B&R Automation Studio with Demo PLC,

HMI Design & Codes

2024-02-13

사커 엠디 샤힌 , 선임연구원
하성훈
HYUNDAI 연구원
E.D.S Co., Ltd.
HYUNDAI E.D.S Co., Ltd.
Overview of Programmable Logic Controllers (PLC)
 What is PLC?
o Programmable Logic Controllers (PLCs) are specialized industrial computers with various input and output drivers which designed
to automate manufacturing processes, control machinery, and monitor industrial facilities.
 Key Components:
o CPU (Central Processing Unit): The brain of the PLC, responsible for executing the control program and coordinating input/output
operations.
o Input Modules: Interface with sensors and switches to receive digital or analog signals representing the state of the controlled
process.
o Output Modules: Connect to actuators such as motors, valves, and relays to control the physical elements of the process.
o Power Supply: Provides electrical power to the PLC system.
o Programming Device: Software used to write and upload control programs to the PLC.

 Operating Principle:
o Programmable Logic Controllers (PLCs) operate based on a scan cycle, where they are continuously:
• Read inputs from connected sensors and switches.
• Execute the control program stored in memory.
• Update outputs based on program logic and input conditions.
o This cycle repeats at high speed, typically in milliseconds, ensuring real-time control and monitoring of industrial processes. 2
Overview of Programmable Logic Controllers (PLC)
 Programming Languages
o Programmable Logic Controllers (PLCs) can be programmed using various languages, including:
• Ladder Logic: Graphical programming language resembling relay logic diagrams, widely used for its simplicity and familiar -
ity to electrical engineers.
• Function Block Diagrams (FBD): Graphical language based on interconnected function blocks representing logic operations.
• Structured Text (ST): Text-based programming language resembling traditional programming languages like C or Pascal, suit -
able for complex algorithms and calculations.
 Applications:
o Programmable Logic Controllers (PLCs) find applications across various industries, including manufacturing, automotive, food and
beverage, pharmaceuticals, and more.
o Common applications include:
• Automated assembly lines
• Process control in chemical plants
• Packaging and material handling systems
• HVAC (Heating, Ventilation, and Air Conditioning) systems
• Water treatment and distribution
• Energy management and monitoring
• Etc.

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Overview of Programmable Logic Controllers (PLC)
 Purpose of Analog I/O Module:
o Analog Input: Analog input devices in PLCs are used to interface with sensors that provide continuous feedback, such as tempera -
ture sensors (thermocouples, RTDs), pressure sensors, flow meters, level sensors, etc. These sensors generate analog signals (e.g.,
voltage, current, resistance) proportional to the measured physical quantities.
• Monitoring and Control of Continuous Processes
• Flexible Interface with Various Sensors
• Process Monitoring, Data Logging, and Alarming

o Analog Output: Analog output devices in PLCs convert digital control signals from the PLC into continuous analog control signals
(voltage or current) to drive actuators such as valves, motors, or variable frequency drives (VFDs).
• Precise Control and Regulation

By utilizing analog input and output devices in PLCs, industrial automation systems can achieve accurate monitoring, control, and regulation
of continuous processes, enhancing efficiency, quality, and safety.

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Overview of Programmable Logic Controllers (PLC)
 Purpose of Digital I/O Module:
o Digital Input: Digital input devices in PLCs are used to connect to sensors, switches, and other devices that provide binary (on/off)
signals. These signals indicate the status of various components or conditions in the controlled process.
• Interfacing with On/Off Devices
• Safety and Emergency Shutdowns
• Sequence Control and Logic Execution

o Digital Output: Digital output devices in PLCs are used to control actuators, such as solenoid valves, motors, relays, and indicator
lights. These devices can be turned on or off by the PLC to actuate specific actions in the controlled process.
• Controlling On/Off Devices
• Sequence Control and Logic Execution

By utilizing digital input and output devices in PLCs, industrial automation systems can effectively monitor, control, and coordinate the
operation of machinery and processes, ensuring efficiency, safety, and productivity in various industrial applications.

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 Overview of Programmable Logic Controllers (PLC)
 Hardware Setup
Bus Controller Module
With Power Supply

Power Supply
Digital and Analog
I/O Modules

Main Central
Processing Unit (CPU)

Flash Memory Card

Ethernet Connection

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Configuration Environment of Automation Studio

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Create a New Project/Program (Continue…)
 Click on File  New project  Name of the Project  Next  Name of the configuration and select the Hard-
ware configuration  Next

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3

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Create a New Project/Program
 Then Select or Write Controller/CPU model number on search bar  Select Controller/CPU 
Mark Active Simulation (Optional)  Finish Activate Simulation

Initial Project Screen

 Activate Simulation  Select Allow access  ARsim RUN

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Operation Screen Configuration

1. Project Explorer
1 - Logical View
- Configuration View
3 - Physical View

2. Workspace
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3. Catalog Toolbox
- Object Catalog
- Hardware Catalog

4. Output Results Window

5. Property Window
5 6. Program Status
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Write PLC programming code (Continue…)
 Select the Logical View  Select the project name  Mark the Program  Choose the Programming Lan-
guage  Double click or Drag and Drop in the Logical view block
 Select Program  Select Variables  Double click or Open As Table  Write the Program variable names

Drag and drop

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Variable Types

 Select type of the vari-

ables and Click Okay

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Write PLC programming code (Continue…)
 Select Program  Go Main.st  Double click or Open As Text  Write the programming code 
Save the all Code

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Adding I/O Driver

Search Bar

I/O Driver model

number

 Select Physical View and Go to the X2X

 Select and Adding the required I/O driver
Drag and drop using drag and drop

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Write PLC programming code (Continue…)

 Select the I/O Drivers and Select the I/O mapping & Configuring the I/O mapping
 Click on the three dot (…) Then appear the variables name and Adding the Process Variables and Save the Program

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 Write PLC programming code

 Save all program  Click on Build/Rebuild/Transfer the program  Click on Transfer  Click on Ok  Then click on again
Transfer  Close
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 Upload program in Flash Card (Offline)
1
3

 Go to Physical view  Right click on ETH and select the Configuration  Then Set the IP address for PLC  Insert the PLC
flash card in the Software PC  Then go to Project  Project Installation and select Offline Installation 17
Upload program in Flash Card (Offline)

 After click on Offline installation and Click on OK  Select the Install

on application storage  Click on Yes  Close

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Monitoring Configuration Status

 Press on Monitoring
and Monitoring the I/O
mapping
 Checking the all vari-
ables and status

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Project Analog & Digital Input Output codes

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Visual Screen Configuration
 Create Visualization Project
 Go VC4 Visualization  Select the Configuration  Next  Next  Finish

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Visual Screen Configuration
 Hardware Configuration

 Go physical view  ETH  Configuration  Configure the Settings like Snap

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Visual Screen Configuration
 Create Common/Global Layers

 Go Visu  Common layers 

Add Layer  Then design the
common layer layout using the
Tools

Design the common layers

using Basic Controls Tools

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Visual Screen Configuration
 Add New Page

 Go Visu  Select Page  Add Page

 Select the page and Rights click on it  Select Add Layer Reference and add common layers on that pages  Ok

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Visual Configuration
 Design Workspace Screen

 After adding the common layers

 Design the HMI Screen
 Full Visual Screen

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 Visual Configuration
 Tools with Properties

 Used tool properties settings

 Set the input output data
variable on the HMI

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 Visual Configuration
 Trend data graph settings from Analog Input data

 Go to Basic Controls tool and select the trend option  Drag and Drop in the Workspace
 Select trend and click on Start trend wizard  Set all settings  Next  Insert the
Analog Input datapoint for trend graph and set the Min & Max value for view Trend graph
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 Next  Set settings  Finish
Visual Configuration (Alarms)
 Alarm settings

 Create Alarm Array variables and set value 0 or False

 Go to Visualization and Select Alarm Groups  Add
Alarm Group  Then Create/Write the Alarms
 Go to properties  Click on the Value  Select
Alarm Image  Set the Alarm variable and Alarm
show perspective of the Index number

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 Visual Configuration (Alarms)
 Alarm settings

 Go to Basic Controls tool and select the Alarm option  Drag and Drop in the Workspace  Click on Alarm text and Go
properties  Select Value and set current on the Source

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 Visual Screen Configuration
 VNC Visualization settings configuration
 Open VNC Viewer  Write the PLC device IP address and Port number  Then Click on Connect  Continue 
Password (Optional)  Ok

PLC Device IP Address and Port Number

HMI Screen
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Visual Configuration
 VNC Visualization Screen

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Sarker Md. Sahin
Research Engineer ( 선임 연구
원)
Hyundai E.D.S Co., Ltd.
Email: smdsahin@heds.co.kr
Mobile: 010-3286-4687