Module 1 - Control Architecture Overview

Controls Architecture Overview
Module 1
CONTROLS ARCHITECTURE OVERVIEW
Copyright 2008. General Motors Corporation. All Rights Reserved

Module Description
• This module provides an overview of the ‘06 Global
Controls Architecture and its hardware and software.
• It provides a focus on:
– Levels of control
– Categories of automation
– Changes from the previous controls architecture.
Copyright 2008. General Motors Corporation. All Rights Reserved Mod 1 - 2

Objectives
• At the completion of this module, the participant will be
able to:
– Describe the ‘06 Global Controls Architecture including:
• Device Layer
• Control Layer
• Information Layer
• Span of Control
• Differences to GMNA ’04 Controls Architecture

Module Performance Task List

MPTL
Task Description
Number
1 Define the span of control for a PLC, PDP, and HMI.

Definitions
• Two key requirements in the design of GM
manufacturing systems is “commonality” and
“scalability”.
• Each installed system has many common
components, layouts, and operations.
• This commonality provides a consistent framework, or
architecture, for the hardware and software.
• A common understanding of terminology is important.
So, we’ll begin with “Definitions.”

Zone Definition
• A Zone (also known as system) is an area in which a
process of interdependent operations takes place to
complete a finished product or sub-assembly
(e.g. door or roof).
• A zone has one or more Cells.
• The system level drawings will show the overall view
of the multiple control areas or cells.

Simplified Zone Example

Cell Definition
• Cells are individual process areas that may contain
combinations of tooling, equipment, or manual
processes.
• Cells are usually enclosed by perimeter guarding.
• Cells are commonly controlled by a single controller.
• Individual Cells may be linked to other Cells in the
process using various transfer schemes including,
conveyors, robots, or manual operators.
• A Cell may contain multiple stations.

Simplified Cell Example

Station Definition
• A Station is an individual process/area for a single operation.
• A station may include one or more of the following:
– Operators
– Robots.
single on-line station

with robots

CATEGORIES OF AUTOMATION
• There are three major categories of automation.
– Low-Automation
– Medium-Automation
– High-Automation
• CCRW uses a common architecture that is applied to
all of the various operations that are to be carried out
in a given process.


• Low-Automation
• The lowest level of control that exists on the shop floor.
• It consists of only a few movements
• This uses simple air logic or DeviceLogix
• Does not include an HMI

• Medium-Automation
– Categorized by having more than four motions but less than
100 I/O points
– CompactLogix or GuardLogix PLC
– Siemens HMI

• High-Automation
– Most common category
– Categorized by having more than 100 I/O points and/or
robots
– GuardLogix PLC
– Siemens HMI.

Automation Usage

Low Automation Architecture Representation

DeviceLogix May Be New To Your Plant

Requirements for Low Automation

• Four or less operations
• No more than one timer
• No more than four logic gates (AND/OR)
• No personnel presence sensing required for safety
• No error proofing
• No robots
• No connection to upper level network or production system
• Single style
• No automatic part transfers or interlocking between cells or
stations
• Manually loaded and unloaded stations

Low Level: 2A

Low Level: 2B

Medium Automation Architecture Representation

Medium Automation: 3A

Medium Automation: 3B

Requirements for Medium Automation

• 5 or more operations
• No more than 100 I/O points
• Personal presence sensing required for safety
• If using distributed architecture, a CompactLogix
controller is used
• If using centralized architecture, a GuardLogix
controller is used

High Automation Architecture Representation

High Automation: 4B

Requirements are for High Automation

• Greater then five operations
• Greater then 100 I/O points
• Personnel presence sensing required for safety

CONTROLS ARCHITECTURE KEY ELEMENTS

• Before 1998, most plants used Allen-Bradley PLC-5s,
with remote I/O and DataHighway Plus (DH+) for
communication.
• After 1998, the CCRW standard shifted to Allen-
Bradley ControlLogix processors, with DeviceNet and
ControlNet for communication.
• Since 2004, the standard has been Allen-Bradley
GuardLogix processors, with DeviceNet, DeviceNet
Safety, EtherNet/IP, and Ethernet for communication

’06 Global Controls Architecture

KEY ELEMENTS (Continued)

• Prior to 2004, safety devices were required to be
“hard-wired”
– Safety Relays / Control Reliability
– Redundancy and Monitoring
• Today
– GuardLogix Controller
– DeviceNet with safety I/O
– Ethernet is used to connect the cell controllers, robots, weld
controllers, and Maintenance Work Stations (MWS)
upstream to the plant’s network server.

NETWORK HIERARCHY
• Network hierarchy is a term used to describe the
levels of functionality of each of the major
communications networks within the ’06 Global
Controls Architecture.
• The networks are organized into layers.
• Each layer offers a unique type and level of control.

NETWORK HIERARCHY
• Information Layer
– Gives higher-level computing systems access to plant floor data.
– Ethernet = Information Layer
– EtherNet/IP provides both information and control capabilities.
• Control Layer
– Allows intelligent automation high-speed control devices to share
information.
– EtherNet/IP is an example of a control layer network.
• Device Layer
– Offers high-speed access to plant-floor data from a broad range of plant
floor devices.
– DeviceNet Fieldbus network is an example of a device layer network.

NETWORK HIERARCHY

Power Distribution
• Weld Power: A separate Weld PDP distributes power
to all the weld controllers for the cell.
• Control Power
– Plant Control Bus Cell Power Distribution Panel (PDP)
– At the Cell PDP, electrical power is distributed to the MCP
and the Cell components.
• 120 VAC “Hot” Power — power for vital loads (PLC, MWS, lighting,
Ethernet switches, Safety I/O devices, etc.)
• 120 VAC Control Power — power is converted into 24VDC in the
MCP for normal control devices (standard I/O)
• 480 VAC Power — power for large devices in the cell (e.g. robots and
variable speed drives).

Bodyshop Power Distribution

Power Distribution Precautions

PROGRAMMABLE LOGIC CONTROLLER (PLC)

• There are two types of controllers specified for use.
– Rockwell CompactLogix
– Rockwell GuardLogix 556xS

One Software Package

• RSLogix 5000 provides
one software package for
the family of Rockwell
controllers.

CompactLogix
• CompactLogix controllers are used for small systems
or medium automation applications.
• A field device (I/O) may connect to the controller by
one of two means:
– Wired to an I/O module mounted in the same chassis as the
controller
– DeviceNet
• Does NOT support DeviceNet Safety
• Communication via EtherNet/IP
• CompactLogix controllers do NOT support control of
I/O over EtherNet/IP.

CompactLogix Controller
I/O
PLC Power Modules
Supply
GuardLogix
• GuardLogix controllers are used for high automation
applications with large numbers of safety devices.
• A field device (I/O) may connect to the controller by
one of three means:
– Wired to an I/O module mounted in the same chassis as the
controller
– DeviceNet
– EtherNet/IP.
• Communication via EtherNet/IP
• GuardLogix controllers DO support DeviceNet Safety.

GuardLogix Controller

SOFTWARE
• There are four software packages that are used to
program and troubleshoot the Cell PLC:
– RSLogix 5000
– RSLinx
– RSNetWorx for DeviceNet
– ControlFlash

RSLogix 5000 Software

• RSLogix 5000 software is the programming software
for the GuardLogix 5000 controller.
• It is used in conjunction with RSLinx and is used to
program and monitor the ladder logic in the PLC.

RSLinx Software
• RSLinx software “links” a personal computer with any
Rockwell software to a physical network in the Cell or
Zone.
• A graphic representation of the network or PLC can be
viewed and monitored online.
• This is accomplished through the use of software
drivers which define the link that is used to access a
physical network.

RSNetworx for DeviceNet Software

• Used to configure, maintain, and troubleshoot
DeviceNet networks.
• Allows you to perform the following maintenance and
troubleshooting tasks:
– View a graphic representation of the network and its status
– Determine which devices are and are not communicating on
the network
– Monitor device parameters
– Determine device-specific faults
– Configure newly added or replaced devices

ControlFlash
• ControlFlash is used to update the firmware in any of
the modules.
• The CCRW/IS&S Coordinated Block-Point Release
contains all of the files to either upgrade or downgrade
a module so it may communicate with the rest of the
modules in the cell.
• This software may be used when a module is replaced
and the new module has the wrong firmware.

Block-Point
• It is important for each plant to use the plant’s approved
versions of software and firmware (this directly affects
troubleshooting/modification of programs and replacement of
hardware).
• The latest version for each plant is available from the CCRW
Block-Point web page.
• The firmware versions of the controllers and communication
modules are important. An older firmware version may not be
compatible with a newer software version (and vice-versa).
• It is important for the troubleshooter to use the correct version
of software for the plant specified in the Block-Point release
schedule.

CCRW / IS&S Coordinated Block-Point Release

COMMUNICATION NETWORKS
• Two types of communication networks that may be
present in a zone:
– DeviceNet
– Ethernet
• There are two protocols used on Ethernet:
– Standard
– EtherNet/IP (industrial protocol)
• There are also two protocols used on DeviceNet:
– Standard
– Safety

Communication Protocols
• DeviceNet (standard) — network for remote I/O communications. It is used
to support communication between the controller and the field I/O or process
equipment. The robots also have their own DeviceNet networks that allow
the robot controller to communicate with the I/O associated with the robot.
• DeviceNet for Safety I/O — network for safety I/O communications. It is
used to support communication between the controller and the safety I/O (e-
stops, light screens, etc.).
• Ethernet (standard) — Communications network for controller (or MWS) to
plant information systems (for example, production monitor and control
server.) Weld controllers also communicate to each other over Ethernet.
This allows all weld controllers in a zone to be programmed by only one
Data Entry Panel (DEP).
• EtherNet/IP — network for controller-to-controller, controller-to-HMI,
controller-to-robot, and controller-to-welder communications.

Controller Communications
Device Network / Type of Data
Protocol
Remote I/O such as DeviceNet1 Input and output signals for station,
VFDs, valves, I/O cell, and zone monitoring and
blocks control.
Safety I/O such as e- DeviceNet for Input and output signals for station,
stops, gate boxes, light Safety I/O1 cell, and zone safety related items.
screens, operator run
stands, safety signals to
robots, C-Flex stations
Other cell controllers EtherNet/IP2 Interlock signals between controllers.
HMIs EtherNet/IP2 Cell and zone status (controller-to-
HMI).
Maintenance Work Ethernet2 Programming communication from
Stations MWS.
Plant Servers and Ethernet2 Status information and controller
Systems backups.
Controller Communication

Robot Controller
• The robot controller must communicate with the cell
controller to coordinate the running of the robot
program with the operation of the cell.
• This includes interlock signals with other robots that
may be in the same cell.
• The robot must communicate with its own I/O to allow
both the robot and the I/O to function correctly.
• The robot must also communicate with the plant’s
information systems to allow robot program backup
and retrieval.

Robot Communications
Device Network / Protocol Type of Data
Robot I/O such as DeviceNet (Robot) Input and output signals for robot device
proximity switches, control. Safety devices are not on this
photo-eyes, clamps, network.
grippers, dense packs
Safety I/O such as e- DeviceNet for Safety Input and output signals for robot safety
stops, safety signals to I/O (Cell) related items. These include robot and
and from cell controller cell e-stops.
Cell controllers, weld EtherNet/IP Interlock signals between robot and cell
controllers controller. (These include body style
and path segment information; as well as
interference zone interlocks.)
Robot to weld controllers
Plant Servers and Ethernet Robot backups and restores.
Systems

Robot Weld Controller

• The robot weld controller must communicate with the
robot controller to coordinate the welding schedule
and gun position with the robot motions.
• The robot weld controller also obtains auxiliary power
from the robot controller.
• The robot weld controller communicates with plant
systems to allow the reprogramming and also backup
and retrieval of weld schedules remotely.

Robot Weld Controller Communications

24 VDC Hard Wiring Weld enable signal from the robot.
Robot controller EtherNet/IP Interlock signals between robot and
robot weld controller. These include
schedule and gun positions.
Plant Servers and Ethernet Robot weld controller backup and
Systems retrieval.

Hard Automatics Welding

• “Hard automatics” refers to stations with fixed tooling
weld guns.
• Hard auto welding is typically in operator stations but
may also be in non-operator stations.
• The Hard Automatic weld controller communicates
with plant systems to allow the backup and retrieval of
weld schedules remotely.

Hard Automatics Communications

24 VDC Hard Wiring Weld enable signal from the PLC.
Cell controller EtherNet/IP Interlock signals between cell
controller and hard automatics weld
controller. These include weld
schedule and status.
Plant Servers and Ethernet Hard automatics weld controller
Systems backup and retrieval.

DeviceNet Network
• A DeviceNet network connects industrial devices such
as limit switches, photoelectric sensors, pushbuttons,
bar code readers, and drives to the controller and PLC
software without the need for separate hardwiring to
I/O modules.

DeviceNet Network
• DeviceNet is considered an “open network,” which
means that many different vendors can manufacture
DeviceNet-compatible products, as long as they
adhere to standard DeviceNet specifications.
• A DeviceNet network is comprised of both hardware
and software components.

DeviceNet Network Hardware

• The following hardware components make up a DeviceNet network:
– Power Supply
– DeviceNet Cable
– Trunk Line Cable
– Drop Line Cable
– Terminating Resistors
– Taps
• T-Port tap
• PowerTee (Refresh Tap)
• DevicePort tap
• Open-style tap
– • Connectors
• Sealed
• Open-style
– Scanner module
– Devices (nodes)

DeviceNet Network Hardware

DeviceNet Network Software

• The following software components are required to
access, configure, and maintain a DeviceNet network:
– Network configuration software such as RSNetWorx for
DeviceNet software
– Linking software such as RSLinx software
– Programming software such as RSLogix 5000 software

EtherNet/IP Network
• Previous architectures (for example, ’98 Controls
Architecture) used Ethernet for the information layer
and ControlNet for the control layer (peer-to-peer)
communications. ControlNet was used since Ethernet
did not have the capacity for handling real time I/O.
• Starting with the ’04 Controls Architecture, ControlNet
has been replaced with EtherNet/IP for peer-to-peer
communication systems. EtherNet/IP is Ethernet with
an additional protocol, Control and Information
Protocol (CIP), to allow for the handling of real time
I/O.
EtherNet/IP Network
• The base protocol for Ethernet is Transmission Control
Protocol/ Internet Protocol (TCP/IP) and allows computers to
communicate with each other and devices across a network.
• These two protocols define the packet of data that is
transmitted over the network.
• Communications are not scheduled
• Device needs to wait until the network is free
• To make sure this data gets to the right location, every
computer/device on the network is assigned an address.
• Addressing will be covered later in the Ethernet Module of this
course.

SPAN OF CONTROL
• Control devices such as PLCs or HMIs control a
defined area or Cell of the Zone.
– Typically one to three HMI’s are provided for each cell.
– Thus the span of control of the HMI is the Cell, not the
upstream or downstream Cells.

SPAN OF CONTROL
• Common hardware (multiple Cell system / Zone):
– Power Distribution Panel (PDP) — distributes 480 VAC and 120 VAC to
the cell’s components
– Main Control Panel (MCP) will contain the PLC and 24 VDC power
supplies.
– Maintenance Work Station (MWS) per system — a system (for the MWS)
is five cells or 15 stations. This is not a hard rule of thumb
– Marquee — marquees are an ASCII echo communication provided by
the IS&S plant floor deployment group. Not all plants have marquees
– Entrance Gate Control Panel — one to six per cell
– HMI — Up to three can be used throughout the cell, either mounted in a
panel or used in a portable configuration

SPAN OF CONTROL
• High automation cells shall have:
– One PDP per cell
– One PLC per cell
– At least one HMI per cell
• Medium automation cells shall have:
– One PDP
– One PLC (GuardLogix or CompactLogix)
– At least one HMI per cell
• Low automation tools (stations) can have:
– DeviceLogix Valve Stack or Air Logic
– Two hand start button design
– No HMI

PLC SPAN OF CONTROL

• There is one PLC per:
– Perimeter guarded work-cell
– Standalone tooling (offline)
• Note: offline tooling that have small processes defined as no more
than five sequence steps may be controlled by air logic. This is an
exception.
– Transfer system located outside of work cell that is intended
to operate as an independent buffer or accumulator. Cell-to-
cell conveyors are typically controlled by the downstream
cell.
– Synchronous transfer system (all transferred parts move at
the same time) that spans more than one cell

PLC SPAN OF CONTROL
• More than one PLC may be used within a single

perimeter guarded workcell if the tooling stations
within the work-cell are too complex to be efficiently
controlled by one PLC (for example, a large framing
station with four tooling gates).

PLC Span Of Control
Example offline sub-assembly cells. Each cell has one PLC. The accumulating
conveyor between the cells is controlled by the PLC in the downstream cell.

CELL POWER DISTRIBUTION PANEL

• Cell power distribution panels (PDP) provide and
distribute the 480 VAC and 120 VAC power to the
components in the cell.
• The installation of PDPs must meet the rules
presented in the following slides:

Cell PDP Installation Rules

• One per mainline cell


• A manually loaded or unloaded accumulator integral to a cell
shall obtain power from the cell’s PDP.


• Offline tools shall obtain power from the nearest cell PDP .


• A group of offline tools within the same area shall share a
PDP.


• Isolated offline tools or cells intended to be mobile and easily
relocated shall have a combination PDP/MCP.


• Offline cells with one or two robots may obtain power from a
nearby cell PDP or be controlled by a PDP/MCP


• A cell shall only have one PDP — splitting a cell between two
PDPs is not permissible

Human Machine Interface (HMI)

• Typically, each cell will have at least one remote color
touch screen Human Machine Interface (HMI) panel or
a portable HMI (PHMI) with its associated interface
panel.
• A PHMI may also be used to:
– Complement the fixed HMI
– Or as the only HMI for the cell.


• The typical HMI span of control:
– No more than three HMIs should be controlled by the same PLC
because of increased memory consumption and increased processing
scan time in the PLC.
– Conveyors integral to the Cell shall be controlled by the Cell’s HMI.
– Multiple HMIs may be required
• Opposite side of the line (Maintenance Accessibility)
• Line-of-sight (improved visibility)
– It is recommended that a separate HMI or PHMI from the main HMI be
used to control palletizing “feed-in” and/or “feed-out” conveyors within a
Cell or Cell-to-Cell conveyors.
– A cell to cell conveyor’s HMI is controlled by the downstream cell’s PLC.
– A HMI is required if the tooling has six sequence steps or more or
requires a diagnostic display.


• The typical HMI span of control:
– It is recommended that a separate HMI or PHMI from the
main HMI be used to control palletizing “feed-in” and/or
“feed-out” conveyors within a Cell or Cell-to-Cell conveyors.
– A cell to cell conveyor’s HMI is controlled by the downstream
cell’s PLC.
– A HMI is required if the tooling has six sequence steps or
more or requires a diagnostic display.

Siemens HMI Scalability

E-Stop Span of Control

• E-Stops have the following requirements:
– All equipment integral to the cell or offline tool is stopped by the E-Stop.
– All cells that share common gating or perimeter guarding are stopped by
the E-Stop. Cells that share perimeter guarding shall have their
emergency stop buttons interlocked.
– With asynchronous transfer systems that move parts one at a time, like
AMS or Skid conveyors, an E-Stop in a cell shall affect the one upstream
cell and the one downstream cell if they share perimeter guarding or are
within 50 feet of each other.
– With synchronous transfer systems that move all parts at the same time,
like overhead lift and carry shuttles, adjacent cell E-Stops shall be
interlocked with the transfer system

Example E-Stop Span of Control
If E-Stop Affected
here.. Area!
E
R
E
R T
R
T T R T R E R
Cell 3
R Conveyor
Cell 1
R Cell 2
Affected
Area! If E-Stop
here..
E
R
E
R T
R
T R T R
T R
E
Cell 3
R Conveyor
Cell 1
R Cell 2

Visual Control
• Visual control is the ability to see automation
equipment without looking around panels.
• Installations must meet these requirements:
– Electrical panels are not to exceed 60 inches tall
– No components on top of panel (for example, transformers)
• exceptions are indicators and annunciators like horns and stack lights

Visual Control: Examples
Pnl 5 ft Safety
fence
Tooling
MCP
PDP

HARDWARE
• The hardware that is used to provide electrical power
and control to equipment complies with GM’s Global
Common Controls Hardware Design Standard
(GCCH-1).
• Drawing packages for the multitude of hardware
panels can be found at the following GM Supply
Power web site:
– http://supplier.body.gm.com/crw/production/main/globalHard
ware/ecs/globalEcs.cfm

CONNECTORS
• General-purpose connectors have the following specifications:
– Harting Han EE Series connectors and cables for power from PDP to
MCP
– Mini 4-pin CENELEC (European Committee for Electrotechnical
Standardization) standard for auxiliary power
• Used to provide remote panels with 24 VDC from MCP
• Used for DeviceNet Refresh
• Used for Hot 24 VDC
• Used for 24 VDC control power
• Used for Switch motion power
– Mini 5-pin used for DeviceNet
– Micro 4-pin are used for switches (proximity, limit, pressure) and remote
valves

Power Distribution Panel (PDP)

• A Power Distribution Panel (PDP) contains:
– Main disconnect for a cell
– 480 VAC branch circuits
– PLC / lighting transformer (“hot power” 120 VAC)
– Control transformer (control 120 VAC)
– Circuit breakers for 120 VAC distribution
• The PDP is 60” high and has a single power drop from the plant
control bus for all process equipment in the cell.
– 480VAC line power distributions for
• robot controllers
• variable speed drives
– Isolates line power from the Main Control Panel (MCP)
– Allows a single-point electrical lockout
• Any transformers required are mounted outside of the PDP.
• Inside the PDP all components are touch-safe.

PDP (ECS-4103)

PDP Subplate Example

MAIN CONTROL PANEL (MCP)

• A Main Control Panel contains:
– PLC, I/O modules, and network modules
– 24 VDC power supplies
– Receptacles
– Terminals
– Circuit breakers

Main Control Panel (ECS-4211)

Main Control Panel (ECS-4211)

OPERATOR FIXTURE BOX

• An operator fixture box provides a single point of connection for
associated tooling fixture components.
– Valves
– Light screens
– Safety mats
– Laser scanners
• There are several ECS designs based on the tooling
application.
• A fixture box contains the following items:
– DeviceNet Safety I/O
– Light screen, safety mats, and laser scanner connectors
– Output power connectors
– Terminals
– 24 VDC power supply for tooling motion power

Operator Fixture Box (ECS-4125)

ENTRANCE GATE CONTROL PANEL

• Entrance gate control panels are provided as part of
the Monitored Power Systems (MPS).
• They are a single point for energy control of a cell.
• As part of the MPS, a gate box is pre-constructed and
certified by an external, non-GM source.
• There are two basic types of gate box designs:
– ECS-4010 (Non-MPS applications)
– ECS-4011 (MPS applications)
Entrance Gate Control Panel (ECS-4011)
SAFETY DEVICE JUNCTION BOX

• A Safety Device Junction
Box provides a common
perimeter guard interface
between the cell’s main
control panel and the
perimeter guard light screen.
• There are several to choose
from based on the tooling
application.
– Examples
• ECS-4080
• ECS-4081
OPERATOR RUN STAND

• An Operator Run Stand contains:
– Cycle Start push button — palm button used to initiate a station cycle
start
– E-Stop push button — mushroom shaped button used to generate an E-
stop (refer to previous Span of Control discussion for more information)
– Return To Load push button — causes tooling to return to the Home
position
– Parts Properly Loaded Light — indicates that parts are present in the
fixture
– Maintenance Call push button — generates an alarm for display on the
area marquee
– Responder Call push button — generates a request for material to the
material supply department
– Auto/Maintenance Selector Switch (Key) — Allows maintenance on the
fixture in manual position. Light curtains can be broken while
maintaining minor output power.
– Fault Buzzer — signals the operator that the part load has not completed
or some other fault has occurred
OPERATOR RUN STAND

• An Operator Run Stand shall
be provided for each
operator tooling station.
• There are different designs,
but ECS-4050 is the most
common.
PANEL-MOUNTED HMI
• The panel-mounted HMI is
used to give the operators
and maintenance personnel
information about the
equipment in the cell.
• Manual functions for the
equipment is displayed in the
form of a scroll list to give the
maintenance personnel full
manual control over the tools
and robots.
• Diagnostics and cell/tool
prompting will be displayed
on the HMI as well.
PORTABLE HMI
• Portable HMI (PHMI)
– Small enough to carry
– Allows a qualified person to get closer to the equipment for manual
operation.
– Has a built-in “live man” switch to enable/disable tool motion
• The PHMI requires a connectivity box for the safe I/O and
Ethernet interface.
– A small multi-conductor cable is provided between the PHMI and
connectivity box to carry the hardwired enable and stop signals to safe
inputs.
• The PHMI manually controls only tooling motion and is NOT a
robot teach pendant.
• A single PHMI may be used to control multiple offline tools
(up to 6) in close proximity to each other
Portable HMI With Connection Box (ECS-4027)
OPERATOR DISPLAY PANEL

• ECS-4049 is a common example
• Small HMI (Siemens TP177) that can assist the
operator in displaying
– Style scheduling information
– Part present information
– Operator functions
• Maintenance Call
• Return to Load
MAINTENANCE WORK STATION (MWS)

• A Maintenance Work Station (MWS) contains a
personal computer (PC) used for maintenance and
troubleshooting of the zone’s controllers and control
components.
• A MWS has the following functions:
– Provide access to PLCs for programming, monitoring,
configuring and troubleshooting
– Supports Ethernet connections to all PLCs, robots, and weld
controllers
– Contains Electronic Data Sheet (EDS) files for DeviceNet
components
MAINTENANCE WORK STATION (MWS)

• A MWS shall meet the
following requirements:
– Shall not span production
systems
– One workstation per every
major sub assembly-system
– Contain software based on the
plant’s CCRW / IS&S
Coordinated Block-Point
Release
• Current operating system is
Windows XP.
• Windows 2000 and Windows
NT has been used in past
programs.
DIFFERENCES FROM GMNA ’04 CONTROLS ARCHITECTURE
Main Control Panel Comparison
HMI Differences
Breakers Replace Fuses
Welding PDP
• Cost Savings
– CCRW / BIW Analysis
– Cost Savings Approach used by
GME for many years
• NA Funding Issue
– Install Group Funds Drops
– CCRW Funds Weld PDP (New Cost
for CCRW)
Global Fittings and Tube

• G-Port Replaces NPT for Fittings
– Parallel Thread (Not Tapered)
– Sealing Face no Pipe Sealer (less leaks)
– Fittings Available Globally
• Push on Tube Replaces Hose ½” or
Less
– Lower Cost
– Quicker Assembly
– Currently used in NA on Robot End-
Effectors
• BSPT (PT) for Header Pipe
– Different than NPT
– Standard for the Rest of the World
– Impacts Tool & Robot Stands
Tooling Valve Manifold Example
Robot Valve Manifold Example
MODULE PROGRESS CHECK

• Take 10 minutes to complete the Module Progress
check.
• We’ll review and discuss the answers.
Low
Medium
High
Lab Exercise: Defining Span of Control

• Time: 10 minutes
• Objectives:
– After completing this Lab Exercise, the participant will be able to:
• Identify Span of Control for
– PDP
– PLC
– HMI
– E-Stop
• Use markers to outline span of control for each of the following:
– PDP Span of Control
– PLC Span of Control
– HMI Span of Control
– E-Stop Span of Control
• Be prepared to discuss your answers.

Module 1 - Control Architecture Overview

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Module 1 - Control Architecture Overview

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Controls Architecture Overview

CONTROLS ARCHITECTURE OVERVIEW

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Module Performance Task List

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Simplified Zone Example

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Simplified Cell Example

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single on-line station

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Low Automation Architecture Representation

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DeviceLogix May Be New To Your Plant

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Requirements for Low Automation

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Medium Automation Architecture Representation

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Requirements for Medium Automation

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High Automation Architecture Representation

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Requirements are for High Automation

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CONTROLS ARCHITECTURE KEY ELEMENTS

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’06 Global Controls Architecture

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KEY ELEMENTS (Continued)

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Bodyshop Power Distribution

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Power Distribution Precautions

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PROGRAMMABLE LOGIC CONTROLLER (PLC)

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One Software Package

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