Automation Industrielle

Industrial Automation
Automation Industrielle
Industrielle Automation
K_TIT
POST_START_TIMER_MOD TIT_REF_MAX_START TIT_RATE_LIM_UP

MAX_INT
TIT_ERROR I P WFD_TIT
TIT_REF_TAB lim PID
N_GT
D
100 TD_TIT
FAULT_STATE[tit1_oor] 0 TIT_RATE_LIM_DN
OR
FAULT_STATE[tit2_oor]
TIT 17.3
2.3 Programmable Logic Controllers (PLCs)

Autómatas programables
Automates Programmables
Speicherprogrammierbare Steuerungen (SPS)
2.3.1 PLCs: Definition and Market
2.1 Instrumentation
2.2 Control
2.3 Programmable Logic Controllers
2.3.2 PLCs: Kinds
2.3.3 PLCs: Functions and construction
2.3.4 Continuous and Discrete Control
2.3.5 PLC Programming Languages
2.3.5.1 IEC 61131 Languages
2.3.5.2 Function blocks
2.3.5.3 Program Execution
2.3.5.4 Input / Output
2.3.5.5 Structured Text
2.3.5.6 Sequential Function Charts
2.3.5.7 Ladder Logic
2.3.5.8 Instruction Lists
2.3.5.9 Programming environment
2013 Programmable Logic Controllers 2.3 - 2
PLC = Programmable Logic Controller: Definition
AP = Automates Programmables industriels

SPS = Speicherprogrammierbare Steuerungen
Definition: “small computers, dedicated to automation tasks in an industrial environment"
Formerly: cabled relay control (hence 'logic'), analog (pneumatic, hydraulic) “governors”
Today: real-time (embedded) computer with extensive input/output
Function: Measure, Control, Protect
Distinguish Instrumentation
flow meter, temperature, position,…. but also actors (pump, …)
Control
programmable logic controllers with digital peripherals & field bus
Visualization
Human Machine Interface (HMI) in PLCs (when it exists) is limited
to service help and control of operator displays
Simple PLC
network digital inputs
analog inputs / outputs
digital outputs
PLC in a cabinet
CPU1 CPU2
serial connections
redundant field
bus connection
inputs/outputs
example: turbine control (in the test lab)
PLC: functions
(Messen, Schützen, Regeln = MSR)
PLC = PMC: Protection, Measurement and Control
• Measure
• Control (Command and Regulation)
• Protection
•Event Logging
•Communication
•Human interface
PLC: Characteristics
• large number of peripherals: 20..100 I/O per CPU, high density of wiring, easy assembly.
• digital and analog Input/Output with standard levels
• operate under harsh conditions, require robust construction, protection against dirt,
water and mechanical threats, electro-magnetic noise, vibration, extreme temperature
range (-30C..85C), sometimes directly located in the field.
• programming: either very primitive with hand-help terminals on the target machine
itself, or with a laptop
• network connection for programming on workstations and connection to SCADA
• field bus connection for remote I/Os
• primitive Human-Machine-Interface for maintenance, either through LCD-display or
connection of a laptop over serial lines (RS232) or wireless.
• economical - €1000.- .. €15'000.- for a full crate.
• the value is in the application software (licenses €20'000 ..€50'000)
PLC: Location in the control architecture
Enterprise Network
Engineer Operator Supervisor
station station Station gateway
Control Bus
(e.g. Ethernet)
PLC
large
COM1
COM 2
Control Station
COM1
COM 2
COM1
CPU
PLC
CPU
CPU
I/O
with Field Bus gateway
PLCs
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
direct I/O
Field Bus Field Bus
COM
COM
COM
COM
CPU
CPU
CPU
COM
I/O
I/O
I/O
I/O
I/O
I/O
I/O
directly connected
I/O
Field Stations FB
gateway Field Devices
small PLC
data concentrators,
not programmable,
but configurable
Sensor Bus (e.g. ASI)
Why 24V / 48 V supply ?
… After the plant lost

electric power, operators
could read instruments only
by plugging in temporary
batteries…
[IEEE Spectrum Nov 2011
about Fukushima]
Photo TEPCO
Global players
Total sales in 2004: 7’000 Mio €

Source: ARC Research, 2005-10
2.3.3 PLCs: Kinds
2.1 Instrumentation
2.2 Control
2.3.2 PLCs: Kinds
Kinds of PLC
(1) Compact
Monolithic construction
Monoprocessor
Fieldbus connection
(2) Modular PLC

Modular construction (backplane)
One- or multiprocessor system
Fieldbus and LAN connection
Small Micro Memory Card (MMC) function possible
(3) Soft-PLC
Windows NT or CE-based automation products
Direct use of CPU or co-processors
Compact PLC
courtesy ABB courtesy ABB courtesy ABB
Monolithic (one-piece) construction

Fixed casing
Fixed number of I/O (most of them binary)
No process computer capabilities (no MMC)
Can be extended and networked by an extension (field) bus
Sometimes LAN connection (Ethernet, Arcnet)
Monoprocessor
Typical product: Mitsubishi MELSEC F, ABB AC31, SIMATIC S7
costs: € 2000
Specific Controller (example: Turbine)
tailored for a specific application, produced in large series

Programming port Relays and fuses
Thermocouple
inputs
binary I/Os,
CAN field bus
RS232 to HMI
courtesy Turbec
cost: € 1000.-
Modular PLC
• tailored to the needs of an application development

RS232 environment
• housed in a 19" (42 cm) rack
(height 6U ( = 233 mm) or 3U (=100mm)
• high processing power (several CPUs) LAN
• large choice of I/O boards

backplane
• concentration of a large number of I/O parallel bus
courtesy ABB
• interface boards to field busses fieldbus
• requires marshalling of signals Power Supply
• primitive or no HMI
CPU CPU Analog I/O Binary I/O
• cost effective if the rack can be filled fieldbus
• supply 115-230V~ , 24V= or 48V= (redundant)

• cost ~ €10’000 for a filled crate
Typical products: SIMATIC S5-115, Hitachi H-Serie, ABB AC110
Small modular PLC
courtesy ABB
courtesy Backmann
mounted on DIN-rail, 24V supply

cheaper (€5000)
not water-proof,
no ventilator
extensible by a parallel bus (flat cable or rail)
Specific controller (railways)
data bus
three PLCs networked by a data bus.

special construction: no fans, large temperature range, vibrations
Compact or modular ?
field bus
€ extension
modular PLC (variable number of I/Os

compact PLC
(fixed number of I/Os)
Limit of local I/O
# I/O modules
Industry- PC
courtesy INOVA courtesy MPI
Wintel architecture Competes with modular PLC

(but also: Motorola, PowerPC), no local I/O,
HMI (LCD..) fieldbus connection instead,
Limited modularity through mezzanine boards costs: € 2000.-
(PC104, PC-Cards, IndustryPack)
Backplane-mounted versions with PCI or Compact-PCI
Soft-PLC (PC as PLC)
• PC as engineering workstation
• PC as human interface (Visual Basic, Intellution, Wonderware)
23 12 • PC as real-time processor
4 2 2 • PC assisted by a Co-Processor (ISA- or PC104 board)
3
3 • PC as field bus gateway to a distributed I/O system
I/O modules
Protection devices
substation measurement communication to operator

transformers Human interface
for status
and
Ir settings
Is
It
Ur Programming
Us interface
UT
trip relay
Protection devices are highly specialized PLCs that measure the current and voltages in an electrical
substation, along with other statuses (position of the switches,…) to detect situations that could
endanger the equipment (over-current, short circuit, overheat) and trigger the circuit breaker (“trip”) to
protect the substation.
In addition, they record disturbances and send the reports to the substation’s SCADA.
Sampling: 4.8 kHz, reaction time: < 5 ms.
costs: € 5000
Comparison Criteria – what matters
Brand Siemens Hitachi

Number of Points 1024 640
Memory 10 KB 16 KB
Programming Language • Ladder logic • Ladder Logic
• Instructions • Instructions
• Logic symbols • Logic symbols
• Basic
• Hand-terminal
• Hand-terminal
Programming Tools Graphical (on PC) Graphical (on PC)
Download no yes
Real estate per 250 I/O 2678 cm2 1000 cm2
Label surface 5.3 mm2 6 mm2

per line/point 7 characters 6 characters
Network 10 Mbit/s 19.2 kbit/s
Mounting DIN rail cabinet

2.3.3 PLCs: Function and construction
2.1 Instrumentation
2.2 Control
2.3.2 PLCs: Kinds
General PLC architecture
RS 232 Ethernet
Real-Time flash serial port ethernet

CPU ROM
Clock EPROM controller controller
extension
bus
parallel bus buffers
fieldbus analog- digital- external

Digital
controller digital analog Digital Output I/Os
Input
converters converters
signal power signal

relays
conditioning amplifiers conditioning
field bus direct Inputs and Outputs
The signal chain within a PLC
y y(i) y(i)
time time time
analog filtering analog- 011011001111

digital- analog
variable & sampling digital analog amplifier variable
(e.g. 4..20mA) scaling converter converter e.g. -10V..10V
1
processing
binary transistor
binary
variable filtering sampling or
variable
(e.g. 0..24V)
0001111
relay
non-volatile
counter memory
y
time
Internals of a protection device
Signal flow in an IED
2.3.4 Continuous and discrete control
2.1 Instrumentation
2.2 Control
2.3.2 PLCs: Kinds
Matching the analog and binary world
discrete control analog regulation
PLC evolution
Binary World Analog World

Relay control, pneumatic Pneumatic and electromechanical
sequencer controllers
I1
A
B
C
P1
P2
combinatorial sequential Regulation, controllers
discrete processes continuous processes
Programmable Logic Controllers

(Speicherprogrammierbare Steuerungen, Automates Programmables)
Continuous Plant (reminder)
Example: traction motors, ovens, pressure vessel,...

The state of continuous plants is described by continuous (analog) state
variables like temperature, voltage, speed, etc.
There exist a fixed relationship between input and output,described by a continuous model in
form of a transfer function F.
This transfer function can be expressed by a set of differential equations.
If equations are linear, the transfer function may expressed as Laplace or Z-transform.
(1+Ts)
x F(s) = y
(1+T1s + T2 s2) time
Continuous plants are normally reversible and monotone.

This is the condition to allow their regulation.
The time constant of the control system must be at least one order of
magnitude smaller than the smallest time constant of the plant.
the principal task of the control system for a continuous plant is its regulation.
Discrete Plant (reminder)
b
init c+d
2 3 4
a e
Examples: Elevators,
c + ¬d
traffic signaling, 1
e
warehouses, etc.
7 6 5
The plant is described by variables which take well-defined, non-overlapping values.

The transition from one state to another is abrupt, it is caused by an external event.
Discrete plants are normally reversible, but not monotone, i.e. negating the
event which caused a transition will not revert the plant to the previous state.
Example: an elevator doesn't return to the previous floor when the button is released.
Discrete plants are described e.g. by finite state machines or Petri nets.
the main task of a control system with discrete plants is its sequential control.
Continuous and Discrete Control (comparison)
"combinatorial"1) "sequential"
e.g. ladder logic, CMOS logic e.g. GRAFCET, Petri Nets

A B
Out = A · B
A
NOT C ladder
logic
B
Out = (A + B) · C
I1
analog
building
P1
blocs
P2
1) not really combinatorial: blocs may have memory

2.3.5 Programming languages
2.1 Instrumentation
2.2 Control
2.3.2 PLCs: Kinds
2.3.5 Programming languages
"Real-Time" languages
Extend procedural languages to Languages developed for cyclic

express time execution and real-time
(“introduce programming constructs to ("application-oriented languages")
influence scheduling and control flow”)
• ADA • ladder logic
• Real-Time Java • function block language
• MARS (TU Wien) • instruction lists
• Forth • GRAFCET
• “C” with real-time features • SDL
• etc… etc...
could not impose themselves wide-spread in the control industry.

Now standardized as IEC 61131
The long march to IEC 61131
NEMA Programmable Controllers Committee formed (USA)

GRAFCET (France)
DIN 40719, Function Charts (Germany)
NEMA ICS-3-304, Programmable Controllers (USA)
IEC SC65A/WG6 formed
DIN 19 239, Programmable Controller (Germany)
IEC 65A(Sec)38, Programmable Controllers
MIL-STD-1815 Ada (USA)
IEC SC65A(Sec)49, PC Languages
IEC SC65A(Sec)67
IEC 848, Function Charts
IEC 64A(Sec)90
IEC 1131-3
Type 3 report
recommendation
IEC 61131-3
name change
70 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
Source: Dr. J. Christensen
it took 20 years to make that standard…

The five IEC 61131-3 Programming languages
http://www.isagraf.com
Function Block Diagram (FBD) graphical languages Sequential Flow Chart (SFC)
CALC1
START STEP
CALC PUMP
AUTO IN1 OUT >=1 DO T1

MAN_ON V N ACTION D1 D1_READY
STEP A
ACT IN2
D ACTION D2 D2_READY
T2
N ACTION D3 D3_READY
STEP B
Ladder Diagram (LD)
CALC1 T3
AUTO CALC PUMP

IN1 OUT
OUT
ACT textual languages Structured Text (ST)
IN2
MAN_ON
VAR CONSTANT X : REAL := 53.8 ;
Z : REAL; END_VAR
VAR aFB, bFB : FB_type; END_VAR
bFB(A:=1, B:=‘OK’);
Instruction List (IL) Z := X - INT_TO_REAL (bFB.OUT1);
A: LD %IX1 (* PUSH BUTTON *) IF Z>57.0 THEN aFB(A:=0, B:=“ERR”);
ANDN %MX5 (* NOT INHIBITED *) ELSE aFB(A:=1, B:=“Z is OK”);
ST %QX2 (* FAN ON *) END_IF
Importance of IEC 61131
IEC 61131-3 is the most important automation language in industry.
80% of all PLCs support it, all new developments are based on it.
Depending on the country, some languages are more popular than others.
Exercise
http://docs.google.com/forms/d/1m4dQkDF89aGj5B
aL0Rzj9Xl7XprDvyU8pB4J0vd4sWo/viewform
2.4.2.1 Function Blocks Language
2.1 Instrumentation
2.2 Control
2.3.2 PLCs: Kinds
2.3.5.2 Function blocks language
Function Block Languages
(Funktionsblocksprache, langage de blocs de fonctions)

(Also called "Function Chart" or "Function Plan" - FuPla)
The function block languages express "combinatorial"

programs in a way similar to electronic circuits.
They draw on a large variety of predefined and custom functions
This language is similar to the Matlab / Simulink language used for simulations
Function Block Examples
Example 1:
A
B & C
Example 2:
external inputs external outputs
Trigger
Tempo &
S Q Spin
Running
Reset R
Graphical programming language, similar to electrical and block

diagrams. Mostly expresses combinatorial logic, but blocks may have
memory (e.g. RS-flip-flops – but no D-flip-flops: no edge-triggered logic).
Function Block Elements
Function block input signals parameters output signals
Example "continuously"
set point PID command executing block,
overflow independent,
measurement no side effects
The block is defined by its:

• Data flow interface (number and type of input/output signals)
• Black-Box-Behavior (functional semantic, e.g. in textual form).
Signals Typed connections that carry a pseudo-continuous data flow.
Connects the function blocks.
set point (set point)

Example (set point)
Function Block Example
Function Block Rules
There exist exactly two rules for connecting function blocks by signals
(this is the actual programming):
• Each signal is connected to exactly one source.
This source can be the output of a function block or a plant signal.
• The type of the output pin, the type of the input pin and the signal type
must be identical.
The function plan should be drawn so the signals flow from left
to right and from top to bottom. Some editors impose additional rules.
Retroactions are an exception to this rule. In this case, the signal direction is
identified by an arrow (forbidden in some editors – use global variables instead).
a
b x
c y
Types of Programming Organisation Units (POUs)
1) “Functions”
- are part of the base library.
- have no memory.
Examples: and gate, adder, multiplier, selector,....
2) “Elementary Function Blocks” (EFB)

- are part of the base library
- have a memory ("static" data).
- may access global variables (side-effects !)
Examples: counter, filter, integrator,.....
3) “Programs” (Compound blocks)

- user-defined or application-specific blocks
- may have a memory
- may be configurable (control flow not visible in the FBD
Examples: PID controller, Overcurrent protection, Motor sequence
(a library of compound blocks may be found in IEC 61804-1)
Function Block library
The programmer chooses the blocks in a block library, similarly to the

hardware engineer who chooses integrated circuits in a catalogue.
The library describes the pinning of each block, its semantics and the
execution time.
The programmer may extend the library by defining function block macros
composed of library elements.
If some blocks are used often, they will be programmed in an external

language (e.g. “C”, micro-code) following strict rules.
Library functions for discrete plants
Basic blocks
logical combinations (AND, OR, NOT, EXOR)
Flip-flop
Selector m-out-of-n
Multiplexer m-to-n
Timer
Counter
Memory
Sequencing
Compound blocks
Display
Manual input, touch-screen
Safety blocks (interlocking)
Alarm signaling
Logging
Analog function blocks for continuous control
Basic blocks
Summator / Subtractor
Multiplier / Divider
Integrator / Differentiator
Filter
Minimal value, Maximum value
Radix
Function generator
Regulation Functions
P, PI, PID, PDT2 controller
Fixed set-point
Ratio and multi-component regulation
Parameter variation / setting
2-point regulation
3-point regulation
Output value limitation
Ramp generator
Adaptive regulation
Drive Control
Function Block library for specialized applications
MoveAbsolute
Axis Axis
AXIS_REF AXIS_REF
BOOL Execute Done BOOL
REAL Position CommandAborted BOOL
REAL Velocity Error BOOL
REAL Acceleration ErrorID WORD
REAL Deceleration
REAL Jerk
MC_Direction Direction
standardized blocks are defined in libraries, e.g. Motion Control or Robot
IEC 61131-3 library (extract)
binary elements analog elements

GE greater equal
AND GT
GT greater than ADD adder
and LT less than
LE less equal
OR IN pos.edge: start SUB subtractor
or TP/TON/TOF
IN Q
PT duration of delay
XOR PT ET Q TP: 1, while PT
exclusive-or TON: 1, at PT MUL multiplier
TOF: 0, at PT
flip-flop ET actual delay
SR CTU DIV divider
S1 dominant set bool
CU
R Q Q:=S1|(Q&!R) Up counter
RESET Q
PV CV (CTD counter down)
INT
RS flip-flop Reset integrator
S
dominant reset bool SEL
PV
R1 Q selector
Q:=!R1&(Q|S) (1:2) In
(if reset) { Out := PV,
R_TRIG int else Out:= Δt *In + Out}
positive MUX
S Q multiplexer
edge (1:N)
More details: http://www.zpss.aei.polsl.pl/content/dydaktyka/PC/PLC_IEC61131-3.pdf

Exercise: What do the following blocks do ?
1. 2.
In1 INT
In ADD (e.g. 1024)
(e.g.10)
Out Reset Out
(initially 2) DIV PresetVal (initially 0)
In2 In
(initially 2)
(if reset) { Out := PV,
else Out:= Δt *In + Out}
3. t1 t2 t3 t4 t5 t6 t7 t8
CTU
CU
RESET Q CU
PV CV
Reset = 0, PV = 3 Q = (CV >= PV) ?
Flipflop: dominant set or reset?

4.
S SR dominant set
S1 Q:=S1|(Q&!R)
R R Q
RS
S dominant reset
Q R1 Q Q:=!R1&(Q|S)
https://docs.google.com/forms/d/1ynmoXf3JTcRn2yv
2_4bKhcK0HJNDYpiTnQQm13lDSso/viewform ftp://advantechdownloads.com/Traini
ng/KW%20training/
Exercise: What do the following blocks do ?
1. 2.
2, 10, 22, 31, 42 If out is initially 0: 0, 0, 0, 0, 0

If out is initially 1024: 1024, 1536, 2304,
3456, 5184
3.
CV = 1, 1, 2, 2, 3, 3, 4, 4
Q = 0, 0, 0, 0, 1, 1, 1, 1
4.
S SR dominant set
S1 Q:=S1|(Q&!R)
R R Q
https://docs.google.com/forms/d/1ynmoXf3JTcRn2yv
2_4bKhcK0HJNDYpiTnQQm13lDSso/viewform ftp://advantechdownloads.com/Traini
ng/KW%20training/
Exercise: Which Behavior belongs to which Timer?
5.
TP/TON/TOF IN pos.edge: start
IN Q PT duration of delay
PT ET Q Timer Pulse: 1, while PT Timer ON delay: 1, at PT Timer OFF delay: 0, at PT
ET actual delay
b)
c)
a)
ftp://advantechdownloads.com/
Training/KW%20training/
https://docs.google.com/forms/d/1ynmoXf3JTcRn2yv2_4bKhcK0HJNDYpiTnQQm13lDSso/viewform
Exercise: Which Behavior belongs to which Timer?
5.
TP/TON/TOF IN pos.edge: start
IN Q PT duration of delay
PT ET Q Timer Pulse: 1, while PT Timer ON delay: 1, at PT Timer OFF delay: 0, at PT
ET actual delay
b)
Timer OFF delay
c)
a)
Pulse
Timer ON delay
ftp://advantechdownloads.com/
Training/KW%20training/
https://docs.google.com/forms/d/1ynmoXf3JTcRn2yv2_4bKhcK0HJNDYpiTnQQm13lDSso/viewform
Exercise: Asymmetric Sawtooth Wave
Build an asymmetric sawtooth wave generator with

the IEC 61131 elements of Slide 51
5s 12s
75
-25
Exercise: Saw-tooth FBD
75.0
-25.0
+ 8.3
-20.0
Specifying the behaviour of Function Block
Time Diagram:
0 T
x y x
y
T
Truth Table:
x1 x2 y
x1 S 0 0 previous state
x2 R 0 1 0
1 0 1
1 1 1
t
x dx y
Mathematical Formula:
Kpx  Kd  Ki  xd
dt 0
Textual Description: Calculates the root mean square of the input with a filtering constant
defined in parameter „FilterDelay“
Function Block specification in Structured Text
Function Block decomposition
A function block describes a data flow interface.

Its body can be implemented differently:
Elementary block The body is implemented in an external language
(micro-code, assembler, IEC 61131 ST):
procedure xy (a,b:BOOLEAN; VAR b,c: BOOLEAN);
begin
......
= ....
end xy;
Compound block The body is realized as a function block program .

Each input (output) pin of the interface is implemented as
exactly one input (output) of the function block.
All signals must appear at the interface to guarantee
freedom from side effects.
Function Block segmentation
An application program (task) is decomposed into segments ("Programs")

for easier reading, each segment being represented on one (A4) printed page.
• Within a segment, the connections are represented graphically
.
• Between the segments, the connections are expressed by signal names
.
Segment A
X1
M2 M1
Y1
Segment B
X2 Y2
M1
X3 M2
2.3.5.3 Program execution
2.1 Instrumentation
2.2 Control
2.3.2 PLCs: Kinds
Execution of Function Blocks
Segment or POU A X01 X

(program organization unit) F1 F2
B
C F4
X02
F3 Y
function F1
Machine Code: input1 A
input2 B
The function blocks are output X01
translated to machine language F2
(intermediate code, IL), X01
that is either interpreted or X
F3
compiled to assembly language B
C
Blocks are executed in sequence, X02
normally from upper left to lower right F4
X
X02
The sequence is repeated every t ms. Y
Input-Output of Function Blocks
Run-time:
read write
inputs outputs
I X O I X O I X O
time
execute individual period
The function blocks are executed cyclically.

• all inputs are read from memory or from the plant (possibly cached)
• the segment is executed
• the results are written into memory or to the plant (possibly to a cache)
The order of execution of the blocks generally does not matter.
To speed up algorithms and avoid cascading, it is helpful to impose an
execution order to the blocks.
The different segments may be assigned a different individual period.
Program configuration
The programmer divides the program into tasks (sometimes called pages or
segments), which may be executed each with a different period.
The programmer assigns each task (each page) an execution period.
Since the execution time of each block in a task is fixed, the execution time
is fixed.
Event-driven operations are encapsulated into blocks, e.g. for transmitting

messages.
If the execution time of these operations take more than one period,
they are executed in background.
The periodic execution always has the highest priority.
IEC 61131 - Execution engine
configuration
resource resource
task task task task
program program program program
FB FB FB FB
global and directly represented variables
access paths
communication function
Legend: execution control path

variable access paths
FB function block
variable
Parallel execution
Function blocks are particularly well suited for true multiprocessing (parallel
processors).
The performance limit is given by the needed exchange of signals by means of a

shared memories.
Semaphores are not used since they could block an execution and make the concerned
processes non-deterministic.
processor processor processor input/

1 2 3 output
shared shared shared shared

memory memory memory memory
2.3.5.4 Input and Output
2.1 Instrumentation
2.2 Control
2.3.2 PLCs: Kinds
2.3.5.4 Input & Output
Connecting to Input/Output, Method 1: dedicated I/O blocks
The Inputs and Outputs of the PLC must be connected to (typed) variables
IN_1 OUT_1
The I/O blocks are configured to be attached to the

corresponding I/O groups.
Connecting to Input / Output, Method 2: Variables configuration
All program variables must be declared with name and type, initial value and volatility.
A variable may be connected to an input or an output, giving it an I/O address.
Several properties can be set: default value, fall-back value, store at power fail,…
These variables may not be connected as input, resp. output to a function block.
predefined addresses
2.1 Instrumentation
2.2 Control
2.3.2 PLCs: Kinds
Structured Text
(Strukturierte Textsprache, langage littéral structuré)
Structured Text is a language similar to Pascal (If, While, etc..)
The variables defined in ST can be used in other languages.
It is used to do complex data manipulation and write blocks
Caution: writing programs in structured text can breach the real-time rules !
Data Types
Function Blocks are typed: the types of connection, input and output must match.
•Elementary Types are defined either in Structured Text or in the FB configuration.
binary types: analog types:

BOOL 1 REAL (Real32)
BYTE 8 LREAL (Real64)
WORD 16
DWORD 32
•Derived Types are user-defined and must be declared in Structured Text

subrange,
enumerated,
arrays,
structured types
(e.g. AntivalentBoolean2)
Variables can receive initial values and be declared as non-volatile (RETAIN), so

after restart they contain the last value before power-down or reset.
61131 Elementary Data Types
No. Keyword Data Type Bits

1 BOOL Boolean 1
2 SINT Short integer 8
3 INT Integer 16
4 DINT Double integer 32
5 LINT Long integer 64
6 USINT Unsigned short integer 8
7 UINT Unsigned integer 16
8 UDINT Unsigned double integer 32
9 ULINT Unsigned long integer 64
10 REAL Real numbers 32
11 LREAL Long reals 64
12 TIME Duration variable
13 DATE Date (only) variable
14 TIME_OF_DAY or TOD Time of day (only) variable
15 DATE_AND_TIME or DT Date and time of day variable
16 STRING Character string variable
17 BYTE Bit string of length 8 8
18 WORD Bit string of length 16 16
19 DWORD Bit string of length 32 32
20 LWORD Bit string of length 64 64
21 variable length double-byte string
Example of Derived Types
TYPE
ANALOG_CHANNEL_CONFIGURATION
STRUCT
RANGE: ANALOG_SIGNAL_RANGE;
MIN_SCALE : ANALOG_DATA ;
MAX_SCALE : ANALOG_DATA ;
END_STRUCT;
ANALOG_16_INPUT_CONFIGURATION :
STRUCT
SIGNAL_TYPE : ANALOG_SIGNAL_TYPE;
FILTER_CHARACTERISTIC : SINT (0.99)
CHANNEL: ARRAY [1..16] OF ANALOG_CHANNEL_CONFIGURATION;
END_STRUCT ;
END_TYPE
2.1 Instrumentation
2.2 Control
2.3.2 PLCs: Kinds
SFC (Sequential Flow Chart)
(Ablaufdiagramme, diagrammes de flux en séquence - grafcet)
START STEP
T1
N ACTION D1 D1_READY
STEP A STEP B
T2
SFC describes sequences of operations and interactions between parallel processes.

It is derived from the languages Grafcet and SDL (Specification and Description
Language, used for communication protocols), mathematical foundation lies in Petri Nets.
SFC: Elements
S0
event condition
"1"
("1" = always true) transitions
Sa example transition condition
Ea Ec = ((varX & varY) | varZ)

states Sb
Eb
token
Sc
The sequential program consists of states connected by transitions.

A state is activated by the presence of a token (the corresponding variable becomes TRUE).
The token leaves the state when the transition condition (event) on the state output is true.
Only one transition takes place at a time, the execution period is a configuration parameter
(task to which this program is attached)
Rule: there is always a transition between two states,

there is always a state between two transitions
SFC: Initial state
State which come into existence with a token are called initial states.
All initial states receive exactly one token, the other states receive none.
Initialization takes place explicitly at start-up.
In some systems, initialization may be triggered in a user program

(initialization pin in a function block).
SFC: Switch and parallel execution
"1" E0
token switch : the token crosses the first active

Sa
transition (at random if both Ea and Eb are true)
Note: transitions are after the alternance
Ea Eb
Sc
Ec
Sb Sd
Ed
token forking : when the transition Ee is true, the token Se
is replicated to all connected states Ee
Note: transition is before the fork
Ef Sg
token join : when all connected states have tokens Sf
and transition Eg is true, one single token is forwarded.
Note: transition is after the join
Eg
SFC: P1, N and P0 actions
State1 P1 State1_P1: do at enter

N State1_N: do while
P0 State1_P0: do at leaving
P1 (pulse raise) action is executed once when the state is entered

P0 (pulse fall) action is executed once when the state is left
N (non-stored) action is executed continuously while the token is in the state
P1 and P0 actions could be replaced by additional states.
The actions are described by a code block written e.g. in Structured Text.
Special action: the timer
rather than define a P0 action “ reset timer….”, there is an implicit variable defined as
<state name>.t that express the time spent in that state.
S.t > t#5s
Sf
SFC: graphic rules
The input and output flow of a state are always in the same vertical line (simplifies structure)
Alternative paths are drawn such that no path is placed in the vertical flow
(otherwise would mean this is a preferential path)
intentional displacement to
avoid optical preference of a
path.
Priority:
• The alternative path most to the left has the
highest priority, priority decreases towards the right.
• Loop: exit has a higher priority than loopback.
SFC: Exercise
Input: Variables
I0, I1, I2, I3;
Output:
Trap = {0: closed; 1: open}
Speed = {+20: +1 m/s; +1: +5 cm/s; 0: 0m/s}
Register = {0: closed; 1: open}
negative values: opposite direction
Register = {0: closed; 1: open}
+speed
trap
I0 I1 Inputs generate “1” as long as

I2 I3 the tag of the vehicle (1cm) is
over the sensor.
initially: move vehicle at reduced speed until it touches I0 and open the trap for 5s
(empty the vehicle). Speed = 5 cm/s between I0 and I1 or between I2 and I3,
speed = 1 m/s between I1 and I2.
1 - Let the vehicle move from I0 to I3 4 - Go back to I0

2 - Stop the vehicle when it reaches I3. 5 - Open the trap and wait 5s.
3 - Open the tank during 5s. repeat above steps indefinitely
Exercise: Wagon SFC
Right2Left
SFC: Building subprograms
T-element
::=
OR: OR:
transition T-sequence alternative paths
S-element
::=
OR: OR: OR:
state S-sequence parallel paths loop
The meta-symbols T and S define structures - they may not appear

as elements in the flow chart.
A flow chart may only contain the terminal symbols: state and transition
SFC: Structuring
Every flow chart without a token generator may be redrawn as a

structured flow chart (by possibly duplicating program parts)
Not structured structured
A
a
A
B
a
b d
B d
C
b
c
C
c B' b
d
A' a
SFC: Complex structures
These general rules serve to build networks, termed by DIN and IEC as flow charts
Problems with general networks: Solution:

Deadlocks, uncontrolled assistance through the flow chart editor.
token multiplication
Function Blocks And Flow Chart
Function Blocks: Sequential Flow Charts:

Continuous (time) control Discrete (time) Control
Many PLC applications mix continuous and discrete control.

A PLC may execute alternatively function blocks and flow charts.
A communication between these program parts must be possible.
Principle:
The flow chart taken as a whole can be considered a function

block with binary inputs (transitions) and binary outputs (states).
Executing Flow Charts As blocks
A function block may be implemented in three different ways:
procedure
xy(...);
begin
...
end xy;
extern (ST) function blocks flow chart
Function blocks and flow chart communicate over binary signals.
Flow Charts or Function Blocs ?
A task can sometimes be written indifferently as function blocs or as flow chart.

The application may decide which representation is more appropriate:
Flow Chart Function Block
S
a
"1"
b R c
NOT d
c
d
a
Flow Charts Or Blocks ? (2)
Flow Chart Function Blocks

init ≥
"1" S
R A
A &
a
a
B
S
b
R B
C c &
b
S
R C
&
c
In this example, flow chart seems to be more appropriate:
2.1 Instrumentation
2.2 Control
2.3.2 PLCs: Kinds
Ladder logic (1)
(Kontaktplansprache, langage à contacts)
The ladder logic is the oldest programming language for PLC

it bases directly on the relay intuition of the electricians.
it is widely in use outside Europe.
It is described here but not recommended for new projects.
Ladder Logic (2)
make contact
origin: (contact travail)
02
electrical 01 relay coil
circuit (bobine)
03 50
break contact
(contact repos)
01 02
corresponding 50 rung
03
ladder diagram
50 05 "coil" 50 is used to move

44 other contact(s)
Ladder logic (3)
The contact plan or "ladder logic" language allows an easy transition from the
traditional relay logic diagrams to the programming of binary functions.
It is well suited to express combinational logic
It is not suited for process control programming (there are no analog elements).
The main ladder logic symbols represent the elements:
make contact contact travail Arbeitskontakt
break contact contact repos Ruhekontakt
relay coil bobine Spule
Ladder logic (4)
Binary combinations are expressed by series and parallel relay contact:
ladder logic representation “logic" equivalent

Series + 01 02 01
50 50
02
Coil 50 is active (current flows) when 01 is active and 02 is not.
Parallel + 01
40 01
02 40
02
Coil 40 is active (current flows) when 01 is active or 02 is not.
Ladder logic (5)
The ladder logic is more intuitive for complex binary expressions than literal languages
textual expression
1 2 3 4
50 !N 1 & 2 STR 3 & N 4 STR N 5
5 6 & 6 / STR & STR = 50
0 1 4 5 12
50 !0 & 1 STR 2 & 3 / STR STR 4
2 3 6 7 & 5 STR N 6 & 7
/ STR & STR STR 10

10 11 & 11 / STR & 12 = 50
Ladder logic (6)
Ladder logic stems from the time of the relay technology.

As PLCs replaced relays, their new possibilities could not be expressed any more
in relay terms.
The contact plan language was extended to express functions:
00 01
literal expression:
FUN 02 200
!00 & 01 FUN 02 = 200
The intuition of contacts and coil gets lost.

The introduction of «functions» that influence the control flow itself, is problematic.
The contact plan is - mathematically - a functional representation.
The introduction of a more or less hidden control of the flow destroys the
freedom of side effects and makes programs difficult to read.
Ladder logic (7)
Ladder logic provides neither:

• sub-programs (blocks), nor
• data encapsulation nor
• structured data types.
It is not suited to make reusable modules.
IEC 61131 does not prescribe the minimum requirements for a compiler / interpreter
such as number of rungs per page nor does it specifies the minimum subset to be
implemented.
Therefore, it should not be used for large programs made by different persons
It is very limited when considering analog values (it has only counters)
→ used in manufacturing, not process control
2.3.6 Instruction Lists
2.1 Instrumentation
2.2 Control
2.3.2 PLCs: Kinds
2.3.5.8 Instructions Lists
Instruction Lists (1)
(Instruktionsliste, liste d'instructions)
Instruction lists is the machine

language of PLC programming
It has 21 instructions (see table)
Three modifiers are defined:

"N" negates the result
"C" makes it conditional and
"(" delays it.
All operations relate to one result

register (RR) or accumulator.
Instruction Lists Example (2)
End: ST temp3 (* result *)
Instructions Lists is the most efficient way to write code, but only for specialists.
Otherwise, IL should not be used, because this language:

• provides no code structuring
• has weak semantics
• is machine dependent
Exercise IEC 61131 Languages
Ladder Diagram Function Block Diagram
A B C
?
-| |--|/|----------------( ) A ? C
?
B
Instruction List Structured Text
? ?
? ? C:= ?
? ?
https://docs.google.com/forms/d/1lGkFXQrlwlnoKc8g
Ug-_ESAdtVy-RgIOLnFbkIOGNa8/viewform
Exercise IEC 61131 Languages
Ladder Diagram Function Block Diagram
A B C
-| |--|/|----------------( ) A AND C
B
Instruction List Structured Text
LD A
ANDN B C:= A AND NOT B
ST C
https://docs.google.com/forms/d/1lGkFXQrlwlnoKc8g
Ug-_ESAdtVy-RgIOLnFbkIOGNa8/viewform
2.1 Instrumentation
2.2 Control
2.3.2 PLCs: Kinds
2.3.5.8 Instructions Lists
Programming environment capabilities
A PLC programming environment (e.g. ABB ControlBuilder,

Siemens Step 7, CoDeSys,...) allows the programmer to
- program the PLC in one of the IEC 61131 languages
- define the variables (name and type)
- bind the variables to the input/output (binary, analog)
- run simulations
- download programs and firmware to the PLC
- upload from the PLC (seldom provided)
- monitor the PLC
- document and print
61131 Programming environment
configuration, editor,
compiler, library
symbols laptop
code
variable
firmware monitoring
and
download forcing
for debugging
network
PLC
Program maintenance
The source of the PLC program is generally on the laptop of the technician.
This copy is frequently modified, it is difficult to track the original in a process

database, especially if several persons work on the same machine.
Therefore, it would be convenient to be able to reconstruct the source programs

out of the PLC's memory (called back-tracking, Rückdokumentation, reconstitution).
This supposes that the instruction lists in the PLC can be mapped directly to graphic
representations -> set of rules how to display the information.
Names of variables, blocks and comments must be kept in clear text, otherwise the
code, although correct, would not be readable.
For cost reasons, this is seldom implemented.
Is IEC 61131 FB an object-oriented language ?
Not really: it does not support inheritance.
Blocks are not recursive.
But it supports interface definition (typed signals), instantiation, encapsulation,

some form of polymorphism.
Some programming environments offer “control modules” for better object-

orientation
Limitations of IEC 61131
- it is not foreseen to distribute execution of programs over several devices
- event-driven execution is not foreseen. Blocks may be triggered by a Boolean variable,

(but this is good so).
- if structured text increases in importance, better constructs are required (object-oriented)
Assessment
Which are programming languages defined in IEC 61131 and for what are they used ?
In a function block language, which are the two elements of programming ?
How is a PLC program executed and why is it that way ?
Draw a ladder diagram and the corresponding function chart.
Draw a sequential chart implementing a 2-bit counter
Program a saw tooth waveform generator with function blocks
How are inputs and outputs to the process treated in a function chart language ?
Program a sequencer for a simple chewing-gum coin machine
Program a ramp generator for a ventilator speed control (soft start and stop in 5s)
Exercise: write the SFC for this task
open V1 until tank’s L1 indicates upper level

open V2 during 25 seconds
V1 V2 open V3 until the tank’s L1 indicate it reached the lower level
while stirring.
L1 upper heat mixture during 50 minutes while stirring
lower empty the reactor while the drying bed is moving
V3 MS
H1 T temperature
(sensor)
heater
(actor)
V4
MD

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Industrial Automation

POST_START_TIMER_MOD TIT_REF_MAX_START TIT_RATE_LIM_UP

2.3 Programmable Logic Controllers (PLCs)

AP = Automates Programmables industriels

Definition: “small computers, dedicated to automation tasks in an industrial environment"

Today: real-time (embedded) computer with extensive input/output

Function: Measure, Control, Protect

network digital inputs

analog inputs / outputs

(Messen, Schützen, Regeln = MSR)

PLC = PMC: Protection, Measurement and Control

… After the plant lost

Total sales in 2004: 7’000 Mio €

(2) Modular PLC

courtesy ABB courtesy ABB courtesy ABB

Monolithic (one-piece) construction

tailored for a specific application, produced in large series

• tailored to the needs of an application development

• large choice of I/O boards

• interface boards to field busses fieldbus

• requires marshalling of signals Power Supply

• supply 115-230V~ , 24V= or 48V= (redundant)

mounted on DIN-rail, 24V supply

three PLCs networked by a data bus.

modular PLC (variable number of I/Os

Limit of local I/O

courtesy INOVA courtesy MPI

Wintel architecture Competes with modular PLC

substation measurement communication to operator

Brand Siemens Hitachi

Label surface 5.3 mm2 6 mm2

Network 10 Mbit/s 19.2 kbit/s

Mounting DIN rail cabinet

Real-Time flash serial port ethernet

fieldbus analog- digital- external

signal power signal

field bus direct Inputs and Outputs

time time time

analog filtering analog- 011011001111

discrete control analog regulation

Binary World Analog World

combinatorial sequential Regulation, controllers

discrete processes continuous processes

Programmable Logic Controllers

Example: traction motors, ovens, pressure vessel,...

Continuous plants are normally reversible and monotone.

The plant is described by variables which take well-defined, non-overlapping values.

e.g. ladder logic, CMOS logic e.g. GRAFCET, Petri Nets

1) not really combinatorial: blocs may have memory

Extend procedural languages to Languages developed for cyclic

could not impose themselves wide-spread in the control industry.

NEMA Programmable Controllers Committee formed (USA)

Source: Dr. J. Christensen

it took 20 years to make that standard…

AUTO IN1 OUT >=1 DO T1

AUTO CALC PUMP

IEC 61131-3 is the most important automation language in industry.

(Funktionsblocksprache, langage de blocs de fonctions)

The function block languages express "combinatorial"