IEU KHIEN LAP TRNH PLC - MANG PLC

Chng 1 Gii thieu tong quan ve PLC

PHAN I

IEU KHIEN LAP TRNH (PLC)

CHNG 1

GII THIEU TONG QUAN VE PLC

Chu e: He Thong ieu Khien La G? Vai tro cua PLC Hoat ong cua PLC Lch s phat trien cua PLC ac iem cua PLC u iem cua PLC ng dung Muc ch: Nam ro ve hoat ong thc thi chng trnh cua PLC

IEU KHIEN LAP TRNH PLC - MANG PLC

Chng 1 Gii thieu tong quan ve PLC

1.1. HE THONG IEU KHIEN LA G? Noi chung, he thong ieu khien la tap hp cac may moc va thiet b ien t mot ni e am bao hoat ong cua qua trnh san xuat hay mot hoat ong cua san xuat on nh, chnh xac va nhp nhang. Nhng thanh tu cua s tien bo vt bac cua khoa hoc cong nghe, cac nhiem vu ieu khien phc tap c hoan thanh nh mot he thong ieu khien t ong cao, o chnh la bo ieu khien lap trnh va co s tham gia cua ca may tnh. Ngoai viec giao tiep tn hieu vi cac trng thiet b vao ra nh ( cac bang van hanh, ong c, cam bien, van ), kha nang giao tiep truyen thong d lieu tren mang gia cac thanh phan ieu khien trong he thong cung c thc hien. Moi thanh phan n gian trong he thong ieu khien eu ong mot vai tro quan trong ma khong can quan tam en kch c. V du hnh 1.1 cho thay rang PLC khong biet ieu g xay ra xung quanh no khi khong co bat ky mot thiet b cam nhan tn hieu. No cung khong the thc hien mot chuyen ong c hoc neu khong co noi ket gia ong c vi no.

Hnh 1.1 He thong ieu khien bang PLC 1.2. VAI TRO CUA BO IEU KHIEN LAP TRNH (PLC) Trong mot he thong t ong, noi chung PLC uc v nh la con tim cua he thong ieu khien. Vi chng trnh ng dung ieu khien ( c lu tr trong bo nh PLC) trong viec thc thi, PLC thng xuyen giam sat tnh trang he thong qua tnh hieu phan hoi cua

IEU KHIEN LAP TRNH PLC - MANG PLC

Chng 1 Gii thieu tong quan ve PLC

thiet b au vao. Sau o se da vao s hp ly cua chng trnh e xac nh tien trnh hoat ong c thc hien nhng thiet b xuat can thiet. PLC co the c s dung ieu khien nhng nhiem vu n gian co tnh lap i lap lai hoac mot vai nhiem vu co the c lien ket cung nhau vi thiet b ieu khien chu hoac may tnh chu khac qua mot loai mang giao tiep e tch hp ieu khien cua mot qua trnh phc tap. Thiet b au vao S thong minh cua mot he thong t ong phan ln da vao kha nang cua PLC e oc tn hieu t nhng loai cam bien t ong khac nhau va thiet b au vao cng bc tn hieu. Nhng nut nhan, ban phm, cong tac gat tao thanh c ban cua giao tiep ngi va may la cac loai thiet b vao cng bc tn hieu. Mac khac, e phat hien vat the, quan sat s di chuyen c cau, kiem tra ap suat va mc chat long va nhieu s kien khac, PLC se phai x ly tn hieu t nhng thiet b cam ng t ong ac biet nh cong tac t, cong tac hanh trnh, cam bien quang ien, cam bien mc o va ... Nhieu loai tn hieu vao PLC co the la ON/OFF hay tng t. Nhng tn hieu vao nay c giao tiep vi PLC qua cac loai moun vao khac nhau. Thiet b xuat He thong t ong khong hoan chnh va he thong PLC that s b te liet neu khong co giao tiep vi thiet b xuat, chang han mot so thiet b thong thng nh: ong c, cuon day, en ch th, chuong baoThong qua s hoat ong cua ong c va cuon day, PLC co the ieu khien t n gian en phc tap. 1.3. KHAI NIEM PLC PLC (Programmable Logic Controller) la thiet b ieu khien lap trnh, c thiet ke chuyen dung trong cong nghiep e ieu khien cac tien trnh x ly t n gian en phc tap, tuy thuoc vao ngi ieu khien ma no co the thc hien mot loat cac chng trnh hoac s kien, s kien nay c kch hoat bi cac tac nhan kch thch (hay con goi la au vao) tac ong vao PLC hoac qua cac bo nh thi (Timer) hay cac s kien c em qua bo em. Khi mot s kien c kch hoat no se bat ON, OFF hoac phat mot chuoi xung ra cac thiet b ben ngoai c gan vao au ra cua PLC. Nh vay neu ta thay oi cac chng trnh c cai at trong PLC la ta co the thc hien cac chc nang khac nhau, trong cac moi trng ieu khien khac nhau. 1.3.1. Cau truc Mot PLC bao gom mot bo x ly trung tam, bo nh e lu tr chng trnh ng dung va nhng moun giao tiep nhap xuat. Hnh 1.2 mo ta s bo ve cau truc cua mot PLC. 1.3.2. Hoat ong Cua PLC Ve c ban, hoat ong cua mot PLC cung kha n gian. au tien, he thong cac cong vao/ra (Input/Output) (con goi la cac Module xuat/nhap) dung e a cac tn hieu t cac thiet b ngoai vi vao CPU (nh cac sensor, contact, tn hieu t ong c ). Sau khi nhan c tn hieu au vao th CPU se x ly va a cac tn hieu ieu khien qua moun xuat ra 7

IEU KHIEN LAP TRNH PLC - MANG PLC

Chng 1 Gii thieu tong quan ve PLC

cac thiet b c ieu khien. Hnh 1.3 minh hoa hoat ong cua PLC khi thc thi chng trnh ng dung.

Kenh ngo ra Rle, Triac hoac Transistor

Kenh ngo vao

Hnh 1.2 S o cau truc cua bo ieu khien lap trnh Trong suot qua trnh hoat ong, CPU oc hoac quet (scan) d lieu hoac trang thai cua cac thiet b ngoai vi thong qua au vao, sau o thc hien cac chng trnh trong bo nh nh sau: mot bo em chng trnh se nhan lenh t bo nh chng trnh a ra thanh ghi lenh e thi hanh. Chng trnh dang STL (Statement List Dang lenh liet ke) hay dang LADDER (dang hnh thang) se c dch ra ngon ng may cat trong bo nh chng trnh. Sau khi thc hien xong chng trnh,sau o la truyen thong noi bo va kiem loi sau o

Hnh 1.3 Mo ta hoat ong PLC 8

IEU KHIEN LAP TRNH PLC - MANG PLC

Chng 1 Gii thieu tong quan ve PLC

CPU se gi hoac cap nhat tn hieu ti cac thiet b, c ieu khien thong qua moun xuat. Mot chu ky gom oc tn hieu au vao, thc hien chng trnh, truyen thong noi va t kiem tra loi va gi cap nhat tn hieu au ra c goi la mot chu ky quet. Nh vay tai thi iem thc hien lenh vao/ra th lenh khong x ly trc tiep vi cong vao ra ma se x ly thong qua bo nh em. Neu co s dung ngat th chng trnh con tng ng vi tng tn hieu ngat se c soan thao va cai at nh mot bo phan chng trnh. Chng trnh ngat ch thc hien trong vong quet khi xuat hien tn hieu ngat va co the xay ra bat k iem nao trong vong quet. Chu ky quet mot vong cua PLC c mo ta nh hnh 1.4. Thc te khi PLC thc hien chng trnh (Program Execution), PLC khi cap Hnh 1.4 Chu ky vong quet cua PLC nhat tn he ngo vao (ON/OFF), cac tn hieu nay khong c truy xuat tc thi e a ra (Update) au ra ma qua trnh cap nhat tn hieu au ra (ON/OFF) phai theo hai bc: khi x ly thc hien chng trnh, vi x ly se chuyen oi cac mc logic tng ng au ra trong chng trnh noi (a c lap trnh), cac mc logic nay se chuyen oi ON/OFF.Tuy nhien luc nay cac tn hieu au ra that (tc tn hieu c a ra tai Module out) van cha c a ra. Khi x ly ket thuc chng trnh x ly, viec chuyen oi cac mc logic (cua cac tiep iem) a hoan thanh th viec cap nhat cac tn hieu au ra mi thc s tac ong len ngo ra e ieu khien cac thiet b au ra. Thng viec thc thi mot vong quet xay ra vi thi gian rat ngan, mot vong quet n (single scan) co thi gian thc hien mot vong quet t 1ms ti 100ms. Viec thc hien mot chu ky quet dai hay ngan con phu thuoc vao toc o x ly lenh, o dai cua chng trnh va ca mc o giao tiep gia PLC vi cac thiet b ngoai vi (man hnh hien th). Vi x ly ch co oc c tn hieu au vao ch khi nao tn hieu nay tac ong vi khoang thi gian ln hn mot chu ky quet. Neu thi gian tac ong au vao nho hn mot chu ky quet th vi x ly xem nh khong co tn hieu nay. Tuy nhien trong thc te san xuat, thng cac he thong chap hanh la cac he thong c kh nen toc o quet nh tren co the ap ng c cac chc nang cua day chuyen san xuat. e khac phuc khoang thi gian quet dai, anh hng en chu trnh san xuat, cac nha thiet ke con thiet ke he thong PLC cap nhat tc thi,dung bo em toc o cao (High Speed Counter) cac he thong nay thng c ap dung cho cac PLC ln co so lng I/O nhieu, truy cap va x ly lng thong tin ln. 1.4. S LC VE LCH S PHAT TRIEN Vao nhng nam cua thap nien 20 cho en 50, khoa hoc ky thuat cua mot so nc tren the a bc qua mot giai oan phat trien, mot so nha san xuat tm va nghien cu a ra nhng giai phap cong nghe nham nang cao hieu qua san xuat nh t ong hoa cac cong 9

IEU KHIEN LAP TRNH PLC - MANG PLC

Chng 1 Gii thieu tong quan ve PLC

oan trong san xuat, giam bt cac loi c sinh ra nhng cong oan phc tap, hay la n gian hoa cac thanh phan ieu khien tao ra nhng thuan li trong lap at, bao tr va thay the, giam thieu toi a khong gian lap at. Nam 1968 thiet b au tien co kha nang ap ng c cac nhiem vu cua cac nha san xuat o la: thiet b ieu khien lap trnh (Programmable Controller) a c nhng nha thiet ke cho ra i (cong ty General Motor - My). Tuy nhien, thiet b nay con kha n gian va cong kenh, ngi s dung gap nhieu kho khan trong viec van hanh he thong . V vay cac nha thiet ke tng bc cai tien thiet b lam cho thiet b n gian, gon nhe, de van hanh, nhng viec lap trnh cho he thong con kho khan, do luc nay khong co cac thiet b lap trnh ngoai vi ho tr cho cong viec lap trnh. e n gian hoa viec lap trnh, thiet b ieu khien lap trnh cam tay(Programmable Controller Handle) au tien c ra i vao nam 1969. ieu nay a tao ra c mot s phat trien thc s cho ky thuat ieu khien lap trnh. Trong giai oan nay cac thiet b ieu khien lap trnh (PLC) ch n gian nham thay the he thong Relay va day noi trong he thong ieu khien co ien. Qua qua trnh van hanh, cac nha thiet ke a tng bc tao ra c mot tieu chuan mi cho he thong, tieu chuan o la: Dang lap trnh dung gian o hnh thang (The Diagram Format). Trong nhng nam au thap nien 1970, nhng he thong PLC con co them kha nang van hanh vi nhng thuat toan ho tr (arithmetic), van hanh vi cac d lieu cap nhat (data manipulation). Do s phat trien cua loai man hnh dung cho may tnh (Cathode Ray Tube: CRT), nen viec giao tiep gia ngi ieu khien e lap trnh cho he thong cang tr nen thuan tien hn. S phat trien cua cong nghe thong tin va mach tch hp ien t vao nhng nam cuoi thap nien 80 a dan dan tao ra he thong phan cng va phan mem hoan thien ve toc o, tin cay, linh ong, giao tiep cho en nay thiet b PLC phat trien manh vi cac chc nang m rong: He thong au vao/ra co the tang len en 8000 cong vao/ra, dung lng bo nh chng trnh tang len hn 128000 t bo nh (word of memory) co the gan them nhieu Module bo nh e co the tang them kch thc chng trnh. Ngoai ra cac nha thiet ke con tao ra ky that ket noi vi cac he thong PLC rieng le thanh mot he thong PLC chung, ket noi vi cac he thong may tnh, tang kha nang ieu khien cua tng he thong rieng le. Toc o x ly cua he thong c cai thien, chu ky quet (scan) nhanh hn lam cho he thong PLC x ly tot vi nhng chc nang phc tap, so lng cong ra/vao ln. Mot so thuat toan c ban dung cho ieu khien cung c tch hp vao phan cng nh ieu khien PID (cho ieu khien nhiet o, cho ieu khien toc o ong c, cho ieu khien v tr), ieu khien m, loc nhieu tn hieu au vao...vv Trong tng lai he thong PLC khong ch giao tiep vi cac he thong khac thong qua CIM (Computer Integrated Manufacturing) e ieu khien cac he thong: Robot, Cad/Cam, Ngoai ra cac nha thiet ke con ang xay dng cac loai PLC vi cac chc nang ieu khien thong minh (intelligence) con goi la cac sieu PLC (super PLC) cho tng lai. Hien nay PLC a c nhieu hang khac nhau san xuat nh: Siemens, Omron, Mitsubishi, Festo, Alan Bradley, Schneider, Hitachi ... vv. Mat khac ngoai PLC cung a bo sung them cac thiet b m rong khac nh :cac cong m rong AI (Analog Input), DI (Digital Input), cac thiet b hien th, cac bo nh Cartridge them vao. 10

IEU KHIEN LAP TRNH PLC - MANG PLC

Chng 1 Gii thieu tong quan ve PLC

1.5. AC IEM BO IEU KHIEN LAP TRNH Nhu cau ve mot bo ieu khien de s dung, linh hoat va co gia thanh thap a thuc ay s phat trien nhng he thong ieu khien lap trnh (programmable-control systems) he thong s dung CPU va bo nh e ieu khien may moc hay qua trnh hoat ong. Trong boi canh o, bo ieu khien lap trnh (PLC Programmable Logic Controller) c thiet ke nham thay the phng phap ieu khien truyen thong dung r-le va thiet b ri cong kenh, va no tao ra mot kha nang ieu khien thiet b de dang va linh hoat da tren viec lap trnh tren cac lenh logic c ban. Ngoai ra, PLC con co the thc hien nhng tac vu khac nh nh th, em, v.v, lam tang kha nang ieu khien cho nhng hoat ong phc tap, ngay ca vi loai PLC nho nhat. Hoat ong cua PLC la kiem tra tat ca cac trang thai tn hieu au vao, c a ve t qua trnh ieu khien, thc hien logic c lap trong chng trnh va kch ra tn hieu ieu khien cho thiet b ben ngoai tng ng. Vi cac mach giao tiep chuan khoi vao va khoi ra cua PLC cho phep no ket noi trc tiep en nhng c cau tac ong (actuators) co cong suat nho au ra va nhng mach chuyen oi tn hieu (transducers) au vao, ma khong can co cac mach giao tiep hay r-le trung gian. Tuy nhien, can phai co mach ien t cong suat trung gian khi PLC ieu khien nhng thiet b co cong suat ln. Viec s dung PLC cho phep chung ta hieu chnh he thong ieu khien ma khong can co s thay oi nao ve mat ket noi day, s thay oi ch la thay oi chng trnh ieu khien trong bo nh thong qua thiet b lap trnh chuyen dung. Hn na, chung con co u iem la thi gian lap at va a vao hoat ong nhanh hn so vi nhng he thong ieu khien truyen thong ma oi hoi can phai thc hien viec noi day phc tap gia cac thiet b ri. Ve phan cng, PLC tng t nh may tnh truyen thong, va chung co cac ac iem thch hp cho muc ch ieu khien trong cong nghiep. Kha nang chong nhieu tot. Cau truc dang moun cho phep de dang thay the, tang kha nang (noi them module m rong vao/ra) va them chc nang (noi them module chuyen dung). Viec ket noi day va mc ien ap tn hieu au vao va au ra c chuan hoa. Ngon ng lap trnh chuyen dung ladder, instruction va function chart de hieu va de s dung. Thay oi chng trnh ieu khien de dang. Nhng ac iem tren lam cho PLC c s dung nhieu trong viec ieu khien cac may moc cong nghiep va trong ieu khien qua trnh. 1.6. U IEM CUA PLC 1.6.1. He thong ieu khien co ien va nhng kho khan cua no Nh a e cap phan lch s va hnh thanh PLC, o la s bat au cuoc cach mang cong nghiep, ac biet vao nhng nam 1960 & 1970, nhng may moc t ong c ieu khien bang nhng r le c ien. Nhng r le nay c lap at co nh ben trong bang ieu khien. Trong mot vai trng hp, bang ieu khien la qua rong chiem khong gian. Moi ket noi ngo r le phai c thc hien. i day ien thng khong hoan hao, no phai mat nhieu thi gian v nhng rac roi he thong va ay la van e rat ton thi gian oi vi 11

IEU KHIEN LAP TRNH PLC - MANG PLC

Chng 1 Gii thieu tong quan ve PLC

nha s dung. Hn na, cac r le b han che ve tiep iem. Neu khi co yeu cau hieu chnh hay cai tien th may phai ngng hoat ong, khong gian lap at b gii han, va noi day phai c lam dau e phu hp nhng thay oi. Bang ieu khien ch co the c s dung cho nhng qua trnh rieng biet nao o khong oi hoi thay oi ngay thanh he thong mi. Trong qua trnh bao tr, cac ky thuat vien ien phai c huan luyen tot va gioi trong viec giai quyet nhng s co cua he thong ieu khien. Noi tom lai, bang ieu khien r le co ien la rat kem linh hoat va khong the thay the c. Nhng bat li cua bang ieu khien co ien Co qua nhieu day trong bang ieu khien S thay oi hoan toan kho khan Viec sa cha vo cung phien phc v ban phai can en nha ky thuat gioi Tieu thu ien nang ln khi cuoc day cua r le tieu thu ien Thi gian dng may la qua dai khi s co xay ra, v phai mat mot thi gian dai e sa cha bang ieu khien No gay ra thi gian dng may lau hn khi bao tr va ieu chnh khi cac ban ve khong con nguyen ven qua thi gian nhieu nam. 1.6.2. Bang ieu khien kha lap trnh va nhng thuan li cua no. Vi s xuat hien cua bo ieu khien kha lap trnh, nhng quan iem va thiet ke ieu khien tien bo to ln. Co nhieu ch li trong viec s dung bo ieu khien lap trnh. V du bang ieu khien PLC c the hien hnh 1.5. Cung vi s phat trien cua phan cng va phan mem, PLC ngay cang tang c cac tnh nang cung nh li ch cua PLC trong hoat ong cong nghiep. He thong day giam en 80% so vi he thong ieu khien r le. ien nang tieu thu giam ang ke v PLC tieu thu t ien nang. Chc nang t chan oan cua PLC cho phep sa cha de dang va nhanh chong nh tnh nang giam sat gia ngi va may (HMI). Kch thc cua PLC hien nay c thu nho lai e bo Hnh 1.5 Bang ieu khien nh va so lng I/O cang nhieu hn, cac ng dung bang PLC cua PLC cang manh hn giup ngi s dung giai quyet c nhieu van e phc tap trong ieu khien he thong. Ch can lap at mot lan (oi vi s o he thong, cac ng noi day, cac tn hieu ngo vao/ra ), ma khong phai thay oi ket cau cua he thong sau nay, giam c s ton kem khi phai thay oi lap at khi oi th t ieu khien (oi vi he thong ieu khien Relay), kha nang chuyen oi he ieu khien cao hn (nh giao tiep gia cac PLC e truyen d lieu ieu khien lan nhau), he thong c ieu khien linh hoat hn. o tin cay cao v PLC c thiet ke ac biet e hoat ong trong moi trng cong nghiep. Mot PLC co the c lap at nhng ni co o nhieu ien cao (Electrical

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IEU KHIEN LAP TRNH PLC - MANG PLC

Chng 1 Gii thieu tong quan ve PLC

Noise), vung co t trung manh, co cac chan ong c kh, nhiet o va o am moi trng cao Kha nang quyen lc ma PLC thc hien c o la s phoi hp gia cac thiet ieu khien, giam sat va truyen thong tao ra mot mang san xuat toan cau: giam sat, ieu khien va thu thap d lieu (SCADA). Bang 1 di ay mo ta So Sanh s bo ve cac he ieu khien: Rle - Mach So -May Tnh va PLC

Bang 1 : So sanh ac tnh ky thuat gia nhng he thong ieu khien Theo bang so sanh, PLC co nhng ac iem ve phan cng va phan mem lam cho no tr thanh bo ieu khien cong nghiep c s dung rong rai. 1.7. NG DUNG PLC Hien nay PLC a c ng dung thanh cong trong nhieu lnh vc san xuat ca trong cong nghiep va dan dung. T nhng ng dung e ieu khien cac he thong n gian, ch co 13

IEU KHIEN LAP TRNH PLC - MANG PLC

Chng 1 Gii thieu tong quan ve PLC

chc nang ong/m (ON/OFF) thong thng en cac ung dung cho cac lnh vc phc tap, oi hoi tnh chnh xac cao, ng dung cac thuat toan trong qua trnh san xuat. Cac lnh vc tieu bieu ng dung PLC hien nay bao gom :

Phan tch vat lieu He thong chuyen tai May ong goi ieu khien robot gap va xep hang ieu khien bm Ho bi X ly nc Thiet b x ly hoa chat Cong nghiep giay va bot giay San xuat thuy tinh Cong nghiep uc be tong San xuat xi mang Cong nghiep in an X ly thc pham May cong cu Cong nghiep thuoc la May CNC May san xuat vat lieu ban dan Thiet b san xuat ng Thiet b san xuat dau co Nganh nang lng

ieu khien may lanh Thiet b san xuat ra tivi Tram ien ieu khien che o x ly San xuat thiet b ien San xuat xang He thong ieu khien giao thong He thong ieu khien ga xe la Cong nghiep san xuat nha Cong nghiep san xuat c kh San xuat xe hi Nha may san xuat sat, thep Toa nha t ong San xuat vo xe San xuat vi mach Thiet b gia cong cong ranh He thong ieu khien tin cay He thong ieu khien nang chuyen He thong ieu khien may phat ien May rut tien t ong ieu khien khu vui chi

Gii thieu mot so hnh anh ve cac lnh vc san xuat s dung bo ieu khien kha lap trnh.

He thong kh mui

Khi ong mem ong c

ieu khien xe nghien rac 14

IEU KHIEN LAP TRNH PLC - MANG PLC

Chng 1 Gii thieu tong quan ve PLC

ieu khien thang may

He thong ra xe t ong

He thong giao tien cua nha bang

ieu khien he bang tai hang hoa

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IEU KHIEN LAP TRNH PLC - MANG PLC

Chng 1 Gii thieu tong quan ve PLC

Giam sat he thong

ieu khien may van vt cong nghiep

May ep than tai sinh

He thong tron be tong ieu khien thi gian ca, en

May hang goc khung ca PVC

He thong ieu khien an toan can truc

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IEU KHIEN LAP TRNH PLC - MANG PLC

Chng 1 Gii thieu tong quan ve PLC

He thong x ly moi trng

May ong sach, tap v

May han ng t ong

ieu khien qua tai he thong ien May bam va nghien vat lieu

May lap ghep bao b kim loai ieu khien may ep nha 17

IEU KHIEN LAP TRNH PLC - MANG PLC

Chng 1 Gii thieu tong quan ve PLC

ieu khien ong c bc

He thong chiet

May lam nguoi kim loai

ieu khien robot ieu khien tau ien

He thong bang tai t hanh ieu khien may CNC 18

IEU KHIEN LAP TRNH PLC - MANG PLC

Chng 1 Gii thieu tong quan ve PLC

Tai lieu tham khao: [1]. TS. Nguyen Th Phng Ha, ieu khien t ong Nha xuat ban khoa hoc va ky thuat. [2]. Automation with Micro PLC SIMATIC S7-200 Siemens, Germany. [3]. Success_e.pdf Siemens, Germany. [4]. A beginners guide to PLC OMRON, Japan. [5]. Robert N.Bateson, Introduction To Control System Technology Maxwell Macmillan International Editions.

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