieved by modem at specified times. In environmental protection, it is always a requirement that measurements should be precise and reliable. The Aethalometer helps to achieve this.

International cooperation

How does that work?

Hardware

BP50 HC16 IO70 IO41 FC/FD10 OM10 DIS 2

5-slot busboard with power supply PC/CHIP CPU, EPROM, RAM, flash 2 x analog output module 4 x analog input module Floppy disk controller and drive 16 x digital input module LCD display

Software

The programming was carried out in C/C++, as would be expected from an American university. Soot measurement, Aethalometer, environmental protection, telemonitoring, modem, C/C++

Keywords

70

Measurement technology, data processing and quality assurance

Monitoring a radio station's highfrequency band

Two measuring receivers, each of which is controlled by an IPC via a separate RS 232C interface, have the task of monitoring a radio station's HF band. This converter station is located on Mount Kilimanjaro at about 6000 m above sea level. Because frequent power failures have to be expected in such a situation, a 12 V car battery is used as a simple uninterruptible power supply unit. The IPC PS1, which records, stores and preprocesses the measured values from the receivers, is integrated into an Ethernet network via which it is operated by remote control. The IPC PS1 is particularly well suited to this task thanks to its ruggedness, its PC compatibility and its ability to work with a 12 V supply while consuming little power.

Hardware

PS1-BP11 PS1-HC17 PS1-CP30 PS1-CP10

3-slot busboard with power supply PC/CHIP CPU, EPROM, RAM, flash Serial interface (2 x) Ethernet interface

Additional components: 2 measuring receivers Battery and charger Software Keywords Pascal Measured data acquisition, remote control, Ethernet, 12 V operation

Measurement technology, data processing and quality assurance

71

Programming in C/C++

Modern-day automation technology has long since advanced beyond the boundaries of Boolean algebra. Whether it is a matter of processing analog measured values, storing test data, the visualisation of production returns or the continuous acquisition of operational data the simple ANDing of a number of digital inputs is a necessary part of this, but it is no longer enough. Today's engineers who are now emerging from university or technical school are moulded by a world of PCs, by communications and measured data, and by the feasibility of what can be achieved with software and hardware. Every graduate of a technical degree course today has at least some idea of what programming in C/C++ means. And many have even done some programming themselves and have learnt what possibilities and freedoms this language offers. All of the central processing units of the IPC system, whether the mini controllers of the IPC FEC or the Pentium CPU of the IPC PS1 Professional, are always a PC as well, and as such can be programmed in C/C++. The fact that this method of programming very much lends itself to many applications such as gateways, user guidance, measured value processing etc. quickly becomes quite clear. The fact that one family of controllers offers this possibility is unique. At many points in this book there are reports of examples which are based on programming in C/C++.

72

Measurement technology, data processing and quality assurance

Process control systems, laboratory technology and hydraulic engineering

Our drinking water meets high quality standards thanks to drinking water treatment, the filtering of drinking water, inspection, and much more besides. Pharmaceuticals or chemicals are subjected to the most careful testing before they are brought into circulation. A single test is meaningless in this context. Hundreds, thousands, or millions of tests are needed in order to obtain reliable findings. Washing powder is supposed to ensure that our washing emerges fresh and clean from the washing machine. How do the manufacturers know what the formulation has to be in order to achieve the best possible results? By an endless number of test wash cycles, all monitored, logged and controlled by automation systems. Process control engineering needs control loops, time, and repetition. The PC-based systems of the IPC PS1 are ideally suited to tasks such as these. In this section you will find a few examples from process control engineering. Enjoy your read.

Process control systems, laboratory technology and hydraulic engineering

73

Water treatment

Many plants and systems used in water treatment have been implemented with the IPC PS1 system in recent years, and previously with the FPC 405. Examples of these include: _ Filtration plant for drinking water with a particularly interesting system for controlling the Keystone flaps, which is implemented with an FPC405 software regulator and Festo proportional valve. _ Water flow regulation for filter cleaning _ Air pressure regulation with fan for filter cleaning _ Telemonitoring of process variables (pressure, temperature, flow rate) _ Test station for Keystone fittings _ Well control, telemonitoring, optimisation _ Measured data acquisition system _ Integration of control systems on the basis of the ViP process visualisation system _ Integration of data into a database (production, distribution, maintenance ...) _ Process visualisation with ViP WIN _ Control of the aeration system, the water storage tank and the pumping stations _ Control, monitoring and regulation of the entire water treatment works consisting of wells, water treatment filtration plant (aeration, filtration plant with sand filter and integration with the ozone block) _ Filtration plant with carbon filter _ Pumping station with water storage tank monitoring system and control room _ Well control systems for various groups of wells over an area _ Control of the pressure filter plants _ Various filtration technologies are used, including sand filters, carbon filters (similar to sand filters) and pressure filters. The Novi Sad water treatment for example works underwent modernisation in 1996. The filtration plant consists of 2 buildings, each with 12 sand filters. Each filter has an area of 36 m2 and a flow rate of approximately 60 l/s. Altogether, the waterworks supplies about 1500 l/s of drinking water.

Sand filter technology

A sand filter works at its best when the flow through the filter is within defined limits. One method of regulation is to measure the flow and control the flap for clean water. Because of the geometry of the pipes, and due to a lack of space, this is not always possible. Flowmeters are expensive. One alternative method is to measure the water level in the filter. The level is kept constant. The geometry and diameter of the pipes ensures that the untreated water is distributed evenly to all filters. Maintaining a constant level means maintaining a constant flow.

74

Process control systems, laboratory technology and hydraulic engineering

Each filter has 6 Keystone flaps controlled by Festo valves for: _ Untreated water _ Clean water (controlled) _ Sewer _ First filtrate _ Cleaning water _ Air for filter cleaning Control of the flap for clean water is carried out: 1. discontinuously with 5/3- or two 3/2-way valves or 2. continuously with the proportional valve. Control of water flow for filter cleaning Untreated water Clean water

Variant 1

Advantages No analog outputs are necessary and manual operation is easy to implement Air consumption is low and regulation is carried out continuously

Nachteile High level of air consumption and difficult to regulate Analog outputs are necessary

The control loops are implemented in accordance with variant 2, with good experience. The regulators are stable. One controller controls 12 filters. A software regulator has 12 control loops. A mathematical model was specifically designed for this purpose. The regulator parameters are optimised with technologists at the waterworks. The flaps must not change position quickly because otherwise the water quality would deteriorate. The parameters can be adjusted with the ViP process visualisation system, which is also used to observe the behaviour of the control loop. Optimum filter cleaning is achieved with a certain rate of water flow. The regulation system was set up to ensure this. The operator can define the setpoint values for the flow rate and the time (duration) in the ViP process visualisation system. A controller with a software regulator assumes the function of the regulator. The values are stored and later evaluated.

Process control systems, laboratory technology and hydraulic engineering

75

Sewer

Water for filter cleaning

Sewer

Fan

Air pressure regulation for filter cleaning

Filter cleaning begins with the feeding of air from below. The rate of air flow is regulated. Too much air can blow the sand out of the filter. The operator can define the setpoints for the flap position and the time (duration) in the process visualisation system. A controller with a software regulator assumes the function of the regulator. The values are stored with an industrial data acquisition system and subsequently evaluated. The distribution of water requires that the pressure and, if applicable, the flow should be measured at various points and the values transmitted, visualised and stored. The local stations are implemented with IPC PS1 modules. The data is transmitted by telephone, over leased lines. The ViP process visualisation system is installed in the dispatcher centre. A special-purpose communications driver takes over the data from the remote stations. The collected data is displayed with ViP Trend2 and stored.

Telemonitoring of process variables

Test station for Keystone fittings

Before and after the Keystone drives are repaired, the customer would like to perform a test. A number of different parameters are measured. In addition, a service engineer can test and adjust the limit switch. The plant for aerating the untreated water comprises two buildings, each with two main pipes. The untreated water arrives with a flow rate of Q0 and a pressure of P0. The regulator must maintain a constant pressure in four pipes. This ensures that the water is evenly distributed and the plant operates at optimum efficiency. A controller and software regulator are provided for the purpose of regulation. A PC with ViP for visualisation and parameterisation of the plant is installed in the control room.

Aeration for untreated water

76

Process control systems, laboratory technology and hydraulic engineering

Q 11, P11

Q 12, P12 Q 0 , P0 Q 21, P21

Q 22, P22

Water storage tank control

The level in the water storage tank is signalled to the pumping station and control centre by radio. In the control room, this information is used for closed-loop control of the entire system. Operation by remote control is also possible, and is used for controlling the flaps or pumps. A separate IPC PS1 station is used for data acquisition. A radio modem and radio transceivers are used for communications. The command centre for the wells is equipped with the system for remote control and monitoring of the individual wells on the basis of the VIP software. BHD wells are equipped with transmitters for water level, pressure and motor current, and with IPC and Profibus communication modules. Data is transmitted via Profibus. The command centre and the central control room are linked by modem via dedicated lines. Optimisation software analyses the values and presents the operator with a recommendation as to what subsequent action needs to be taken.

Well control

Measured data acquisition system

A large number of measured values are gathered at the command centre. About 40 analog signals are connected to a controller and are visualised and evaluated with a ViP station. The PC with the ViP process visualisation is part of the network, and the collected data is analysed and processed on various workstations. All of the control stations mentioned above should be integrated into one control console. Water production (wells and the filtration plant) and distribution (pumping stations, water storage tank and network) are integrated into a VIP WIN online database system. All technical and real-time data is stored in one common database and is made available to various workstations. The maintenance team has its own workstation that

Integration of control systems

Process control systems, laboratory technology and hydraulic engineering

77

displays all alarms and preventive maintenance data. All information about pumps, flaps and other devices is stored in the database. This makes maintenance work easier, and increases the availability of the plant. The plant technologist carries out process analysis at a workstation at which all online data, recorded operational data and special-purpose calculation programs are available to him. Laboratory data is entered manually, and evaluated together with the other data. Keywords Proportional valves, waterworks, wells, filters, filter cleaning, flow rate, fans, Keystone flaps, process control systems, telemonitoring, process visualisation, remote data transmission via modem and radio, operational data acquisition

78

Process control systems, laboratory technology and hydraulic engineering

Ensuring cleanliness in cheese production

Many blue cheeses count as delicacies for the cheese connoisseur. And the mere mention of a genuine Irish Cheddar is enough for some people to start salivating in anticipation. After a little thought, however, it very quickly becomes plain that the maturing of cheese from milk or the process of blue cheese "going mouldy" does not just happen "somehow", but has to be carried out under reproducible, precisely defined conditions. One external and necessary prerequisite for reproducibility and hence also consistent quality is the cleaning of and maintaining the cleanliness of all pipes, tubes, connections and valves. The requirements regarding cleanliness in the food sector are immense. On the one hand this is a matter of the actual process of cleaning, which at heart is a relatively simple form of sequence control. A series of process steps, starting with flushing and proceeding through heating and the addition of various cleaning agents, has to be worked through consecutively. A particularly critical task, on the other hand, is checking and logging the results of the cleaning work. It is not enough simply to go through the usual tasks one after the other, it is also of the very greatest importance to check precisely that the cleaning work has indeed brought about the desired result, and to record that fact. An Irish cheese producer controls and monitors every aspect of cleaning the pipes and tubes with the IPC PS1 Professional. In collaboration with Festo Ireland, the system was set up in such a way that an IPC is responsible for each section of piping that belongs together. A master computer collects the data via a fieldbus, and makes it available to a process visualisation system. The process visualisation system is responsible for recording and storing the process data. In addition, the operating personnel at the central visualisation station are presented with a clear overview of all process data.

Hardware

The master computer is equipped as follows: BP40 14-slot busboard PS10 Power supply unit IO10 8 x analog input module HC16-F PC/CHIP CPU with FST kernel CP61 Festo fieldbus master IM11 16-bit digital input module OM11 16-bit digital output module CP14 Ethernet interface All of the IPC PS1s are programmed in FST, as is the master computer. The reason for this is above all that it is very easy to program the actual cleaning process, as well as the fact that it provides excellent support for the fieldbus and the Ethernet interface. Food industry, process visualisation, Festo fieldbus, Ethernet, FST

Software

Keywords

Process control systems, laboratory technology and hydraulic engineering

79

Statistical process control in the manufacture of thermocylinders

The production of thermocylinders for thermostats in the automotive industry has been automated. The existing production machine, which operated semi-automatically, is now controlled by an lPC; this allows the production parameters to be changed easily when required. Because a 100% test is required at the end of the production process, a test station was also automated with the aid of an IPC controller. The test station performs a statistical analysis of the results of measurement of a defined test variable, and in the event that the predetermined limit values are exceeded, it proposes readjustment of the parameters in the production machine. In addition, the measured values can be processed with a standard spreadsheet program. The method of statistical process control implemented in this way ensures that the level of production quality achieved is consistently high. Storage of the test results ensures that the traceability required by the DIN EN ISO 9000 ff series of standards can be guaranteed.

Special features

Separate programs have to be developed for the production station and the test station, but these are networked and exchange data between each other. Standard software is used on the test PC. The advantages of a PC-compatible controller such as that provided by the PS1 system in a design created for a manufacturing environment are quite obvious in this situation. The production station essentially contains the digital inputs and outputs required for controlling the production machine, together with an analog input module that enables the production machine to be monitored:

Hardware

BP50 5-slot busboard HC12 PC/CHIP CPU, EPROM, RAM IM10 16-bit digital input module OM10 16-bit digital output module CP70 Printer interface IO10 8 x analog input module DIS2 LCD display In addition: printer and standard software package for analysis of the data. Company: Dauphinoise Thomson, France

Keywords

Statistical process control, quality assurance, DIN EN ISO 9000ff

80

Process control systems, laboratory technology and hydraulic engineering

Data acquisition in sewage treatment plants

In sewage treatment plants there is a large amount of operational data that needs to be monitored and visualised. In this application the IPC PS1 operates as an autonomous data acquisition system alongside the control system for the sewage works as a whole. 16 analog and 80 digital signals are recorded. The analog signals are archived and statistically analysed. The digital signals are evaluated as faults, counters or elapsed time meters. The preprocessed data is passed to a visualisation system via an RS232 link. Thanks to its rugged and modular design, its compact dimensions and its ability to be programmed in high-level languages, the IPC PS1 is a highly suitable yet at the same time cost-effective choice for decentralised data acquisition systems of this type. As well as this, its low energy requirements are another obvious benefit in this connection.

Hardware

A typical configuration consists of the following: BP40 14-slot busboard PS10 Power supply unit HC16 PC/CHIP CPU, EPROM, RAM, flash 5 x IM10 16-bit digital input module OM10 16-bit digital output module CP31 Serial interface (2 x) 2 x IO11 8 x analog input module ZP70 Printer interface Radio-controlled clock with connection to RS232c Printer The engineering consultants Ingenieurbro Katz, who were responsible for every aspect of implementation of the system, used C/C++ as the programming language: above all this offers flexibility in data management and the control of serial data transmission, and is easy to use with the IPC PS1. Data acquisition systems, statistical analysis, C/C++, sewage treatment plants, printer, clock

Software

Keywords

Process control systems, laboratory technology and hydraulic engineering

81

Controlling a biological trickling filter scrubber

System engineering GmbH Ilmenau is a company that uses the PS1 system in various configurations for solving a variety of problems. One of the most recent applications is the control of a biological trickling filter scrubber. This is a reactor built on a pilot scale with the objective of removing hydrocarbon compounds from the exhaust air from production plants by biological means. The trickling filter scrubber consists of a cylinder, about three metres in height, through which the air that is to be cleaned flows as well as a flow of liquid to supply the biomass with water and trace elements. The bacteria themselves are situated on carrier structures inside this cylinder.

In order to deal with the task in hand, about 20 analog and digital signals have to be monitored, such as liquid levels, temperatures, flow rates of gas and liquid, and pH values. The process is influenced by means of a variety of actuators: mass flow controller, electrical and pneumatic valves and any number of pumps, the speeds of which in some cases are controlled using frequency converters.

82

Process control systems, laboratory technology and hydraulic engineering

Hardware

BP40 14-slot busboard PS10 Power supply unit HC20 32-bit CPU, CF, flash IM11 16-bit digital input module 2 * IO11 8 x analog input module, current IO12 8 x analog input module, voltage OM12 32-bit digital output module IO60 4 x analog output module CP3x RS232 interface All sensors and actuators are electrically isolated from the IPC modules by coupling relays or analog couplers. The software used for the controller is a small process control system on the basis of WinErs, software developed by engineering consultants Ing.-Bro Dr.Schoop. The drivers for this were developed at SEI. In addition to the possibility of allowing graphical planning of the controller, this system also provides modules for data acquisition, archiving and visualisation. The installation is operated from a PC running Microsoft Windows, which is connected to the IPC either via a null modem cable, a modem or Ethernet. This means that monitoring can also be performed from a remote location. In standalone operation without an operating computer, the accruing measurement data is buffered in the IPC's CPU for up to several days. Various operating modes are run through automatically (startup, cleaning, operation), while control in manual mode is also possible. The illustration shows part of the control system as a sequencer. In this way, WinErs can be used both for programming and later for visualisation of the control system.

Software

Part of the control system as a sequencer

Keywords

Biological exhaust air purification, level measurement, temperature measurement, flow rate, pH value, process control, telemonitoring 83

Process control systems, laboratory technology and hydraulic engineering

Determining the cell state of microorganisms

Of course you know that "plastic" is not degradable. This is why we have recycling markings on packaging, why we segregate different types of waste, why there is an ongoing discussion on replacing plastic packaging with paper packaging, for example. In the meantime, however, biologically degradable types of plastic have been developed. These are produced, for example, by microorganisms (such as bacteria) "eating" raw materials and in so doing converting them into types of plastic which in turn can be decomposed by other bacteria. The microorganisms are alive a prerequisite for them being able to "work" at all. The degree of well-being of these organisms can be identified from their consumption of oxygen in much the same way as with us humans. When we are fit and producing our top performance we consume more oxygen than when we are worn out and tired. On the basis of the level of oxygen consumption, therefore, it is possible to draw direct conclusions as to the productivity of the system. Measurement of the oxygen provides information on the progress of production, on the speed of production and finally on whether production is completed this is because at some time or other the bacteria will start to consume the desired end product. After all, it is biodegradable. In addition to the use of oxygen measurement within the production of materials, this method of measurement can also be used to establish whether bacteria are capable of decomposing certain materials: contaminated soil, mixtures of chemicals and many other similar substances can be selectively fed to bacterial cultures to be "eaten" the bioactivity sensor determines whether the bacteria are able to eliminate the contaminants.

What does the "cell state" tell us?

What does the PS1 system do?

The core of the system for determining the cell state is an oxygen electrode. The electrode requires a defined voltage supply and a specific method of signal conditioning. An independent input module was developed specially for this purpose, and was integrated into the IPC PS1 system. In order to obtain a meaningful analysis of the data from the oxygen electrode, a powerful computer system is required. The program must be structured in such a way that the test can be adapted to a range of different tasks. After the system has been configured, the data has to be logged, stored and displayed. This is where the openness of the PC is ideal. At the same time, it should be possible to put the system to use directly in production or in mobile laboratory systems, which is why suitability for industrial use was called for. The compact IPC PS1 is therefore an obvious choice.

84

Process control systems, laboratory technology and hydraulic engineering

Hardware

HC15 OM74 OM70 IO12 IPC-OXi

PC/CHIP CPU, EPROM, RAM 16-bit relay output module 6-bit relay output module with max. 8A switching capacity for direct control of the pumps 8 x analog input module Company-developed analog module for the oxygen electrode

The IPC-OXi module: Electrode bias voltage: Measured current:

-500 to -900 mV up to 10 A. Variable adjustment of the gain with external potentiometer Operating voltage: 12 to 36 V from the PS1 busboard Output voltage: 0 to 10 V Power demand: approx. 1 W Connection of 2 Clark electrodes per module Software Programming was carried out in C/C++ with the aid of the Borland C compiler. First a program flowchart is drawn up by hand for the purpose of program planning, and this is then converted into C code. The Quinn-Curtis library is used for visualisation of the measured values. Measuring bioactivity, Clark electrode, bacteria

Keywords

Process control systems, laboratory technology and hydraulic engineering

85

Filling up with liquefied natural gas

Diehl Automation GmbH produces the entire control system for the first mobile filling station for liquefied natural gas (LNG) in Germany, on the basis of the PS1 system. Liquefied natural gas is one of the energy options of the future for traffic on our roads. LNG is based on natural gas, the stocks of which according to today's understanding will last longer than the stocks of mineral oil. The essential advantage of using LNG in internal combustion engines is that an LNG-powered engine emits 80% less carbon monoxide (CO) than a petrol engine and 60% less than a diesel engine. Oxides of nitrogen (NOx) are reduced by 65% and 80% respectively, while benzene and soot particles are not produced by LNG engines at all; the generation of ground-level ozone, the cause of summer smog, is reduced by 60%. LNG therefore stands out because of its environmental friendliness in comparison with traditional petrol or diesel engines. The temperature of LNG is 161 C; it is in the liquid state at this temperature, and must be stored in appropriately isolated tanks.

Mobile LNG tank

The mobile filling station that was developed and built for Messer Griesheim GmbH is designed to deliver supplies of LNG for vehicles which are intended to prove the suitability of LNG engines in real, everyday use. Diehl DAS 5 Diehl Automation calls the control system DAS5. The basis for the hardware is provided by the IPC PS1 with analog and digital I/Os in conjunction with communication to a control system via a modem. The software uses the RT kernel to create a real-time-capable multitasking system. Building on this, function blocks were written for all functions of the filling station. This modular software concept makes for easier maintenance and troubleshooting. This is because the individual functions such as cooling, filling the tank, refuelling vehicles etc. are each provided as separate modules.

86

Process control systems, laboratory technology and hydraulic engineering

Sending a log fax by modem

A GSM modem connected to an RS232 interface sends a log fax about every refuelling and filling operation to the central control desk at Messer Griesheim. As a result, Messer Griesheim always has an up-to-date overview of the operational status of the LNG filling station.

The control cabinet mounted on the truck

PS1 configuration

BP40 HC27 CP30 MC10 AS11 x IM11 OM40 OM70 IO11

14-slot busboard 486 CPU Additional COM2 (for terminal) and COM3 (for GSM modem) PCMCIA interface (for program updates via SRAM card) Pushbuttons and LEDs for maintenance 16 digital inputs 16 digital outputs with connection to Festo CPV valve terminals 6 relay outputs 8 analog inputs

Keywords

Filling station, remote data transmission, fax, RT kernel, GSM

Process control systems, laboratory technology and hydraulic engineering

87

Providing for clean water

Water is the stuff of life. Drinking water is a vitally essential commodity. The quality of the drinking water provided must be healthy and pure. The PS1 system helps to safeguard the supply of drinking water. Water comes out of the tap and disappears down the plughole. That's all. Have you ever stopped to think about everything that is necessary to maintain the cycle of water extraction, water distribution, water disposal and water purification? Hardly any of us step back to give this any thought any more. To make sure that we don't have to think, other people have done some serious thinking and have used the PS1 system.

Wells by the Danube

The extraction of drinking water in the vicinity of rivers is often based on the use of wells. The wells, which may be more than 100 m deep, draw groundwater that has been filtered through the sand strata in the area alongside the river. The water is pumped to a water treatment plant, which removes contaminants which have not been trapped by the natural sand filtering, and is finally pumped to the consumers. In order to supply a mid-sized city of around half a million inhabitants, dozens of wells are required. Every well represents a considerable investment. It is generally the case that entire families of wells are built. Often this means several "small" wells being arranged around a "larger" well. The way in which the water is drawn from the well is one of the decisive factors in the longevity of a well. If the well is constantly pumped empty, to the very limit, this is just as damaging as if it is not used at all for a long period of time. The role of the PS1 system is to optimise water extraction with this in mind.

Remote maintenance

Festo Austria has supplied and installed the entire set of remote maintenance and telemonitoring equipment for well installations of this type. A well installation consisting of about 10 wells extending over an area totalling perhaps 5 km in diameter is combined to form a single group. Each individual well is "taken care of" by an IPC PS1. The wells are networked with each other by means of Profibus FMS, and the data is collected in a separate IPC PS1 for each group. A small local control console belonging to the group of wells includes a standard PC, where visualisation of the group is provided on site with the aid of VIP, the process visualisation system from Festo Austria. Functions for telemonitoring, remote diagnosis, remote control and data acquisition are all implemented on the control console. The group IPC is connected via a modem to a higher-level control station that enables all of the groups of wells to be brought together under one umbrella and visualised accordingly. As a result, in the specific project we are referring to here, in Novi Sad, it is possible for the first time to view and manipulate well parameters from a central control room with the aid of VIP, the visualisation of industrial processes.

88

Process control systems, laboratory technology and hydraulic engineering

Well control

Every well is assigned its own IPC, which operates autonomously to ensure optimum control of the pumps for the well. To help it do this there is a system of sensors that provides information about the water level, pressure, flow rate, electricity consumption, pump parameters etc. The electrical parameters of the three to four pumps for each well are monitored by a separate measuring device. These measuring instruments are connected to a PS1-CP30 via an RS485 interface. Networking with the other stations and the control console is via Profibus FMS. The unusual situation of a well installation requires special protective measures for the electronics. Above all, there are three particular aspects that are important: Firstly, the immediate surroundings of the well are cooled to a large extent by the water extracted from deep in the earth. In winter, though, it can become bitterly cold and damp. For that reason, all of the control cabinets are heated. Secondly, in a distributed system of this nature it is quite possible for the power supply to fail fairly frequently. Consequently, an uninterruptible power supply is fitted in the control cabinet for each local control console; this safeguards the power supply for a period of roughly 15 minutes. That is enough time to be sure of informing the control centre that the power has failed. Thirdly, in a system that is spread out over distances of several kilometres there is a risk of lightning strikes on the connecting lines. To counter this, all sensors are decoupled by means of surge voltage protectors, the actuators are controlled with the aid of relays and the Profibus is run via fibre optic cable. A converter from RS485 to fibre optic cable is provided for this purpose at every station. The overall effect of these protective measures has stood the test excellently in practice.

Environmental conditions

Process control systems, laboratory technology and hydraulic engineering

89

A control cabinet with a heater

Hardware

Example of a PS1 configuration: BP31 8-slot busboard PS10 Power supply unit HC16-F CPU I048 Analog input module IM11 Digital input module OM21 Digital I/O module CP61 Profibus FMS module CP30 with RS485 The systems are programmed with FST software. One of the key reasons for choosing the FST software was the openness of the software for additional drivers. For example, an external firm of engineering consultants, being familiar with the driver interface for the FST software, wrote a driver for the RS485 interface to the measuring devices and a driver for controlling the modems. To this must be added the fact that the Cl, the interface for troubleshooting, is so simply designed that a large range of software and devices are very easily able to access systems programmed with FST. Well control, pump parameters, telemonitoring, remote diagnosis, RS485, Profibus, process visualisation, lightning protection, environmental conditions

Software

Keywords

90

Process control systems, laboratory technology and hydraulic engineering

Edutainment and simulation

Have you ever driven a formula 1 racing car? Did you think it was out of the question? Well, perhaps you can after all. Because advanced simulation technology, which was previously only available for the training of aircraft pilots, has now found its way into much more widespread use. Pneumatic or hydraulic drives, sophisticated control technology, video sequences which allow the depiction of every road from every viewing angle all of these are already in use today. One aspect is the excitement and fun to be had in a simulated car race, but there is also the possibility of imparting knowledge, for example in museums. In those applications, figures and images are set in motion in order to make history and literature come to life and be easier to learn.

In this section you will find a few examples of edutainment applications using the very latest automation technology. Have fun reading about them.

Edutainment and simulation

91

Discoveries on the high seas

How can history be made into something that can be experienced, or even sensed and felt as if at first hand? What does it actually mean when we hear and read about seafarers who went on voyages of discovery many years ago? At the Heureka science museum in Finland, an attempt has been made to answer this question using modern simulation technology. In 1878/79, the explorer Adolf Erik Nordenskild and his crew were the first to traverse the Northeast Passage in his ship the "Vega". A reconstruction of the forward section of the "Vega" is on show at the Heureka science centre, mounted on a pneumatically driven platform. The system is set in motion by means of an intelligently arranged cylinder combination in such a way that people standing on it are given the impression of being on a ship on the high seas. Within the controller's multitasking system, each cylinder has a separate program dedicated to it which controls the valves. Each cylinder can be set individually, with the settings ranging from storm to calm seas, and from light waves to full sail. A truly impressive experience.

The octahedron of the pneumatic cylinders and the associated controller are designed in such a way that they can create motion in all sorts of different models. As a result, 92

Edutainment and simulation

Heureka is making the simulation technology itself an exhibit of the museum: a small model of a ship, about 1 m long, uses exactly the same simulation technology as the "Vega", only on a smaller scale. This is learning about history and technology by sensing it and experiencing it. Hardware BP50 HC16-F OM22 IO10 IO60 5-slot busboard PC/CHIP CPU, EPROM, flash, FST kernel Digital input/outputs, each 16-bit 8 x analog input module 4 x analog output module

Software

FST, the multitasking programming system, can provide a separate task for every cylinder. Edutainment, simulation

Keywords

Edutainment and simulation

93

Keepers in the wild

Usually, as we know from many examples in our experience, a zoo keeps animals in cages or artificial enclosures, behind glass or fences. The Victoria Open Range Zoo in Australia takes a quite different approach. There the animals are allowed to run free as if in the wild. Over an area of about 200 hectares, the animals have a habitat at their disposal that is left in its natural state. Visitors to the zoo can go out and observe the animals on a safari tour. To do this, they travel in large, air-conditioned buses. To a certain extent, therefore, in this case it is the human visitors who are sitting behind glass, while the animals live in the open. In order to make visiting this zoo safer and more comfortable, Rambler Concept Vehicles has developed a safari bus in which giant windows can be opened and the doors can open up the entire side of the bus to allow people to get in and out.

Because of the large forces involved, the doors are driven with hydraulic cylinders, while the windows are moved by very slimly built DNC cylinders. The panorama side of the bus is controlled by an IPC FEC, which obtains its electrical supply directly from the 24 V system available on the bus. A particularly ingenious feature is the way the window cylinders are controlled, for example. They are moved carefully with their own low-pressure circuit until they are finally fully closed at the end under normal pressure. Hardware Software Keywords IPC FEC FC20 Mini controller with AM186 processor FST Vehicle technology, door control, tour bus

94

Edutainment and simulation

Learning to use modern automation technology

At the vocational training school in Hamburg, a group of teachers have got together to enable them to give practical instruction in modern automation technology. Two things had to be done to make this possible. Firstly, the teachers sat down with trainees to develop dynamic models that can be used for practising programming, commissioning and troubleshooting. And secondly, the school bought controllers which can be programmed according to the international standard IEC 6 1131-3, and which can also be networked with Ethernet both IPC PS1 systems and IPC FEC Compact controllers.

In a second phase, the controllers will also be used as PCs in information technology lessons, which means that IT in general and programming in C/C++ or Pascal will not be seen merely as theoretical toys but as tools that can be put to practical use. Hardware IPC FEC FC34-MWT IPC PS1 the mini controller with Ethernet, programmable with MULTIPROG with HC02 CPU and various analog and digital input/output modules

Software Keywords

MULTIPROG, C/C++ Vocational training, networking

Edutainment and simulation

95

96

Applications with the IPC@CHIP

The IPC@CHIP is considered to be the world's smallest industrial PC. Even if superlatives such as these are always questionable, the combination of processor technology, memory, flash memory for the safe storage of applications and data even in the event of a power failure, serial interface, Ethernet network and access to the input/output level in a single chip is a quite outstanding technical gem. Although the first chips were only delivered as recently as November 1999, just a year later there are finished products on the market with quite exceptional qualities. Although the independent development of automation systems by individual companies is not the main concern of this little book, the IPC@CHIP and its applications are so directly involved in automation technology that they are worthy of a place here.

In this section you will find a few examples of applications with the IPC@CHIP. Enjoy your read.

Edutainment and simulation

97

Ethernet - CAN gateway

CAN is an unusual and special type of fieldbus. Because of its origins in automotive engineering, it is optimised for a high standard of reliability in data transmission, fast responses and relatively short transmission distances. The CAN bus has been successfully introduced in many applications, and thanks to its particular qualities it is well established. Increasingly, though, the data from these CAN-based applications is also coming to be required in local networks. Nowadays, however, these networks are almost always Ethernet networks. Two companies, Port GmbH and EMS Wnsche, have got together to develop an Ethernet - CAN gateway to deal with this problem. The gateway ensures that the CAN bus can operate without interference, while the data is made available in the Ethernet network.

Inside the EtherCAN_186/RMD there is an IPC@CHIP doing its stuff on the Ethernet side, and on the CAN side a Full-CAN processor. One notable fact about the EtherCAN module is that it was developed in its entirety within 5 months of the first delivery of the IPC@CHIP. On the one hand this proves the degree of know-how available to the development team from Port and EMS, but at the same time it illustrates the simplicity with which the IPC@CHIP can be put into service if the people involved have knowledge of programming PCs. Hardware Software Internet Keywords IPC@CHIP SC12 C/C++ is the programming language of choice for applications of this type. http://www.port.de CAN, Ethernet

98

Edutainment and simulation

Controlling with the IPC@CHIP

!ASCO is a system house in the field of weighing and metering technology which has developed a universal basic printed circuit board with the IPC@CHIP for its own applications and those of its customers. Depending on how it is equipped, the printed circuit board can be used either as a lowcost microcontroller or an embedded PC.

Optiterm, as the board is named, is ideally suited to carrying out control tasks in the !ASCO load cells, recording measured values and making the data available on the network for further processing. Hardware Software Internet Keywords IPC@CHIP SC12 C/C++ http://www.asco-online.com Weighing technology, measuring technology, network

Edutainment and simulation

99

Learning with the IPC@CHIP

The vocational academy or Berufsakademie (BA) in Mosbach offers courses leading to a qualification as Dipl.-Ing (BA) in a variety of subject areas. In the subjects of electrical engineering, information technology and mechatronics, the IPC@CHIP is used for course work and project work. The aim is that the students should gain experience in the development of printed circuit boards with microcontrollers (hardware) and in the programming of such systems. With the IPC@CHIP, it is also possible at the same time to bridge the gap to the study areas covering automation engineering and network technology. To help to do this, an experimental printed circuit board was developed with the IPC@CHIP at BA Mosbach. All of the data relating to the printed circuit board is public, which means that the students can use it as the basis for their own developments.

Hardware Software Internet Keywords

IPC@CHIP SC12 C/C++ is the programming language for the engineer. http://www.ba-mosbach.de Engineering studies, experimental printed circuit board, training and further education

100

Edutainment and simulation

Monitoring with the IPC@CHIP

Rittal is one of the world's largest manufacturers of control cabinets. Many control cabinets are used in computer centres, where monitoring the availability of the computer systems is a matter of crucial importance. This is why Rittal has had the CMC developed (short for Computer Monitor Control), which incorporates a control cabinet monitoring facility. The variables that are monitored include the temperature in the control cabinet, for example, but also vibration, which provides an indication that someone is attempting to open the control cabinet by force. The CMC is integrated into the network, so the monitoring data can be retrieved via the network both locally and if required via the Internet or through a modem. The centrepiece of the CMC is the IPC@CHIP, which is the ideal choice for establishing the link between the sensor signals for monitoring and the network technology.

Hardware Software Keywords

IPC@CHIP SC12 C/C++ is the language of the computer world. Control cabinet, monitoring, CMC

Edutainment and simulation

101

Hardware

All of the applications in this book are closely tied to the IPC system from Festo and Beck. A whole family of central processing units allows the creation of automation systems which are all characterised by the fundamental philosophy of the IPC family.

IPC@CHIP

IPC FEC Compact

IPC FEC Standard

102

Edutainment and simulation

IPC PS1

_ All systems are PC-based at their core. This means that essentially every CPU can also be used as a DOS computer (or in the case of the 32-bit CPUs also as a Windows computer). Most of the applications are descriptions of PLC applications, though. Nevertheless, the PC core is always there in the background, because it is this that opens up the possibility of easily linking with important state-of-the-art functions such as Ethernet networking, file handling, flexibility in the use of drivers and modules, and much more besides. _ All systems are small in relation to their performance capability extremely small. Whether or not the IPC@CHIP is in fact the world's smallest industrial PC, every CPU is representative of the claim in its performance segment to build small, to enable the use of small control cabinets, to save space and energy and in this respect is a world champion. _ All systems are network-capable. Every CPU can be equipped with Ethernet, every CPU even the smallest can be programmed via Ethernet and communicate via Ethernet. Advanced automation technology needs the Ethernet network all of the CPUs in the IPC FEC range as well as the IPC PS1 range support Ethernet. _ All systems are PLCs as much as they are PCs. Tens of thousands of CPUs are used in the same way as traditional PLCs with the PLC programming languages. And just as many systems could not do their job without the link to the PC world.

Edutainment and simulation

103

104

Index A B C

Agriculture ........................................................................................................................20 ASi....................................................................................................................................34 Assembler ........................................................................................................................44 Basic ..........................................................................................................................45, 65 Boolean Algebra...........................................................................................................9, 72 C/C++.........................................................7, 17, 21, 29, 34, 43, 44, 53, 55, 59, 61, 62, 63, ..........................................................................67, 69, 70, 72, 81, 85, 95, 98, 99, 100, 101 CAN ..................................................................................................7, 8, 21, 34, 68, 69, 98 Checkbox ..................................................................................................7, 16, 17, 60, 61 CIM .................................................................................................................................. 42 Clark Electrode................................................................................................................ 85 COMX........................................................................................................................ 52, 87 Edutainment ...........................................................................................................8, 91, 93 Ethernet .............................................................5, 8, 23, 30, 31, 34, 35, 36, 37, 44, 47, 49, ........................................................................................53, 64, 71, 79, 83, 95, 97, 98, 103 Excel ............................................................................................................................... 57 EXOR ............................................................................................................ 19, 20, 30, 31 Fax .....................................................................................................................................4 Flash ....................................................................................................................43, 44, 67 FST ............................................................................ 7, 11, 13, 15, 18, 19, 20, 23, 30, 31, ................................................................................... 32, 33, 34, 37, 41, 47, 79, 90, 93, 94 Gateway ...........................................................................................................................43 GSM ...............................................................................................................21, 46, 54, 87 Hall Sensor.................................................................................................................58, 59 Handling .....................................................................................................................12, 13 Internet..................................................................................7, 34, 35, 47, 98, 99, 100, 101 IPC FEC FC20................................................................................................................... 11, 94 FC30......................................................................................................................... 39 FC34............................................................................................................. 36, 37, 47 FC38......................................................................................................................... 46 IPC PS1 module AM11 ............................................................................................................ 15, 24, 57 AM20 ........................................................................................................................ 29 AS11............................................................................................................. 47, 59, 87 BG10 ............................................................................................................ 56, 68, 69 BG20 ............................................................................................................ 27, 60, 61 BP11........................................................................................... 13, 27, 45, 47, 53, 55 BP31........................................................................................... 19, 41, 43, 44, 69, 90 BP40................................................................... 20, 21, 24, 27, 30, 59, 79, 81, 83, 87 BP50............................................................. 15, 17, 44, 53, 57, 61, 62, 67, 70, 80, 93 CP10................................................................................................................... 27, 53 CP11......................................................................................................................... 64 CP12......................................................................................................................... 44 CP14............................................................................................................. 30, 47, 79

G H I

Index

105

IPC PS1 module CP30..........................................................................20, 52, 53, 55, 59, 67, 69, 87, 90 CP31............................................................................................................. 41, 62, 81 CP3X ........................................................................................................................ 44 CP61....................................................................................................... 20, 30, 79, 90 CP70................................................................................................................... 62, 80 CP81......................................................................................................................... 69 DIS 2......................................................................................................................... 70 FC/FD10....................................................................................................... 41, 59, 70 FD10......................................................................................................................... 25 HC01............................................................................................................. 18, 19, 44 HC02................................................................................................................... 23, 95 HC12............................................................................... 24, 52, 53, 55, 62, 63, 64, 80 HC15................................................................................................................... 45, 85 HC16......................... 13, 15, 20, 21, 23, 27, 30, 41, 47, 56, 60, 61, 70, 79, 81, 90, 93 HC17......................................................................................................................... 57 HC20....................................................................................................... 44, 54, 55, 83 HC27............................................................................................................. 27, 69, 87 HC50......................................................................................................................... 54 HD50......................................................................................................................... 59 HD51......................................................................................................................... 43 IM10................................................................................ 13, 20, 21, 56, 63, 64, 80, 81 IM11.......................................................................... 19, 27, 30, 41, 43, 79, 83, 87, 90 IM12.......................................................................................................................... 59 IO10............................................................................................ 15, 61, 62, 79, 80, 93 IO11........................................................................................................ 63, 81, 83, 87 IO12............................................................................................ 20, 21, 57, 59, 83, 85 IO40.......................................................................................................................... 67 IO41.......................................................................................................................... 70 IO60.................................................................................................. 21, 27, 61, 83, 93 IO70.................................................................................................................... 64, 70 MC10 ................................................................................................ 45, 52, 53, 55, 87 OM10........................................................................ 13, 20, 21, 56, 63, 64, 70, 80, 81 OM11.................................................................................... 19, 23, 27, 30, 43, 59, 79 OM12........................................................................................................................ 83 OM20.................................................................................................................. 45, 57 OM21.......................................................................................... 15, 17, 44, 67, 69, 90 OM22............................................................................................................ 59, 61, 93 PS10............................... 19, 20, 21, 24, 27, 30, 41, 43, 44, 56, 64, 69, 79, 81, 83, 90 PS11......................................................................................................................... 59 SM14 ........................................................................................................................ 53 ZL31 ................................................................................................................... 53, 55 ZP11......................................................................................................................... 55 IPC@CHIP................................................................. 8, 47, 97, 98, 99, 100, 101, 102, 103 DK40......................................................................................................................... 47 SC12................................................................................................... 98, 99, 100, 101 LNG ............................................................................................................................86, 87 Modem............................................................................................................39, 41, 45, 55 MULTIPROG..................................................................................7, 27, 48, 49, 50, 67, 95 Multitasking..................................................................................................................... 33

L M

106

Index

N P

Novell ...............................................................................................................................64 Packaging technology .....................................................................................................11 Pascal ..........................................................................................25, 56, 57, 64, 67, 71, 95 PLCOpen......................................................................................................................... 48 Positioning .......................................................................................................... 15, 29, 57 Profibus ............................................................................................. 23, 34, 77, 88, 89, 90 Quality....................................................................................................................7, 24, 64 Random ............................................................................................................................31 Real-Time.........................................................................................................................44 RS232.................................................................. 20, 27, 45, 53, 55, 57, 59, 69, 81, 83, 87 RS485............................................................................................................ 44, 63, 89, 90 Rubber ............................................................................................................................. 66 S5 ...............................................................................................................................29, 59 Sawmill.............................................................................................................................29 Scall ................................................................................................................................ 45 SPC200 ..................................................................................................................... 30, 31 Telemonitoring ...........................................................................................................74, 76 Valve terminal ..................................................................................................................20 VIP..................................................................................................................77, 78, 88, 89 Visual Basic.............................................................................................................. 23, 39 Water ..........................................................................................................8, 74, 77, 78, 88 WEB Server......................................................................................................................34 Welding ..................................................................................................................... 15, 62 Windows NT........................................................................................................ 39, 42, 43

Q R

T V

Index

107

108

Index

You might also like