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6401-6.4.1, Distributed Diagnostic and Machine Control, Application

1. Figure 4 1 Diagram of Two station Drill Machine Cycle AUTO i MANUAL FWD O Conveyor Station 1 Used LS9 HO Advance Drill 2772 NO Clamp 1 Assembly n n 151 153 154 NO NO 165 Held Open FWD Station 2 Advance Drill 22277 NO 2 Assembly 152 O Nc 186 157 NO NO 158 Held Open Not oe LS10 FO Used 17635 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 Chapter 4 Organizing a Drill Machine Application Figure 4 2 Relay Logic Diagram of Two station Drill Machine Start Sto SP ew NZ CRM 5 Off Auto 1 3 Manual dn T T 172 s 6 18 72 e i LS1 DR1D 5 9 CL1 15 DR1D LS5 I 572 5 Io CL1 Y i DR1D 11 t E olo rCycle 6 15 dod ee N Y 20 19 e 8 SAIR 14 CL1 LS4 G 11 DM1 74 6 pue DR1D 1831 TR T 5 ae saan 15 604 155 ist 16 lt OnQ F OnO DR1D N DR2D LS6 m fO 152 tos 26 9 9 W INN 11 r 18 26 52 26 2 2
2. Figure 4 4 Drill Station 1 OFF Ed AUTO 1 MANUAL FWD Conveyor Motor i Not Station 1 Used 159 Advance Drill Clam Assembly Motor 222222 NO 1 p X 9 se NC 153 154 NO 165 Held Open Figure 4 5 Relay Logic Diagram of Station 1 CL1 1 Y A 8 9 0 07 10 11 9 6 15 x Y 20 10 T 19 11 e e i 8 SAIR CL1 LS4 13 e hs 11 74 6 DR1D 183 TRI 14 e ag saan 4 12 a ame 15 mis el DR1D 6 7 8 7 14 16 DR1D uie 16 F EHe 17 Chapter 4 Organizing a Drill Machine Application Defining Inputs and Outputs To define the possible states in station 1 we need to know the inputs and outputs Inputs for station 1 Physical returned limit switch 1 53 s advanced limit switch 1 54 full depth limit switch 1 55 Logical advance command return command Outputs for station 1 Physical station 1 on off SAIM station 1 forward motor SAIF Station 1 reverse motor SAIR drill motor DM1 Using the formula 21 we can determine that we have 32 possible states for drill station 1 since we have five inputs 2 32 As with the drill motor example in chapter 3 several of the possible states are not practical for this application Analyzing the Sequence of By referri
3. eua 1 Specific Sections of the 2 ATTENTION and Important Notes P 3 Terms and Conventions P 3 Related Publications 4 Understanding DDMC Instructions and their Purpose 1 1 Chapter 1 1 Understanding the SDS Instruction 41 1 Understanding the DFA Instruction 1 6 Summa 5 325 ous upay squa 1 6 Implementing DDMC to a Specific Level 2 1 Chapter 2 1 Implementing DDMC for Messaging Only Level 1 2 2 Implementing DDMC for Messaging and Diagnostics Level 2 2 9 Implementing DDMC for Messaging Diagnostics and 2 4 Implementing DDMC for Operator Guidance Messaging 25 Preparing to Apply DDMC Instructions 2 1 Summa ee Beles usa 2 7 Getting Started with State Transition Conditional Logic Programming 3 1 Chapter 3 1 Decomposing Your Machine 3 1 A Drill Motor 3 8
4. 3 13 Organizing a Drill Machine Application 4 1 Chapter 4 1 Becoming Familiar with the Machine 4 1 Decomposing the Drill Machine 4 4 Defining States for a Drill Machine Segment 4 6 Defining Inputs and Outputs 4 8 Table of Contents Analyzing the Sequence of Operation Setting up a State Diagram Setting a State Table Assigning l O 62 ik 53 a Combining the SDS Instruction with Ladder Logic Using the SDS Instruction Integrating the SDS Instruction with Ladder Logic Summary Organizing Transfer Line Application Chapter Objectives Decomposing the Transfer Detailing the I O Organizing the Logic Associating Motions with SDS Instructions Developing State Diagrams and State Tables SUMMA ede See ee ates Applying DDMC Instructions to Common Mechanisms Chapter Applying the SDS Instruc
5. 200 END report 8 7 Chapter Objectives Accounting for Scan Dependencies Other Application Examples This chapter provides guidelines to help you implement the Smart Directed Sequencer SDS instruction in various applications In this chapter we define guidelines for accounting for scan dependencies prioritizing SDS messages adding power loss detection and management logic providing flashing push buttons for operator guidance Like the PLC 5 program each SDS instruction is scanned and executed sequentially You must account for this when interlocking SDS instructions or when monitoring or using interlocks or other signals from external logic If real I O controlled from another SDS or external logic is being monitored within an SDS you may need to use immediate input or output commands prior to the SDS to ensure it has the most accurate I O image table data If situations exist where the transition of two inputs within an SDS race each other for example activating the ADVANCE COMMAND and the RETURN COMMAND at the same time you should make sure they are exclusive and unique states by adding to or modifying the driving ladder logic 9 1 9 Other Application Examples Prioritizing SDS Messages 9 2 You can prioritize SDS messages generated by the SDS four ways The first three methods are built into the DDMC system the fourth method
6. 5 Organizing a Transfer Line Application Table 5 1 State Table for SDS 1 Brake State Input Description Input Transition Next State Output Description Output Status 1 Release Request Request lOFF ON gt ON State 2 Release Command OFF Brake Con Energized OFF gt ON State 5 Released Indication OFF 2 Release Request ON gt OFF Release Command ON Brake Con Energized OFF gt ON Released Indication OFF Timer 2 seconds ON gt OFF 3 Release Request ON gt OFF State 4 Release Command ON Brake Con Energized ON gt OFF State 5 Released Indication ON 4 Release Request OFF gt ON State 3 Release Command OFF Brake Con Energized ON gt OF State 1 Released Indication ON Timer 2 seconds OFF gt ON State 5 5 Release Request Release Command OFF Released Indication OFF Brake Con Energized Timer 2 seconds OFF gt ON State 0 SDS 2 Feed Advance Rapid Return The feed advance rapid return has seven inputs and four outputs They are Inputs feed motor starter confirmation rapid return motor starter confirmation returned position limit switch advanced position limit switch torqued limit switch feed request rapid return request Outputs advanced indication returned indication feed advance command rapid return command Figure 5 6 shows the state diagram for the feed advance rapid return Table 5 J shows the state table for the feed adv
7. Advanced LS On Slide Rapid Return Motor Restarted Between Return amp Advanced LS Feed Heq Off 15 Slide Coast Feeding at Advanced LS Return Req Off Torqued LS Off Advanced LS Off Feed Req On Returning Off Feed Req Off Return Req On 9 Return Req On Slide Feeding Slide Returning 16 Feedi g Off Peed Req On at Advanced LS Interlocked Slide Coast Slide Stopped 5 at Advanced LS gt gt Torque Torqued LS On Return Req Off Torqued LS On Returning On Returning Off n ui s Req Off 8 Slide Returning at Torqued LS Slide Advanced at Torqued LS From States Slide Feed Interlock Removal 25 Slide Error Return Req On Feeding Off ERROR cade To All States Initialization 5 17 5 Organizing a Transfer Line Application 5 18 State Input Description Feed Request Return Request Returned LS Advanced LS Torqued LS Feed Motor Starter Return Motor Starter Feed Request Return Request Returned LS Advanced LS Torqued LS Feed Motor Starter Return Motor Starter Feed Request Return Request Returned LS Advanced LS Torqued LS Feed Motor Starter Return Motor Starter Feed Request Return Request Returned LS Advanced LS Torqued LS Feed Motor Starter Return Motor Starter Feed Request Return Request Retu
8. STEP 2 RETD amp ADVANCING TIMER 1 00 WARNING MESSAGE OFF Input ID Transition Destination No Output ID State 0 STA 6 ADV REQUEST ON gt OFF STEP 1 0 STA 6 ADV SLIDE MOTO ON 1 STA 6 RET REQUEST OFF gt ON INITIALIZE 1 STA 6 RET SLIDE MOTO OFF 2 STA 6 RET TO TL CHG gt ERSTEP 18 2 STA 6 FEED MOTOR ON 3 FEED POSITION LS gt ERSTEP 18 3 STA 6 FEED AREA OFF 4 ADVANCED LS OFF gt ON ERSTEP 18 4 STA 6 SLIDE ADVD OFF 5 RETURNED LS ON gt OFF STEP 3 5 STA 6 RETURNED LT ON 6 TOOL CHG POSN LS gt ERSTEP 18 6 STA 6 TOOL CHG POSN OFF 7 RESET STA 6 FLT STEP 3 RAPID ADVANCING TIMER 5 00 ERSTEP 18 MESSAGE OFF Input ID Transition Destination No Output ID State 0 STA 6 ADV REQUEST ON gt OFF STEP 17 0 STA 6 ADV SLIDE MOTO ON 1 STA 6 RET REQUEST OFF gt ON INITIALIZE 1 STA 6 RET SLIDE MOTO OFF 2 STA 6 RET TO TL CHG gt ERSTEP 18 2 STA 6 FEED MOTOR ON 3 FEED POSITION LS gt STEP 4 3 STA 6 FEED AREA OFF 4 ADVANCED LS OFF gt ON ERSTEP 18 4 STA 6 SLIDE ADVD OFF 5 RETURNED LS OFF gt ON STEP 2 5 STA 6 RETURNED LT OFF 6 TOOL CHG POSN LS gt ERSTEP 18 6 STA 6 TOOL CHG POSN OFF 7 RESET STA 6 FLT STEP 4 ADVG IN FEED AREA TIMER 2 50 WARNING MESSAGE OFF Input ID Transition Destination No Output ID State STA 6 ADV REQUEST gt STEP 17 0 STA 6 ADV SLIDE OFF STA 6 RET REQUEST OFF gt ON INITIALIZE 1 STA 6 RET SLIDE MOTO OFF STA 6 RET TO
9. Switch Motor 3 4 Chapter 3 Geting Started with State Transition Conditional Logic Programming Setting up a Truth Table A truth table shows all possible states of a machine The number of possible conditions in a truth table depends on the number of inputs When setting up a pure state transition application you must be able to determine the state transitions you need to include when programming You can determine the number of possible states using the following formula 2 where P possible number of input state transitions 1 number of inputs For example if you have two inputs you have four possible state transitions because 2 4 The number of possible states refers to physical or logical actions that could theoretically occur The number of possible states does not always equal the number of states you use in a state application Some will be impractical and can be ignored due to the nature of the machine You can determine the number of practical states by setting up a truth table and analyzing the information To set up a truth table list all inputs and outputs in a row a possible states of each input use 175 and 0 to represent ON OFF states or equations that represent a set of conditions that must be met logical outputs based on the machine configuration Table 3 A shows the truth table for our motor example 3 5 Chapter 3 Geting Started with Stat
10. ERSTEP No Ot P OO N F O 11 amp FOR Input ID RETURN REQUEST ADVANCE REQUEST RETURNED LS ADVANCED LS RETURN MEMORY ADVANCE MEMORY RESET SDS FAULT 12 REV TO RETURN Input ID RETURN REQUEST ADVANCE REQUEST RETURNED LS ADVANCED LS RETURN MEMORY ADVANCE MEMORY RESET SDS FAULT 13 REV TO ADVANCE Input ID RETURN REQUEST ADVANCE REQUEST RETURNED LS ADVANCED LS RETURN MEMORY ADVANCE MEMORY RESET SDS FAULT 14 FAULT Input ID RETURN REQUEST ADVANCE REQUEST RETURNED LS ADVANCED LS RETURN MEMORY ADVANCE MEMORY RESET SDS FAULT REQ Equation gt gt gt gt gt OFF ON Equation ON gt OFF gt Equation gt ON gt OFF Equation gt 0 Destination STEP 12 STEP 13 STEP 9 STEP 10 ERSTEP 14 ERSTEP 14 TIMER 0 10 Destination INITIALIZE INITIALIZE TIMER 0 10 Destination INITIALIZE INITIALIZE TIMER 0 0 Destination INITIALIZE 0 00 sec DISABLED Chapter 6 Applying DDMC Instructions to Common Mechanisms MESSAGE OFF No Output ID State 0 RETURN SOL OFF 1 ADVANCE SOL OFF 2 RETURNED PL OFF 3 ADVANCED PL OFF 4 RETURN MEMORY OFF 5 ADVANCE MEMORY OFF sec INITIALIZE No Output ID RETURN SOL ADVANCE SOL RETURNED PL ADVANCED PL RETURN ADVANCE MEM hh Hc sec INITIALIZE MESSAGE O
11. 03 04 05 06 Symbolic Name CLAMP 2 SAIR CYC DRILLMTR1 SAIM CYC SAIF CYC CLAMP 1 C FORWARD CONV MTR SA2F CYC ADVCOMD2 DRILLMTR2 REVMTR2 Description CLAMP 2 CL2 STATION ONE REVERSE SAIR DRILL MOTOR ONE DM1 STATION ONE ON SAIM STATION ONE FORWARD SAIF CLAMP ONE CL1 CONVEYOR MOTOR FORWARD CMF CONVEYOR MOTOR ON CMM STATION TWO FORWARD SA2F STATION TWO ON SA2M DRILL MOTOR TWO DM2 STATION TWO REVERSE SA2R Chapter 4 Organizing a Drill Machine Application Figure 4 8 Data Worksheet for Two station Drill Machine RACK ADDRESS GROUPING 0 PAGE or 2 PROJECT NAME Two station drill machine MODULE GROUP 1 uon DESIGNER Address Symbolic Name Description 00 01 152 LIMIT SWITCH 2 162 02 03 156 LIMIT SWITCH 4 6 156 04 151 LIMIT SWITCH 1 N O 05 CYCLE PUSH BUTTON 06 AUTO POSITION 1 07 MANUAL POSITION 3 10 ADV 157 LIMIT SWITCH 7 LS7 11 FD2 158 LIMIT SWITCH 4 8 N O 156 12 13 14 FD 155 LIMIT SWITCH 4 5 N O 195 15 ADV 154 LIMIT SWITCH 4 154 16 153 LIMIT SWITCH 3 193 4 15 Chapter 4 Organizing a Drill Machine Application Combining the SDS Instruction with Ladder Logic 4 16 By combining the SDS instruction with ladder logic you can develop an effective application program in less time while increasing your machine s diagnostic capab
12. Logging IMC Faults Sent as Messages by the PLC 5 Processor Figure 8 2 Configured Data Table at Message Instruction Control File Address Radix shown in ASCII M 0 1 2 3 4 5 6 ah 8 zi N12 0 4 10 D D M C N00 N00N03 N00N03 00 00 00 00 00 00 N12 10 00 00 500500 N00NOO Press a function key or enter a value N12 1 Program Forces None Data ASCII Addr Decimal 5 15 Addr 0 DDMCIMC Change Specify Next Prev Radix Address File File ut F5 F8 D Providing PLC Programming Logic The PLC 5 ladder program must do the following determine when an error is occurring load the proper data in words 7 through 12 of the message instruction send message Determining an Error Condition Your PLC 5 ladder program must determine when an error condition has occurred You can structure your program to do this by 1 monitoring the IMC data in block 0 block 0 is the status block word 5 and word 6 Any non zero data in these words indicates an error or status condition monitoring the fault bit bit 4 in the IMC to PLC single status word monitoring the detailed error code returned from the MML program through block 6 You can also combine these methods to achieve the desired results 8 4 Sample Motion Program Which Reports Errors Chapter 8 Logging IMC Faults Sent as Messages by the PLC 5 Processor Loading the Data in Words 7 12 Whenever a fault condition is detected your
13. STA 6 RET TL CHG gt STEP 13 2 STA 6 FEED MOTOR OFF FEED POSITION LS gt ERSTEP 18 3 STA 6 FEED AREA OFF ADVANCED LS OFF gt ON ERSTEP 18 4 STA 6 SLIDE ADVD OFF RETURNED LS OFF gt ON ERSTEP 18 5 STA 6 RETURNED LT OFF TOOL CHG POSN LS gt ERSTEP 18 6 STA 6 TOOL CHG POSN OFF RESET STA 6 FLT z 2 2 2 OQ N 2 S N F co Chapter 6 Applying DDMC Instructions to Common Mechanisms OQ N F STEP 12 STOPPED IN FEED AREA TIMER 0 00 sec DISABLED MESSAGE OFF Input ID Transition Destination No Output ID State STA 6 ADV REQUEST gt STEP 4 0 STA 6 ADV SLIDE OFF STA 6 RET REQUEST gt STEP 8 1 STA 6 RET SLIDE MOTO OFF STA 6 RET TO TL CHG gt STEP 13 2 STA 6 FEED MOTOR OFF FEED POSITION LS ON gt OFF ERSTEP 18 3 STA 6 FEED AREA ON ADVANCED LS OFF gt ON ERSTEP 18 4 STA 6 SLIDE ADVD OFF RETURNED LS OFF gt ON ERSTEP 18 5 STA 6 RETURNED LT OFF TOOL CHG POSN LS gt 0 ERSTEP 18 6 STA 6 TOOL CHG POSN OFF RESET STA 6 FLT STEP 13 RETG TO TOOL CHG TIMER 0 00 sec DISABLED MESSAGE OFF Input ID Transition Destination No Output ID State STA 6 ADV REQUEST gt 0 ERSTEP 18 0 STA 6 ADV SLIDE STA 6 REQUEST gt ERSTEP 18 1 STA 6 RET SLIDE MOT
14. RESET STA 6 FLT STEP 16 RETD TL CHG amp ADVG TIMER 0 00 sec DISABLED MESSAGE OFF Input ID Transition Destination No Output ID State STA 6 ADV REQUEST ON gt OFF STEP 17 0 STA 6 ADV SLIDE MOTO ON STA 6 RET REQUEST gt 0 ERSTEP 18 1 STA 6 RET SLIDE MOTO STA 6 TL gt ERSTEP 18 2 STA 6 FEED MOTOR ON FEED POSITION LS gt ERSTEP 18 3 STA 6 FEED AREA OFF ADVANCED LS OFF gt ON ERSTEP 18 4 STA 6 SLIDE ADVD OFF RETURNED LS OFF gt ON ERSTEP 18 5 STA 6 RETURNED LT OFF TOOL CHG POSN LS ON gt OFF STEP 3 6 STA 6 TOOL CHG POSN ON RESET STA 6 FLT 6 19 6 Applying DDMC Instructions to Common Mechanisms STEP 17 COASTING TIMER 0 00 sec DISABLED MESSAGE OFF No Input ID Transition Destination No Output ID State 0 STA 6 ADV REQUEST 0 STA 6 ADV SLIDE MOTO OFF 1 STA 6 RET REQUEST 1 STA 6 RET SLIDE MOTO OFF 2 STA 6 RET TO TL CHG 2 STA 6 FEED MOTOR OFF 3 FEED POSITION LS 3 STA 6 FEED AREA OFF 4 ADVANCED LS 4 STA 6 SLIDE ADVD OFF 5 RETURNED LS 5 STA 6 RETURNED LT OFF 6 TOOL CHG POSN LS 6 STA 6 TOOL CHG POSN OFF 7 RESET STA 6 FLT ERSTEP 18 FAULT TIMER 0 00 sec DISABLED ESSAGE 0 No Input ID Transition Destination No Output ID State 0 STA 6 ADV REQUEST 0 STA 6 ADV SLIDE MOTO OFF 1 STA 6 RET REQUEST 1 STA 6 RET SLIDE MOTO OFF 2 STA 6 RET TO TL CHG 2 STA 6 FEED MOTOR OFF 3 FEED POSITION LS 3 STA 6 FEED AREA OFF 4 ADVANCED LS 4 STA 6 SLIDE ADVD OFF 5 RE
15. Rapid Advance Inputs Outputs 1 brake contactor energized 1 brake release indication 2 brake release request 2 brake release command 3 feed motor starter energized 3 feed advance command 4 rapid return motor starter energized 4 rapid return command 5 returned position limit switch 5 returned indication 6 advanced position limit switch 6 advanced indication 7 torqued limit switch 8 feed request 13 rapid advance return motor overloads 9 rapid return request 10 rapid advance motor starter energized 7 rapid advance command 11 feed position limit switch 8 in feed area indication 12 rapid advance request 13 rapid advance return motor overloads 9 overload okay indication 14 feed motor overload 15 reset overload request 5 12 5 Organizing a Transfer Line Application Table 5 F decomposes the SDS block into four motions based on view 3 brake engage feed advance rapid return rapid advance motor overload This approach reduces the complexity of the SDS instruction in view 3 Table 5 F Mw 44014505 Block Brake Engage Feed Advance Rapid Return Rapid Advance and Motor Overloads Inputs brake release request feed motor starter energized rapid return motor starter energized returned position limit switch o oy AL c ro advanced position limit switch torqued limit switch feed request o S NI PL ajl 5 rapid return requ
16. 1 RETURNED 2 BETWEEN ADVD amp 3 ADVANCED sec DISABLED No Output ID ADVANCE SOL RETURNED BETWEEN ADVD amp ADVANCED o sec INITIALIZE No Output ID 0 ADVANCE SOL 1 RETURNED 2 BETWEEN ADVD amp 3 ADVANCED MESSAGE OFF 1 1 1 1 1 MESSAGE OF RETD MESSAGE OFF State OFF ON OFF OFF RETD MESSAGE O State OFF RETD O MESSAGE OF State OFF LAST LAST LAST RETD Chapter 6 Applying DDMC Instructions to Common Mechanisms Applying the DFA Instruction to a Spindle The next five lines of logic show how to implement diagnostics on a spindle By using timers to check the reaction time on the starter contactor and the flow switch we can verify that they are in the proper state The timer done bit is then monitored in the DFA instruction to display a fault message whenever neccessary The DFA would also be used to monitor any other static faults pertaining to the station ex OVERLOADS OK STA 6 START ISTA 6 HEAD LUBE OVERLOADS SPINDLE SPINDLE PB AUTO SS FLOW OK OK SPINDLE CHECK OK SPINDLE 065 065 065 B3 B3 0 065 wp J 13 07 06 29 28 05 START STA 6 SPINDLES AUTO SS B3 1 065 5 1 seset 6 07 SPINDLE SPINDLE ON 0 065 I 065 tas dqeee e Y 05 05 SPINDLE SPI
17. PLC 5 ladder program must load the IMC fault log message into words 7 through 12 of the data table The error code found in word 7 must be passed back from the IMC program There is the variable ERROR in the IMC program Refer to next section for a sample MML program that passes this detailed error code number back to the PLC 5 processor If this code is not available your program must place a zero 0 in word 7 Your program should copy IMC to PLC block 0 words 2 through 6 into words 8 through 12 when a fault is detected You can use copy or move instruction to do this When the error code is not available in word 7 error information in block 0 is used to identify the error Sending the Error Message After the error condition has been detected and the data loaded your program should activate the message instruction to send the message The following is an example of an IMC 123 program that demonstrates the techniques for passing error information The information is passed back through the short integers which can then be passed to the PLC processor through block 6 Important In the following sample program programmers comments will be indicated by the sections marked by dashed lines on the left hand side PROGRAM report CONST max splcos 20 VAR abort flag ret val boolean i err integer OUTPUT ERRS E This subroutine passes the errors back to the ROUTINE output_errs VAR ir inte
18. RESET SLIDE FAULT STEP 11 FAULT TIMER 0 00 Input ID Transition Destination STA 7 ADV SLIDE REQ STA 7 RET SLIDE REQ ADVANCED LS RETURNED LS RESET SLIDE FAULT gt STEP 0 0 00 DISABLED MESSAGE OFF No Output ID State 0 ADVANCE SLIDE SOL OFF 1 RETURN SLIDE SOL OFF 2 SLIDE ADVANCED ON 3 SLIDE RETURNED OFF sec WARNING MESSAGE OFF No Output ID State 0 ADVANCE SLIDE SOL OFF 1 RETURN SLIDE SOL ON 2 SLIDE ADVANCED ON 3 SLIDE RETURNED OFF sec WARNING MESSAGE OFF No Output ID State 0 ADVANCE SLIDE SOL OFF 1 RETURN SLIDE SOL ON 2 SLIDE ADVANCED OFF 3 SLIDE RETURNED OFF sec DISABLED MESSAGE OFF No Output ID State 0 ADVANCE SLIDE SOL OFF 1 RETURN SLIDE SOL ON 2 SLIDE ADVANCED OFF 3 SLIDE RETURNED ON sec DISABLED MESSAGE OFF No Output ID State 0 ADVANCE SLIDE SOL OFF 1 RETURN SLIDE SOL OFF 2 SLIDE ADVANCED OFF 3 SLIDE RETURNED OFF sec INITIALIZE MESSAGE OFF No Output ID State 0 ADVANCE SLIDE SOL OFF 1 RETURN SLIDE SOL OFF 2 SLIDE ADVANCED LAST 3 SLIDE RETURNED LAST sec DISABLED MESSAGE ON No Output ID State 0 ADVANCE SLIDE SOL OFF 1 RETURN SLIDE SOL OFF 2 SLIDE ADVANCED OFF 3 SLIDE RETURNED OFF Chapter 6 Applying DDMC Instructions to Common Mechanisms Applying the SDS These three lines of ladder logic show an example of an SDS for a detented Instruction to a Machine valve This line is used to request the clamp to advance Clamp Detented Valve ADVANCE MACHINE
19. TL CHG gt ERSTEP 18 2 STA 6 FEED MOTOR ON FEED POSITION LS ON gt OFF ERSTEP 18 3 STA 6 FEED AREA ON ADVANCED LS OFF gt ON STEP 5 4 STA 6 SLIDE ADVD OFF RETURNED LS OFF gt ON ERSTEP 18 5 STA 6 RETURNED LT OFF TOOL CHG POSN LS gt ERSTEP 18 6 STA 6 TOOL CHG POSN OFF RESET STA 6 FLT STEP 5 ADVD amp ADVANCING TIMER 0 00 sec DISABLED MESSAGE OFF Input ID Transition Destination No Output ID State STA 6 ADV REQUEST ON gt OFF INITIALIZE 0 STA 6 ADV SLIDE MOTO OFF STA 6 RET REQUEST OFF gt ON INITIALIZE 1 STA 6 RET SLIDE MOTO OFF STA 6 RET TO TL CHG gt ERSTEP 18 2 STA 6 FEED MOTOR OFF FEED POSITION LS gt ERSTEP 18 3 STA 6 FEED AREA O ADVANCED LS ON gt OFF ERSTEP 18 4 STA 6 SLIDE ADVD O RETURNED LS OFF gt ON ERSTEP 18 5 STA 6 RETURNED LT OFF TOOL CHG POSN LS gt ERSTEP 18 6 STA 6 TOOL CHG POSN OFF RESET STA 6 FLT STEP 6 ADVANCED TIMER 0 00 sec DISABLED MESSAGE OFF Input ID Transition Destination No Output ID State STA 6 ADV REQUEST gt 0 ERSTEP 18 0 STA 6 ADV SLIDE STA 6 REQUEST gt 7 1 STA 6 SLIDE OFF STA 6 RET TO TL CHG gt STEP 13 2 STA 6 FEED MOTOR OFF FEED POSITION LS gt ERSTEP 18 3 STA 6 FEED AREA ON ADVANCED LS ON gt OFF ERSTEP 18 4 STA 6 SLIDE ADVD ON RETURNED LS OFF gt ON ERSTEP 18 5 STA 6 RETURNED LT OFF TOOL CHG POSN LS gt 0 ERSTEP 18 6 STA 6 T
20. TRANSFER RETURN CLAMP ADVANCE CLAMP PB HAND PL LOWERED CLAMP FAULT CLAMP 1 012 0 001 B3 B3 N32 0 B3 Eee 10 07 15 51 12 50 AUTO CYCLE ON 00 B3 4 4 1 05 SDS instruction this line of logic is used control the machine clamp POWER ON POWER MACHINE DWELL CRM CLAMP 4 1 001 5 5 SSS J th IRIE gS Ss 5 DIRECTED SEQUENCER EN DN 00 Control File N32 0 Step Desc File N33 0 ST Length 286 INo of Steps 14 ER Position Step 0 Ne of I O 8 ES Prog file number 3 This rung of logic is used to request the clamp to return RETURN MACHINE TRANSFER ADVANCE CLAMP RETURN CLAMP PB HAND PL RETURNED CLAMP FAULT CLAMP REQ 1 012 0 001 B3 B3 N32 0 B3 5 E Il oeren e 11 07 14 50 12 51 AUTO CYCLE ON 3 nn asan 05 6 5 6 Applying DDMC Instructions to Common Mechanisms Step Directory Control File N116 0 Step Description File N117 0 Input Q D Q N P Output Qn Q N P Inputs and Outputs Logical Address B3 1 B3 0 1 000 03 1 000 02 B3 10 B3 11 1 000 07 Logical Address 0 000 04 0 000 05 0 000 06 0 000 07 B3 10 B3 11 I O CROSS REFERE
21. Transition Destination No Output ID State 0 ADVANCE REQUEST ON gt OFF STEP A 0 ADVANCE SOL O 1 RETURNED LS OFF gt 0N ERSTEP 7 1 RETURNED OFF 2 ADVANCED LS ON gt OFF ERSTEP 7 2 BETWEEN ADVD amp RETD OFF 7 RESET FAULT 3 ADVANCED ON 6 11 6 Applying DDMC Instructions to Common Mechanisms STEP 4 ADVANCED amp RETURNING TIMER 0 00 No Input ID Transition Destination 0 ADVANCE REQUEST gt 0 STEP 3 1 RETURNED LS gt ERSTEP 7 2 ADVANCED LS ON gt OFF STEP 5 7 RESET FAULT STEP 5 RETURNING TIMER 2 00 No Input ID Transition Destination 0 ADVANCE REQUEST OFF gt ON STEP 2 1 RETURNED LS gt STEP 6 2 ADVANCED LS gt ERSTEP 7 7 RESET FAULT 5 6 RETURNED TIMER 0 00 No Input ID Transition Destination 0 ADVANCE REQUEST gt 0 1 RETURNED LS ON gt OFF ERSTEP 7 2 ADVANCED LS OFF gt ON ERSTEP 7 7 RESET FAULT ERSTEP 7 FAULT TIMER 0 00 No Input ID Transition Destination 0 ADVANCE REQUEST 1 RETURNED LS 2 ADVANCED LS 7 RESET FAULT gt STEP 0 STEP 8 COASTING TIMER 0 50 No Input ID Transition Destination 0 ADVANCE REQUEST 1 RETURNED LS 2 ADVANCED LS 7 FAULT 6 12 DISABLED Output ID 0 ADVANCE SOL 1 RETURNED 2 BETWEFN ADVD amp 3 ADVANCED sec WARNING Output ID 0 ADVANCE SOL 1 RETURNED 2 BETWEEN ADVD amp 3 ADVANCED sec DISABLED No Output ID 0 ADVANCE SOL
22. eX SA2M e 19 SA2R 52 CL2 LS7 e 28 TE E DR2D 56 TR2 ir 164 SA2R 158 152 227 OQ DR2D N E 26 CRM 3 8 13 10 11 12 6 7 8 14 16 14 19 24 3 21 22 23 17 18 19 25 27 25 17636 4 3 Chapter 4 Organizing a Drill Machine Application Decomposing the Drill To decompose our drill machine we use some of the methods previously Machine described for decomposition Our first level of decomposition is the two station drill machine see Figure 4 1 and Figure 4 2 Decomposing to the Second Level Using the diagram of the drill machine at Figure 4 1 we can see three basic operations a conveyor operation and two drilling operations Therefore we decompose the drill machine into three second level segments drill station 1 drill station 2 indexing conveyor Decomposing to the Third Level To decompose to the next level we need to look at what happens at each operation By referring back to Figure 4 1 and analyzing the sequence of operation for the drill machine we can decompose each operation into suboperations Table 4 A gives us an overview of the drill machine operations Table 4 A Overview of Drill Machine Operations Type of Operation Description System Initialization and Shutdown Turn the SELECTOR SWITCH to Auto position 1 or Manual position 2 Press the START BUT
23. gt OFF INITIALIZE 0 RETURN SOL ON 1 ADVANCE REQUEST gt STEP 13 1 ADVANCE SOL OFF 2 RETURNED LS ON gt OFF ERSTEP 14 2 RETURNED PL ON 3 ADVANCED LS gt 0 ERSTEP 14 3 ADVANCED PL OFF 4 RETURN MEMORY 4 RETURN MEMORY ON 5 ADVANCE MEMORY gt ERSTEP 14 5 7 RESET SDS FAULT STEP 9 RETD amp WTG FOR REQ TIMER 0 00 sec DISABLED MESSAGE OFF No Input ID Equation Destination No Output ID State 0 RETURN REQUEST gt STEP 12 0 RETURN SOL OFF 1 ADVANCE REQUEST gt STEP 13 1 ADVANCE SOL OFF 2 RETURNED LS gt 5 11 2 RETURNED PL ON 3 ADVANCED LS OFF gt ON ERSTEP 14 3 ADVANCED PL OFF 4 RETURN MEMORY gt ERSTEP 14 4 RETURN MEMORY OFF 5 ADVANCE MEMORY gt ERSTEP 14 5 ADVANCE MEMORY OFF 7 RESET SDS FAULT STEP 10 ADVD amp WTG FOR REQ TIMER 0 00 sec DISABLED MESSAGE OFF No Input ID Equation Destination No Output ID State 0 RETURN REQUEST gt STEP 12 0 RETURN SOL OFF 1 ADVANCE REQUEST gt 5 13 1 ADVANCE SOL OFF 2 RETURNED LS OFF gt ON ERSTEP 14 2 RETURNED PL OFF 3 ADVANCED LS gt 5 11 3 ADVANCED PL ON 4 RETURN MEMORY gt 0 14 4 RETURN MEMORY OFF 5 ADVANCE MEMORY gt ERSTEP 14 5 ADVANCE MEMORY OFF 7 RESET SDS FAULT 6 8 STEP No CON 0 STEP No N STEP No amp
24. logic Assigning 1 0 Chapter 4 Organizing a Drill Machine Application Before you can develop your program you must assign addresses to your inputs and outputs I O module assignments are the same regardless of the control method used Addresses are entered onto rungs on the ladder program and into the I O definition screen in the SDS instruction Addressing The PLC 5 processor can address its I O in 2 slot 1 slot and 1 2 slot groups Refer to PLC 5 Family Programmable Controllers Installation Manual publication 1785 6 6 1 for information on how to address your hardware Refer to PLC 5 Programming Software Documentation Set publication 6200 N8 001 or PLC 5 250 Programming Software Documentation Set publication 6200 N8 002 for information on formatting I O addresses As you program you will want to have addresses descriptions and symbolic names of I O accessible Symbolic names can be up to 10 characters long in 6200 series software Figure 4 7 and Figure 4 8 shows Worksheet 1 and Worksheet 2 I O Data Worksheets for the two station drill machine Outputs are listed on the first worksheet inputs are on the second worksheet 4 13 Chapter 4 Organizing a Drill Machine Application PROJECT NAME Two station drill machine 4 14 Data Worksheet for Two station Drill Machine Outputs Figure 4 7 RACK ADDRESS GROUPING MODULE GROUP 0 0 PAGE or 2 DATE DESIGRNER_ Address 00 01 02
25. scan 9 Other Application Examples dependencies prioritizing messages adding power loss detection and management logic providing flashing push button guidance for operators Worksheets for building state tables to configure SDS Appendix A SDS Instruction Worksheets instructions ATTENTION and Important Notes Terms and Conventions Preface Using this Manual Information that is especially important to note is identified with an ATTENTION or Important note circumstances that can lead to personal injury or death property ATTENTION identifies informaton about practices or damage or economic loss Important provides you with information that is important for the successful application of DDMC In this manual we use the following terms This Combinatorial Equation DDMC Distributed Diagnostics and Machine Control DFA Diagnostic Fault Annunciator 505 Smart Directed Sequencer State Step State Transition Watchdog Timer Interlock A chain of events or steady state conditions a Boolean equation in the SDS instruction this is limited to ANDed conditions This type of equation doesn t care about the order or sequence in which inputs occur it only cares that they all did occur An industrial automation system containing hardware and software components that help you configure a control and diagnostics system for your equipment An instruction that resides in ladder logic providin
26. sequence of operation Figure 5 2 shows the physical arrangement of the slide s devices 5 3 5 Organizing a Transfer Line Application Figure 5 2 Slide Representation Drill ud pei Dril 2222 m With Rapid Motor Adv A Ret R IN Side K hao amp Feed B wi Motors AX Ballnut J NN S NN NN C Advanced i h E Returned Feed Limit Switch Advance Limit 0 5 LS N Switch 17639 The slide s devices are fairly simple with the exception of the sun planetary gearbox Figure 5 3 shows mechanical drawings detailing slide s devices and their movement Figure 5 3 Slide Mechanical Drawings Gear on the surface of the Gear Cage n by Feed Motor Worm Gear L anetary Energize CP DC Coils SP Planetary Gear Gear D N Platen for K lt Drive Motor ref only Output SS N Sun Gear lt NN IN V Slide K D i Ball Screw iN Planetary Gear Ball Nut J Spring Return Input Sun End View of Feed Motor Gear C Worm Gear Feed Motor B Sheaves a 8 V belts and Brake O not shown in this V belt Vi
27. shows how you can add conditional logic for prioritizing messages These methods are described below Method 1 The first or highest class of prioritization is provided by the MMS portion of the DDMC software Refer to the DDMC User s Manual publication 6401 6 5 1 for details on the MMS software capabilities The software contains a utility that lets you assign on of 10 levels of message priority based on the following PLC processor message type s SDS DFA control file A message generated with a Level 1 priority will replace a message with a priority of Level 2 on the operator interface display Method 2 The second method of prioritizing messages is based on the position of an SDS instruction within a program scan If two faults of the same priority as configured in the MMS software were to occur on the same program scan then the first SDS to be scanned would provide the message displayed on the annunciator panel The second message would remain in the fault queue until the first fault is cleared thereby allowing the second message to be sent to the first panel Method 3 The third method of prioritization is based on the order of the inputs in the SDS instruction For example if 2 inputs monitored by the same SDS instruction changed state on the same program scan the first input to appear in the SDS I O configuration would be the one included in the fault message Method 4 Because SDS instructions are part of ladde
28. you could configure part of the STA 6 SPINDLE CONTACTOR FAULT STA 6 HEAD LUBE FLOW FAULT STA 6 SPINDLE OVERLOAD TRIPPED INPUT CROSS REFERENCE Address Symbol B3 28 I 065 06 B3 35 SPINDLE FAULT HEAD LUBE FAULT MOTOR OVERLOAD FAULT Address Comment SPINDLE CHECK OK HEAD LUBE FLOW OK OVERLOADS OK State ON OFF OFF Applying the SDS Instruction to a Mechanical Slide STA 6 ADVANCE SLIDE PB I 065 ISTA 6 CYCLE STATION B3 POWER ON DWELL 4 1 5 6 RETURN SLIDE PB 1 065 5 6 CYCLE STATION B3 STA 6 RETURN TO TOOL CHG POSN PB Chapter 6 Applying DDMC Instructions to Common Mechanisms The next four lines of logic show the request logic and the SDS instruction for a mechanical slide station Note that all motions are initiated with a line of request logic It is in this request logic that any sequence interlocks are handled It should also be noted that whenever possible the permissives used in the request line should be internal bits that are controlled from some other SDS instruction or ladder logic e g CLAMP ADVANCED 5 6 5 6 SPINDLE CLAMP 5 6 RET SLIDE ISTA 6 ADV AUTO SS ON ADVANCED REQUEST FAULT REQUEST 1 065 1 065 B3 B3 N26 0 B3 wa p 07 05 54 31 12 30 STA 6 FULL DEPTH 0 065 07 POWER ON MECHANICAL CRM SLIDE I 00
29. 1 GD GS SSS SSeS SSS SSS SSH See seregee eI 5 DIRECTED SEQUENCER EN 00 IControl File N26 0 Step Desc File N27 0 ST Length 234 INo of Steps 18 ER Position Step O INo of I O 8 ES Prog file number 3 4R 2 2 2 2 5 6 STA 6 5 6 OVERLOADS RETURNED ISTA 6 ADV SLIDE ISTA 6 RET AUTO SS OK LT REQUEST FAULT REQUEST 1 065 B3 B3 B3 N26 0 B3 a Whereas 07 35 36 30 12 31 STA 6 FULL DEPTH 0 065 1 07 STA 6 5 6 5 6 TOOL SLIDE STA 6 RET AUTO SS CHG POSN FAULT TO TL CHG 1 065 B3 N26 0 B3 1 yp N 07 37 12 32 6 15 6 Applying DDMC Instructions to Common Mechanisms Step Directory Control File N26 0 Step Description File N27 0 Step Step Name Step Step Name 0 INITIALIZATION 10 RETD amp RETURNING 1 RETURNED 11 STPD BTW FEED amp RETD 2 RETD amp ADVANCING 12 STOPPED IN FEED AREA 3 RAPID ADVANCING 13 RETG TOOL CHG 4 ADVG IN FEED AREA 14 RETD TL CHG amp RETG 5 ADVD amp ADVANCING 15 RETD TO TOOL CHANGE 6 ADVANCED 16 RETD TL CHG amp ADVG 7 ADVD amp RETURNING 17 COASTING 8 RETG IN FEED AREA 18 FAULT 9 RETURNING Inputs and Outputs I O CROSS R
30. 7 ADV SLIDE REQ OFF gt ON STEP 2 0 ADVANCE SLIDE SOL OFF 1 STA 7 RET SLIDE REQ gt STEP 8 1 RETURN SLIDE SOL OFF 2 ADVANCED LS OFF gt ON ERSTEP 11 2 SLIDE ADVANCED OFF 3 RETURNED LS ON gt OFF ERSTEP 11 3 SLIDE RETURNED ON 7 RESET SLIDE FAULT STEP 2 RETD amp ADVANCING TIMER 1 00 sec WARNING MESSAGE OFF No Input ID Transition Destination No Output ID State 0 STA 7 ADV SLIDE REQ ON gt OFF STEP 1 0 ADVANCE SLIDE SOL ON 1 STA 7 RET SLIDE REQ OFF gt ON INITIALIZE 1 RETURN SLIDE SOL OFF 2 ADVANCED LS OFF gt ON ERSTEP 11 2 SLIDE ADVANCED OFF 3 RETURNED LS ON gt OFF STEP 3 3 SLIDE RETURNED ON 7 RESET SLIDE FAULT STEP 3 ADVANCING TIMER 5 00 sec WARNING MESSAGE OFF No Input ID Transition Destination No Output ID State 0 STA 7 ADV SLIDE REQ ON gt OFF STEP 10 0 ADVANCE SLIDE SOL ON 1 STA 7 RET SLIDE REQ OFF gt ON INITIALIZE 1 RETURN SLIDE SOL OFF 2 ADVANCED LS OFF gt ON STEP 4 2 SLIDE ADVANCED OFF 3 RETURNED LS OFF gt ON ERSTEP 11 3 SLIDE RETURNED OFF 7 RESET SLIDE FAULT STEP 4 ADVD amp ADVANCING TIMER 0 00 sec DISABLED MESSAGE OFF No Input ID Transition Destination No Output ID State 0 STA 7 ADV SLIDE REQ ON gt OFF INITIALIZE 0 ADVANCE SLIDE SOL ON 1 STA 7 RET SLIDE REQ OFF gt ON INITIALIZE 1 RETURN SLIDE SOL OFF 2 ADVANCED LS ON gt OFF ERSTEP 11 2 SLIDE ADVANCED ON 3 RETURNED LS OFF gt ON ERSTEP 11 3 SLIDE RETURNED OFF 7 RESET SLIDE FAULT 6 3 6 Applying DDMC Instruction to C
31. A following the figure explains each rung of the logic 9 5 9 Other Application Examples Figure 9 3 Ladder Logic for Power Loss Detection and Management POWER ON Power 1 2 second delay 000 TON 1 1r TIMER ON DELAY 4 irs Timer T4 80 0t Time base 01 DN Preset 050 Accum 0 POWER OK Machine Control T4 80 SDS 2 SMART DIRECTED SEQUENCER HEN DN Control File N11 0 Step Desc File 11 102 5 Length 144 No of Steps 12 ER Position Step 0 No of I O 8 ES Prog file number 3 Subsequent 5055 POWER OK 4 80 505 T 3 lt SMART DIRECTED SEQUENCER DN Control File N20 0 Step Desc File 20 102 ST Length 144 No of Steps 12 ER Position Step 0 No of I O 8 ES Prog number 3 Monitor only SDS UNCONDITIONAL SDS 4 SMART DIRECTED SEQUENCER EN H Control File N21 0 Step Desc File N21 102 ST Length 24 No of Steps 2 Position Step 0 No of I O 16 ES Prog file number 3 Providing Flashing Push Buttons for Operator Guidance Chapter 9 Other Application Examples Table 9 A Ladder Rung Explanations Rung s Explanation The timer conditions the power available signal allows for system settling at power up and allows for a half second delay 2 and 3 The power on done bit of the timer Power OK conditions the SDS instructions used for control and m
32. ALLEN BRADLEY Distributed Diagnostics and Machine Control Cat No 6401 DDMC SDSC 6402 DDMC 6403 DDMC Application Notes Important User Information Because of the variety of uses for this product and because of the differences between solid state products and electromechanical products those responsible for applying and using this product must satisfy themselves as to the acceptability of each application and use of this product For more information refer to publication SGI 1 1 Safety Guidelines For The Application Installation and Maintenance of Solid State Control The illustrations charts and layout examples shown in this manual are intended solely to illustrate the text of this manual Because of the many variables and requirements associated with any particular installation Allen Bradley Company cannot assume responsibility or liability for actual use based upon the illustrative uses and applications No patent liability is assumed by Allen Bradley Company with respect to use of information circuits equipment or software described in this text Reproduction of the contents of this manual in whole or in part without written permission of the Allen Bradley Company is prohibited Throughout this manual we make notes to alert you to possible injury to people or damage to equipment under specific circumstances ATTENTION Tells readers where people may be hurt if procedures are not followed properly ATTENTION T
33. AND FLASH Zu L il 1 L ORIGINAL REQUEST PUSH BUTTON NEW REQUEST 3 L E Ji E Ji N AUTO J E jJ L LES LESS THAN ids 4 Source A T4 80 ACC x 0 Source B N11 0 2 TON TE TIMER ON DELAY EN 4 1 5 4 80 DN Time base 1 0 DN Preset 4 Accum 0 Chapter 9 Other Application Examples Table 9 B Ladder Rung Explanations Rung s Explanation The original motion request is used as an input to the SDS instructions Typical examples of this request are the advance and return command The ladder circuit contains the elements that permit the motion 2 top portion This portion of the rung depicts the logic that is used to turn on an indicator light when a motion or command is complete This indicator is usually driven by an input device such as a limit switch that trips when the motion or command is complete 2 bottom portion This portion of the rung shows how rung 2 can be modified to flash on and off when a motion is required in the hand mode but is not yet complete The limit switch that provides the feedback to turn on the indicator when a requested motion has been completed can be ORed with the request e g hand and a flashing pulsing contact to flash the indicator 3 This rung is necessary to recondition the original requested signal to create a new one using a storage bit This bit is then used to replace the ori
34. DRILL MOTOR OFF 3 ADVANCE COMMAND OFF gt ON STEP 2 4 RETURN COMMAND Press a function key Program edit mode PLC 5 25 Addr 1 Equatn Display Step Step Edit Step Msg Input Output Marked List Symbol Name Type Step Timer Transit State Exit F2 ES FA F5 F6 F8 F9 F10 Solenoid Chapter 1 Understanding DDMC Instructions and their Purpose To What Mechanisms Can You Apply the SDS Instruction As a rule you may want to limit the use of an SDS instruction to a single sequence or motion like a rotary or linear axis Refer to the following examples Suppose that you have an actuator such as a solenoid that actuates several mechanically independent cylinders Figure 1 3 These cylinders move at different speeds Figure 1 3 Independent cylinders actuated by one solenoid Cylinder 1 Cylinder 2 152 Cylinder 3 153 provide accurate diagnostics for above mechanism you would want to assign one SDS instruction to each cylinder to diagnose the reaction of the position sensor switches associated with that cylinder If you included all of the cylinders in the above example in one SDS instruction the diagnostics would be lost because the cylinders operate at different speeds not sequential In addition any messages generated by a single SDS instruction would not be precise and indicate which cylinder had faulted On the other hand say that you have t
35. EFERENCE Input Logical Address Address Symbol Address Comment 0 B3 30 B3 30 STA 6 ADV REQUEST 1 B3 31 B3 31l STA 6 RET REQUEST 2 B3 32 B3 32 STA 6 RET TO TL CHG 3 1 065 01 1 065 01 FEED POSITION LS 4 1 065 02 065 02 ADVANCED LS 5 1 065 00 065 00 RETURNED LS 6 1 065 03 1 065 03 TOOL CHG POSN LS 7 B3 39 B3 39 RESET STA 6 FLT Output Logical Address Address Symbol Address Comment 0 0 065 00 0 065 00 STA 6 ADV SLIDE MOTO 1 0 065 01 0 065 01 STA 6 RET SLIDE MOTO 2 0 065 02 0 065 02 STA 6 FEED MOTOR 3 B3 33 B3 33 STA 6 FEED AREA 4 B3 34 B3 34 STA 6 SLIDE ADVD 5 B3 36 B3 36 STA 6 RETURNED LT 6 B3 37 B3 37 STA 6 TOOL CHG POSN Step Tables STEP 1 RETURNED TIMER 0 00 sec DISABLED MESSAGE OFF No Input ID Transition Destination No Output ID State 0 STA 6 ADV REQUEST gt STEP 2 0 STA 6 ADV SLIDE OFF 1 STA 6 RET REQUEST gt ERSTEP 18 1 STA 6 SLIDE OFF 2 STA 6 RET TO TL CHG gt STEP 13 2 STA 6 FEED MOTOR OFF 3 FEED POSITION LS gt ERSTEP 18 3 STA 6 FEED AREA OFF 4 ADVANCED LS OFF gt ON ERSTEP 18 4 STA 6 SLIDE ADVD OFF 5 RETURNED LS ON gt OFF ERSTEP 18 5 STA 6 RETURNED LT ON 6 TOOL CHG POSN LS gt 0 ERSTEP 18 6 STA 6 TOOL CHG POSN OFF 7 RESET STA 6 FLT 6 16 2 2 2 2 2 Chapter 6 Applying DDMC Instructions to Common Mechanisms OO N F O t S OQ N
36. FF State ON OFF OFF OFF ON OFF RY ORY MESSAGE OFF No Output ID State 0 RETURN SOL OFF 1 ADVANCE SOL ON 2 RETURNED PL OFF 3 ADVANCED PL OFF 4 RETURN MEMORY OFF 5 ADVANCE MEMORY ON 0 sec DISABLED MESSAGE ON No Output ID State 0 RETURN SOL OFF 1 ADVANCE SOL OFF 2 RETURNED PL OFF 3 ADVANCED PL OFF 4 RETURN MEMORY OFF 5 ADVANCE MEMORY OFF 6 9 6 Applying DDMC Instructions to Common Mechanisms Applying the SDS Instruction to a Part Stamp Spring Return Valve STA 9 ADVANCE SLIDE PB I 066 ISTA 9 ICYCLE ISTATION B3 I POWER ON DWELL 6 10 These two lines of ladder logic show an example of an SDS for a spring return valve This line is used to request the part stamp to advance 5 9 5 9 5 9 CLAMP PART PART STAMP STA 9 ADV AUTO SS ADVANCED PRESENT FAULT STAMP REQ 1 066 B3 B3 N34 0 B3 Sees ste se sa essa f 07 54 71 12 60 5 9 FULL DEPTH 0 076 Tee p 07 The SDS instruction in this line of logic is used to control the part stamp POWER ON PART STAMP 5 5 lt 5 DIRECTED SEQUENCER EN Control File N34 0 Step Desc File N35 0 ST Length 104 of Steps 8 ER Position Step 0 No of I O 8 ES Prog file number 3 4R 2 2 2 2 Step Step Directory C
37. FF Torqued 15 OFF gt ON State 25 Feed Motor Starter OFF gt ON State 25 Return Motor Starter ON gt OFF State 19 5 20 State 19 20 21 22 23 24 Input Description Feed Request Return Request Returned LS Advanced LS Torqued LS Feed Motor Starter Return Motor Starter Feed Request Return Request Returned LS Advanced LS Torqued LS Feed Motor Starter Return Motor Starter Feed Request Return Request Returned LS Advanced LS Torqued LS Feed Motor Starter Return Motor Starter Feed Request Return Request Returned LS Advanced LS Torqued LS Feed Motor Starter Return Motor Starter Feed Request Return Request Returned LS Advanced LS Torqued LS Feed Motor Starter Return Motor Starter Feed Request Return Request Returned LS Advanced LS Torqued LS Feed Motor Starter Return Motor Starter Table 5 J Chapter 5 State Table for 505 2 Feed Advance Rapid Return cont Output Description Output Status Input Transition gt ON gt OFF OFF gt ON ON gt OFF OFF gt ON OFF gt ON OFF gt ON Next State State 21 State 24 State 25 State 25 State 25 State 25 State 25 State 25 State 22 State 23 State 25 State 25 State 25 State 25 State 25 State 19 State 25 State 25 State 25 State 25 State 4 State 25 State 20 State 25 State 25 State 25 State 25 State 5 State 25 State 25 State 20 State 25 State 25 State 25 State 25 Sta
38. L CHG POSN RESET STA 6 FLT STEP 9 RETURNING TIMER 0 00 sec DISABLED MESSAGE OFF Input ID Transition Destination No Output ID State STA 6 ADV REQUEST OFF gt ON INITIALIZE 0 STA 6 ADV SLIDE MOTO OFF STA 6 RET REQUEST ON gt OFF STEP 17 1 STA 6 RET SLIDE MOTO ON STA 6 RET TO TL CHG gt ERSTEP 18 2 STA 6 FEED MOTOR OFF FEED POSITION LS gt ERSTEP 18 3 STA 6 FEED AREA OFF ADVANCED LS OFF gt ON ERSTEP 18 4 STA 6 SLIDE ADVD OFF RETURNED LS OFF gt ON STEP 10 5 STA 6 RETURNED LT OFF TOOL CHG POSN LS gt 0 ERSTEP 18 6 STA 6 TOOL CHG POSN OFF RESET STA 6 FLT STEP 10 RETD amp RETURNING TIMER 0 00 sec DISABLED MESSAGE OFF Input ID Transition Destination No Output ID State STA 6 ADV REQUEST OFF gt ON INITIALIZE 0 STA 6 ADV SLIDE MOTO OFF STA 6 RET REQUEST ON gt OFF INITIALIZE 1 STA 6 RET SLIDE MOTO ON STA 6 RET TO TL CHG gt ERSTEP 18 2 STA 6 FEED MOTOR OFF FEED POSITION LS gt ERSTEP 18 3 STA 6 FEED AREA OFF ADVANCED LS OFF gt ON ERSTEP 18 4 STA 6 SLIDE ADVD OFF RETURNED LS ON gt OFF ERSTEP 18 5 STA 6 RETURNED LT TOOL POSN LS gt 0 ERSTEP 18 6 STA 6 TOOL CHG POSN OFF RESET STA 6 FLT STEP 11 STPD BTW FEED amp RETD TIMER 0 00 sec DISABLED MESSAGE OFF Input ID Transition Destination No Output ID State STA 6 ADV REQUEST gt STEP 3 0 STA 6 ADV SLIDE MOTO OFF STA 6 RET REQUEST gt STEP 9 1 STA 6 SLIDE
39. MC Implementation Level 3 e SDS Instruction for Control and Diagnostics Level 2 DFA Instruction for Messages e Ladder Logic for Control e SDS Instruction for Messages and Diagnostics Level 1 e DFA Instruction for Messages Ladder Logic for Control and Diagnostics e DFA Instructions for Messages Important A Level 3 Implementation does not limit you to only using the SDS instruction for control and diagnostics You may also include Level 1 and Level 2 Implementations for diagnostics outside of the Level 3 SDS instruction for example lube faults or overloads Table 2 A Description of DDMC Levels This level Uses this DDMC Control is handled Diagnostics are Message instruction by Generation is handled by 1 ladder logic ladder logic DFA 2 SDS and DFA ladder logic SDS and DFA 3 SDS and DFA SDS SDS SDS and DFA In addition to operational levels you can implement DDMC to be used for operator guidance messages Read this chapter to learn more about the level of implementation that best suits your application Chapter 2 Implementing DDMC to a Specific Level Implementing DDMC for The Level 1 implementation of the DDMC uses the DFA instruction as a Messaging Only Level 1 fault message generator The PLC ladder logic is required to control the machine and to detect faults You configure the instruction to monitor these fault bits for a transition to the faulted state Upon t
40. NCE Address Symbol B3 1 B3 0 1 000 03 1 000 02 B3 10 B3 11 1 000 07 Address Symbol 0 000 04 0 000 05 0 000 06 0 000 07 B3 10 B3 11 Step Step Name Step Step Name 0 INITIALIZATION 8 RETD amp RETURNING 1 RETURNED 9 amp WTG FOR REQ 2 ADVANCING 10 ADVD amp WTF FOR REQ 3 SHIFTED ADVANCE FI BTWN amp WTG FOR REQ 4 ADVD amp ADVANCING 12 REV RETURN 5 ADVANCED 13 REV TO ADVANCE 6 RETURNING 14 FAULT 7 SHIFTED RETURN Address Comment RETURN REQUEST ADVANCE REQUEST RETURNED LS ADVANCED LS RETURN MEMORY ADVANCE MEMORY RESET SDS FAULT ddress Comment ETURN SOL DVANCE SOL ETURNED PL DVANCE PL ETURN MEMORY ADVANCE MEMORY gt Chapter 6 Applying DDMC Instructions to Common Mechanisms Step Tables STEP 1 RETURNED TIMER 0 00 sec DISABLED MESSAGE OFF No Input ID Equation Destination No Output ID State 0 RETURN REQUEST gt 0 STEP 8 0 RETURN SOL OFF 1 ADVANCE REQUEST gt STEP 13 1 ADVANCE SOL OFF 2 RETURNED LS ON gt OFF ERSTEP 14 2 RETURNED PL O 3 ADVANCED LS OFF gt ON ERSTEP 14 9 ADVANCED PL OFF 4 RETURN MEMORY ON gt OFF ERSTEP 14 4 RETURN MEMORY 5 ADVANCE MEMORY gt ERSTEP 14 5 ADVANCE MEMORY OFF 7 RESET SDS FAULT STEP 2 ADVANCING TIMER 3 00 sec WARNING MESSAGE OFF No Input ID Equation Destination No Output ID State 0 RETURN REQUEST gt INITIALIZE 0 RETURN SOL OFF 1 ADVANCE
41. NDLE CONTACTOR SPINDLE ON CHECK 0 065 065 TTON 1 TIMER DELAY 05 05 Timer T4 2 ISPINDLE Time base 0 01 DN SPINDLE ON Preset 5 0 065 I 065 Accum 01 aZ JZ de 05 05 SPINDLE IHEAD LUBE LUBE FLOW SPINDLE IFLOW OK CHECK 0 065 065 PEON sesama at 4 1 TIMER DELAY 05 06 Timer 4 3 HEAD LUBE Time base 0 01 DN SPINDLE FLOW OK Preset 3801 9 065 065 Accum 0 1 05 06 6 13 6 Applying DDMC Instructions to Common Mechanisms SPINDLE SPINDLE CONTACTOR LUBE FLOW FAULT FAULT T4 2 T4 3 DN DN POWER ON DWELL 4 1 F imita R DN DFA instruction Inputs Input Logical Address 0 B3 28 1 1 065 06 2 B3 35 DFA Messages No Input ID Message 0 SPINDLE CHECK OK 1 HEAD LUBE FLOW OK 2 OVERLOADS OK 6 14 SPINDLE CHECK OK B3 pst VS s C Jes 28 STA 6 SH SSS Seep sete DIAGNOSTIC FAULT EN Control File N30 01 ST INo of I O 8 ER Prog file number 4 ES following examples of messages
42. NING When station 1 retracts past and deactivates 1154 the station is RETURNING Once station 1 actuates LS3 it is back to its original position at RETURNED AND READY After you have determined all of the normal states from the sequence of operation you need to determine the error states For example once the returned limit switch 1 53 goes on it should remain on until station 1 returns to its original position after cycling If LS3 goes off when the advance limit switch LS4 goes on then we have an error state Your state diagrams and state tables should account for all error states that could occur 4 9 Chapter 4 Organizing a Drill Machine Application 4 10 Setting up a State Diagram Figure 4 6 shows the state diagram for drill station 1 Figure 4 6 State Diagram for Drill Station 1 1 Returned LS Off 2 Advance Command On 9 2 Returning Advance Command Ready to Advance Advanced LS Off Returned LS On Advance 8 Return Command Command off On ES 1 amp Returning Advancing Stopped Full Depth LS Off Return Advance Command Command Advanced 15 On 7 Off FD amp Re a turning Advanced Return Command Off Timer Off gr Full Depth LS On Full Depth Dwell At Full Depth k Return n Command 0 10 Error Chapter 4 Organizing a Drill Machine Application Important In the state diagram the error step has no trans
43. O STA 6 RET TL CHG ON gt OFF STEP 17 2 STA 6 FEED MOTOR OFF FEED POSITION LS 3 STA 6 FEED AREA OFF ADVANCED LS 4 STA 6 SLIDE ADVD OFF RETURNED LS 5 STA 6 RETURNED LT OFF TOOL CHG POSN LS gt 5 14 6 STA 6 TOOL 5 RESET STA 6 FLT STEP 14 RETD TL CHG amp RETG TIMER 0 00 sec DISABLED MESSAGE OFF Input ID Transition Destination No Output ID State STA 6 ADV REQUEST gt 0 ERSTEP 18 0 STA 6 ADV SLIDE STA 6 REQUEST gt ERSTEP 18 1 STA 6 RET SLIDE MOTO STA 6 RET TO TL CHG gt STEP 17 2 STA 6 MOTOR FEED POSITION LS gt ERSTEP 18 3 STA 6 FEED AREA OFF ADVANCED LS OFF gt ON ERSTEP 18 4 STA 6 SLIDE ADVD OFF RETURNED LS OFF gt ON ERSTEP 18 5 STA 6 RETURNED LT OFF TOOL CHG POSN LS ON gt OFF ERSTEP 18 6 STA 6 TOOL CHG POSN RESET STA 6 FLT STEP 15 RETD TO TOOL CHANGE TIMER 0 00 sec DISABLED MESSAGE OFF Input ID Transition Destination No Output ID State STA 6 ADV REQUEST gt 0 STEP 16 0 STA 6 ADV SLIDE STA 6 REQUEST OFF ON ERSTEP 18 1 STA 6 RET SLIDE MOTO OFF STA 6 RET TO TL CHG gt ERSTEP 18 2 STA 6 MOTOR OFF FEED POSITION LS gt ERSTEP 18 3 STA 6 FEED AREA OFF ADVANCED LS OFF gt ON ERSTEP 18 4 STA 6 SLIDE ADVD OFF RETURNED LS OFF gt ON ERSTEP 18 5 STA 6 RETURNED LT OFF TOOL CHG POSN LS ON gt OFF ERSTEP 18 6 STA 6 TOOL CHG POSN
44. OOL CHG POSN OFF RESET STA 6 FLT STEP 7 ADVD amp RETURNING TIMER 0 00 sec DISABLED MESSAGE OFF 6 17 6 Applying DDMC Instructions to Common Mechanisms 6 18 No OO N 2 2 N F O 2 N 2 Q S QO N Input ID Transition Destination No Output ID State STA 6 ADV REQUEST gt ERSTEP 18 0 STA 6 ADV SLIDE OFF STA 6 RET REQUEST ON gt OFF STEP 17 1 STA 6 RET SLIDE MOTO ON STA 6 RET TO TL CHG gt ERSTEP 18 2 STA 6 FEED MOTOR OFF FEED POSITION LS ON gt OFF ERSTEP 18 3 STA 6 FEED AREA ADVANCED LS ON gt OFF STEP 8 4 STA 6 SLIDE ADVD ON RETURNED LS OFF gt ON ERSTEP 18 5 STA 6 RETURNED LT OF TOOL CHG POSN LS gt 0 ERSTEP 18 6 STA 6 TOOL CHG POSN OFF RESET STA 6 FLT STEP 8 RETG IN FEED AREA TIMER 0 00 sec DISABLED MESSAGE OFF Input ID Transition Destination No Output ID State STA 6 ADV REQUEST OFF gt ON INITIALIZE 0 STA 6 ADV SLIDE MOTO OFF STA 6 RET REQUEST ON gt OFF STEP 17 1 STA 6 RET SLIDE MOTO ON STA 6 RET TO TL CHG gt ERSTEP 18 2 STA 6 FEED MOTOR OFF FEED POSITION LS ON gt OFF STEP 9 3 STA 6 FEED AREA O ADVANCED LS gt ERSTEP 18 4 STA 6 SLIDE ADVD OFF RETURNED LS gt ERSTEP 18 5 STA 6 RETURNED LT OFF TOOL CHG POSN LS gt 0 ERSTEP 18 6 STA 6 TOO
45. REQUEST ON gt OFF INITIALIZE 1 ADVANCE SOL ON 2 RETURNED LS EQ4 STEP 4 2 RETURNED PL OFF 3 ADVANCED LS 04 5 4 3 ADVANCED PL OFF 4 RETURN MEMORY OFF gt 0N ERSTEP 14 4 RETURN MEMORY OFF 5 ADVANCE MEMORY 5 ADVANCE MEMORY ON 7 RESET SDS FAULT EQ4 NED LS 0 AND ADVANCED LS 1 STEP 3 SHIFTED ADVANCE TIMER 3 00 sec WARNING MESSAGE OFF No Input ID Equation Destination No Output ID State 0 RETURN REQUEST OFF gt ON STEP 12 0 RETURN SOL OFF 1 ADVANCE REQUEST OFF gt ON INITIALIZE 1 ADVANCE SOL OFF 2 RETURNED LS EQ5 STEP 5 2 RETURNED PL OFF 3 ADVANCED LS EQ5 STEP 5 3 ADVANCED PL OFF 4 RETURN MEMORY gt ERSTEP 14 4 RETURN MEMORY OFF 5 ADVANCE MEMORY ON gt OFF ERSTEP 14 5 ADVANCE MEMORY ON 7 RESET SDS FAULT EQ5 NED LS 0 AND ADVANCED LS 1 STEP 4 ADVD amp ADVANCING TIMER 0 00 sec DISABLED MESSAGE OFF No Input ID Equation Destination No Output ID State 0 RETURN REQUEST OFF gt ON INITIALIZE 0 RETURN SOL OFF 1 ADVANCE REQUEST ON gt OFF STEP 5 1 ADVANCE SOL ON 2 RETURNED LS OFF gt ON ERSTEP 14 2 RETURNED PL OFF 3 ADVANCED LS ON gt OFF ERSTEP 14 3 ADVANCED PL ON 4 RETURN MEMORY OFF gt ON ERSTEP 14 4 RETURN MEMORY OFF 5 ADVANCE MEMORY 5 ADVANCE MEMORY ON 7 RESET SDS FAULT STEP 5 ADVANCED TIMER 0 00 sec DISABLED MESSAGE OFF No Input ID Equation Destination No Output ID State 0 RETURN REQUEST OFF gt ON STEP 12 0 RETURN SOL OFF 1 ADVANCE REQUEST gt 5 4 1 ADVANCE SOL OFF 2
46. RETURNED LS gt 0 ERSTEP 14 2 RETURNED PL OFF 3 ADVANCED LS ON gt OFF ERSTEP 14 3 ADVANCED PL ON 4 RETURN MEMORY OFF gt ON ERSTEP 14 4 RETURN MEMORY OFF 5 ADVANCE MEMORY ON gt OFF ERSTEP 14 5 ADVANCE MEMORY ON 7 RESET SDS FAULT 6 7 6 Applying DDMC Instructions to Common Mechanisms STEP 6 RETURNING TIMER 3 00 WARNING MESSAGE OFF No Input ID Equation Destination No Output ID State 0 RETURN REQUEST ON gt OFF INITIALIZE 0 RETURN SOL ON 1 ADVANCE REQUEST gt INITIALIZE 1 ADVANCE SOL OFF 2 RETURNED LS 04 STEP 8 2 RETURNED PL OFF 3 ADVANCED LS 04 STEP 8 3 ADVANCED PL OFF 4 RETURN MEMORY 4 RETURN MEMORY ON 5 ADVANCE MEMORY gt ERSTEP 14 5 ADVANCE MEMORY OFF 7 RESET SDS FAULT EQ4 NED LS 1 AND ADVANCED 15 0 STEP 7 SHIFTED RETURN TIMER 3 00 sec WARNING MESSAGE OFF No Input ID Equation Destination No Output ID State 0 RETURN REQUEST gt 0 INITIALIZE 0 RETURN SOL OFF 1 ADVANCE REQUEST gt STEP 13 1 ADVANCE SOL OFF 2 RETURNED LS 5 STEP 1 2 RETURNED PL OFF 3 ADVANCED LS EQ5 STEP 1 3 ADVANCED PL OFF 4 RETURN MEMORY ON gt OFF ERSTEP 14 4 RETURN MEMORY ON 5 ADVANCE MEMORY gt FRSTEP 14 5 ADVANCE MEMORY OFF 7 RESET SDS FAULT 5 NED LS 1 AND ADVANCED 15 0 STEP 8 RETD amp RETURNING TIMER 0 00 sec DISABLED MESSAGE OFF No Input ID Equation Destination No Output ID State 0 RETURN REQUEST ON
47. Rap Ret Command Advanced Indication Returned Indication Chapter 5 Organizing a Transfer Line Application Table 5 J State Table for 505 2 Feed Advance Rapid Return cont State Input Description Input Transition Next State Output Description Output Status 7 Feed Request OFF gt ON State 25 Feed Adv Command OFF Return Request OFF gt ON State 8 Rap Ret Command Returned LS OFF gt ON State 25 Advanced Indication Advanced LS ON gt OFF State 25 Returned Indication Torqued 15 ON gt OFF State 25 Feed Motor Starter OFF gt ON State 25 Return Motor Starter OFF gt ON State 25 8 Feed Request OFF gt ON State 25 Feed Adv Command Return Request ON gt OFF State 7 Rap Ret Command Returned LS OFF gt ON State 25 Advanced Indication Advanced LS ON gt OFF State 25 Returned Indication Torqued LS ON gt OFF State 25 Feed Motor Starter OFF gt ON State 25 Return Motor Starter OFF gt ON State 9 9 Feed Request OFF gt ON State 25 Feed Adv Command Return Request ON gt OFF State 18 Rap Ret Command Returned LS OFF gt ON State 25 Advanced Indication Advanced LS ON gt OFF State 25 Returned Indication Torqued LS ON gt OFF State 10 Feed Motor Starter OFF gt ON State 25 Return Motor Starter ON gt OFF State 25 10 Feed Request OFF gt ON State 25 Feed Adv Command Return Request ON gt OFF State 17 Rap Ret Command Returned LS OFF gt ON State 25 Advanced Indication Advanced LS ON gt OFF State 11 Ret
48. S Prog file number 3 4R 2 2 2 t This rung of logic is used to request Station 7 slide to return STA 7 STA 7 ISTA 7 5 7 RETURN 5 7 OVRLOADS ISLIDE SLIDE STA 7 ADV STA 7 RET SLIDE PB AUTO SS OK RETURNED FAULT SLIDE REQ SLIDE REQ 066 066 B3 B3 N28 0 B3 B3 ducere Jn 1 J 10 07 49 44 12 40 41 5 7 5 7 CYCLE FULL STATION DEPTH B3 0 066 99 93 48 07 Step Directory Control File N28 0 Step Description File N29 0 Step Step Name Step Step Name 0 INITIALIZATION 6 ADVD amp RETURNING 1 RETURNED 7 RETURNING 2 RETD amp ADVANCING 8 RETD amp RETURNING 3 ADVANCING 9 STOP D BTW ADV amp RET 4 ADVD amp ADVANCING 10 COASTING 5 ADVANCED 11 FAULT Chapter 6 Applying DDMC Instructions to Common Mechanisms Inputs and Outputs I O CROSS REFERENCE Input Logical Address Address Symbol Address Comment 0 3 40 B3 40 STA 7 ADV SLIDE REQ 1 B3 41 B3 41 STA 7 RET SLIDE REQ 2 1 066 01 1 066 01 ADVANCED LS 3 1 066 00 1 066 00 RETURNED LS 7 B3 42 B3 42 RESET SLIDE FAULT Output Logical Address Address Symbol Address Comment 0 0 066 00 0 066 00 ADVANCE SLIDE SOL 1 0 066 01 0 066 01 RETURN SLIDE SOL 2 B3 43 B3 43 SLIDE ADVANCED 3 B3 44 B3 44 SLIDE RETURNED Step Tables STEP 1 RETURNED TIMER 0 00 sec DISABLED MESSAGE OFF No Input ID Transition Destination No Output ID State 0 STA
49. STEP STEP INPUTSIOUTPUTS L 8 5 gt STEP 9 10 11 12 13 14 15 16 5 STEP gt 5 INPUTS OUTPUTS 1 gt STEP 2 gt STEP 3 gt STEP 4 gt STEP 5 gt STEP 6 gt STEP 7 gt STEP 8 gt STEP 10 A 4 Symbols Empty 7 2 Numbers 6200 Series Software using message instruction for IMC faults 8 1 A addressing 4 13 assigning 4 13 audience for manual 1 C combinatorial logic drill motor example 3 11 constantlyl lmonitored interlocks 7 5 control permissives 7 4 critical interlocks _7 4 D data table editing for logging IMC faults 8 2 decomposition drill machine example 4 1 levels of 3 1 methods of 3 3 process 3 1 detented valve example 6 5 DFA instruction in spindle example 6 14 overview 1 6 sample messages 6 14 F flashing push buttons for op guidance 9 7 full depth in SDS instructions 1 5 G glossary P 3 Index H hydraulic slide example 6 1 I O addressing 4 13 assigning 4 13 data worksheet 4 14 2 IMC faults 8 1 interlock terminology 7 4 interlocks constantly monitored 7 5 critical 7 4 process 7 5 L ladder program example with SDS instructions 4 19 4 21 levels of SDS instruction implementation 2 1 logging faults 8 1 machine example 6 5 manual s objectives 1 mechanical slide example 6 15 mes
50. TEP 2 3 COND 3 ON gt OFF STEP 2 7 3 7 Applying DDMC Instructions for Operator Guidance Understanding Interlock Terminology 7 4 In Figure 7 1 three conditions from the old logic were transferred to the SDS instruction To make the transfer valid an interlock called OK was included in the new ladder logic An interlock refers to a condition that affects another motion Interlocks are based on logical or mechanical safety considerations usually related to multiple sequences Below we define the terms relating to interlocks and describe their use Control Permissives A control permissive is a command to allow or condition the next motion within a sequence In manual control a control permissive may be the operation of a push button however in automatic mode it may be dependent on a number of states for example left and right hand clamps open and retracted Another example of a control permissive is part in place permissive Where multiple machine states are required to provide a control permissive we recommend placing control permissives in ladder logic Although the permissives can be placed in a separate SDS instruction you gain little by doing this since the individual permissives have their own diagnostics associated with their SDS instruction and as part of their own logic program Critical Interlocks Critical interlocks are conditions that are required regardless of the machin
51. TON to start the conveyor Press the E STOP BUTTON to shut the entire machine down Sequence of Operation A part is placed on the start end of the indexing conveyor The part actuates the part in place limit switch LS1 indicating the part is at the drill station 1 Drill station 1 clamp solenoid is energized and the conveyor motor is de energized AUTO Drill station assembly 1 moves forward MANUAL Press cycle button moving drill station assembly 1 forward Chapter 4 Organizing a Drill Machine Application Type of Operation Description 5 Drill station assembly 1 actuates the advanced limit switch LS4 energizing drill motor 1 6 Drill station assembly 1 actuates the full depth limit switch 155 stopping drill station assembly 1 and initiating a three second dwell 7 After the three second dwell delay drill station assembly 1 begins to retract 8 Drill station assembly 1 retracts past 154 154 opens de energizing drill motor 1 9 Drill station assembly 1 actuates the returned limit switch 153 stopping the assemble de energizing CL1 and starting the indexing conveyor to move the part to drill station 2 Steps 4 through 9 are repeated for drill station 2 Now that we understand the working relationship of operations we can decompose each operation into the following suboperations indexing conveyor conveyor index clamp assembly drill station 1 drill motor
52. TURNED LS 5 STA 6 RETURNED LT OFF 6 TOOL CHG POSN LS 6 STA 6 TOOL CHG POSN OFF 7 RESET STA 6 FLT gt STEP 0 Summary This chapters showed you examples of logic that apply the DDMC instruction to common mechanisms You can refer to these examples when you set up similar applications Chapter 7 shows examples of using DDMC instruction in a DDMC implementation for operator guidance 6 20 Chapter Objectives Getting Started with Providing Operator Guidance Applying Instructions for Operator Guidance In addition to implementing DDMC at various levels you can implement the instructions to provide operators with messages that guide them to perform sequential steps For example when a machine faults in automatic mode the operator may need to perform steps to get the machine back to home position so that it can be placed back in automatic mode You can use the messages generated by the DDMC instructions to tell the operator what to do Read this chapter to gain a basic understanding of providing operators with guidance messages and to better understand the terminology used in DDMC instructions for operator guidance As stated on page 1 1 you can use the SDS instruction in two different Ways state transitional mode inputs are where individual input state transitions and changes are analyzed combinatorial mode inputs or steady states are ANDed to analyze logical conditions To achieve operat
53. ages Loss of field power can be caused by the following hardwired normally closed E stops being activated power brown outs remote rack or adapter faults breakers to remote control cabinets To prevent false generation of messages we recommend the following or similar approach to manage the loss of field power Hardwiring Figure 9 2 shows an example of suggested hardwired ac power explanation follows 9 4 Figure 9 2 Hardwired ac power E STOP MASTER CONTROL C RELAY MCR AC INPUT Local Rack MCR d MODULE 1 000 01 S Power OK S Chapter 9 Other Application Examples 1 Reserve an input in the local rack to detect if power is available A local rack is required since loss of power to a remote rack could result in the loss of power to the adapter and I O modules and might otherwise go undetected If power is lost to the local rack the processor goes through an orderly shut down and automatically disables the SDS instructions The instructions then reset to their initialization state at power up If power is lost to a remote rack the SDS remains active 15 not reset 2 Bring into the local rack a contact from the master control relay that is hardwired and external to the PLC has been designed to accommodate safety and other critical aspects of machine control such as the E stop circuit Ladder Logic Figure 9 3 shows an example of suggested ladder logic Table 9
54. al world example of a transfer line The second section of the manual provides several programming examples and techniques that you can use when building your own custom DDMC application Table P A Sections of the Manual If you want to read about Refer to chapter SDS and DFA instruction basics Understanding DDMC Instructions and Their Purpose Levels of DDMC implementation using the DDMC instruction for operator guidance messages Implementing DDMC to a Specific Level Decomposing your machine into manageable segments 3 Getting Started with State understanding the basics of truth tables state diagrams and Transition Conditional Logic state tables Programming Applying state transition conditional logic to a drill machine Organizing a Drill Machine example Application Applying state transition conditional logic to a transfer line 5 Organizing a Transfer Line example Application Applying DDMC instructions to a hydraulic slide machine clamp part stamp spindle and a mechanical slide Applying DDMC Instructions to Common Mechanisms 2 7 Using DDMC Instructions to provide operators with guidance Applying DDMC Instructions for messages Operator Guidance Applying a technique that uses the PLC 5 message instruction to simulate fault messages like those created with the SDS instruction Logging IMC Faults Sent as Messages by the PLC processor Using DDMC instructions for various applications such as
55. ance rapid return 5 16 Chapter 5 Organizing a Transfer Line Application Figure 5 6 State Diagram for 505 2 Feed Advance Rapid Return Returning Off 12 Slide Returned Slide Returning Interlock Removed Returned LS On Feed Req Off Slide Returned and Feeding Returned LS On Feeding Off 18 Slide Coast Returning Between Returned amp Advanced LS Return Req On Feeding On 19 Slide Stopped Between Returned amp Advanced 15 Slide Coast Feeding at Returned LS Feed Req Off Return Req Slide Returning Between Returned amp Advanced LS Returning Off Feed Req On 3 Slide Feed terlocked Feed Req Off Feed Req On Slide Feed Motor Advanced LS Off Restarted between Returned amp Advanced LS Returning On Slide Rapid Return Motor Restarted at Advanced LS Returned LS Off Afivanced LS Off Slide Coast Feeding Between Returned amp Advanced LS Feeding On Feeding Off Returning On Return Req Off 17 Return Req On Advanced LS On 22 Slide Feedin 9 Between Slide Feed Motor Returned amp Advanced LS Slide Returning Return Re Restarted at q at Advanced LS Advanced LS Advanced LS Return Req Off Feeding On
56. are Testing and Maintenance PLC 5 250 Programming Software Instruction Set Reference PLC 5 250 Programming Software I O Configuration Software 5000 6 4 15 User Manual Operator Interface Terminal 1784 6 5 6 6160 6 5 1 6171 6 5 15 T35 Plant Floor Terminal User s Manual T60 Industrial Workstation User s Manual RealRAM Enhanced Memory Card cat no 6174 DMB10 User s Manual RealRAM Enhanced Memory Card cat no 6190 MB14 User s Manual 6190 6 5 15 Communications Data Highway Data Highway Plus Protocol and Command Set 1770 6 5 16 User s Manual Peer Communication Link Interface Module cat no 1784 KT 1784 23 Product Data ControlView ControlView Core User s 2 6190 6 5 1 ControlView Mouse GRAFIX Editor User s Manual 6190653 P 4 Chapter Objectives Understanding the SDS Instruction SDS SMART DIRECTED SEQUENCER Control File Step Desc File Length No of Steps Position Step No of I O Prog file number ST Understanding Instructions and their Purpose Read this chapter to get an overview of DDMC instructions that you will use as part of your ladder program to build an application In this chapter we describe the SDS instruction Smart Directed Sequencer DFA instruction Diagnostic Fault Annunciator You can use the Smart Directed Sequencer SDS instru
57. assembly Slide assembly drill station 2 drill motor assembly Slide assembly Based on the sequence of operation and sketch of the drill machine we can establish that our suboperations for each operation are fairly simple Therefore we can determine states from the second level of decomposition without decomposing further Figure 4 3 graphically shows the decomposition process for the two station drill machine 4 5 Chapter 4 Organizing a Drill Machine Application Figure 4 3 Decomposition Process for Drill Machine Two station Drill Machine Drill Station 1 Drill Station 2 Conveyor Drill motor Slide Drill motor Slide Index Clamp In the event that you decompose to a level and find that your number of states for each segment becomes unmanageable we recommend that you decompose the segment to the next level Defining States for a Drill After decomposing the drill machine into manageable segments we can Machine Segment define states and transitions for each segment as described in chapter 3 We use the segment of drill station 1 as an example Figure 4 4 and Figure 4 5 shows drill station 1 and the relay logic diagram for its operation Refer to Figure 4 1 to see how these segments fit into the overall machine process 4 6 Chapter 4 Organizing a Drill Machine Application
58. aults in automatic mode the operator may need to perform steps to get the machine back to home position so that it can be placed back in automatic mode You can use the messages generated by the DDMC instructions to tell the operator what to do stated on page 1 1 you can use the SDS instruction in two different ways state transitional mode inputs are where individual input state transitions and changes are analyzed combinatorial mode inputs or steady states are ANDed to analyze logical conditions To achieve operator guidance you still would want to keep those actions related to the motion of the mechanism in a separate SDS instruction Information for analyzing expected conditions that are being monitored by the SDS instruction and allow the operator s request to be acted upon should be kept in another SDS instruction Important You do this to reduce the complexity in the instruction and to display messages different than those used to indicate control faults You use the configuration utility differently to configure operator guidance messages than to configure warning messages To configure operator guidance messages you first analyze existing or standard request logic relocate the permissive and interlocks from the ladder logic and put them in their own SDS instruction as shown in Figure 2 5 The permissives in the request logic must not allow for parallel paths For sample programs that show DDMC imp
59. cifically the SDS instruction to a larger application that uses state transition logic Chapter Objectives Decomposing the Transfer Line Organizing a Transfer Line Application Read this chapter to see how state transitional logic is applied to a transfer line In this chapter we decompose the transfer line into manageable segments implement state control with ladder logic show methods of determining the number of SDS instructions develop a state diagram and state table for each SDS instruction A transfer line is composed of several smaller assemblies Seting up a state application for such a large system requires the decomposition process When decomposing the transfer line you want to break the line down into manageable segments By using the methods previously described you can decompose level by level until you achieve segments that are manageable Figure 5 1 shows a block diagram of the transfer line where each block represents a station We use this block diagram to visualize the complexity of the transfer line so we can decompose it 5 1 5 Organizing a Transfer Line Application Figure 5 1 Transfer Line Block Diagram R H LOADING STATION L H PRESS STATION L H PRESS STATION R H PRESS STATION R H PRESS STATION L H PROBE GAUGE R H BORE amp REAM LH SLIDE R H PROBE GAUGE R H EJECT STATION R H CNC STATION R H MILLING STATION Decomposing to
60. ction in many ways such as providing fault diagnostic information about sensing devices like limit switches pressure switches proximity switches The SDS instruction allows two basic types of logic equations Transitional Logical OR Combinatorial Logical AND Transition equations provide traditional state based control In other Words a transition equation defines the destination step for the transition either ON gt OFF or OFF gt ON of a desired input Combinatorial equations define the destination step based on the steady state values and the relationship between a collection of inputs Currently the only valid relationship is the logical AND function This allows you to accommodate complex combinations in the instruction while keeping the number of steps within a configuration to a minimum You can define up to 4 logical AND combinations in an 8 input SDS instruction You can define up to 8 ANDed conditions in a 16 or 32 input SDS instruction Using the combinatorial feature of the SDS instruction you can replace complex ladder logic required for permissives in a state transition SDS instruction obtain diagnostic information on logical conditions use for operator guidance develop shadow mode diagnostics the instruction follows what the machine is doing without controlling any outputs Chapter 1 Understanding DDMC Instructions and their Purpose Figure 1 1 shows an example of th
61. d the machine diagnostics are integrated Similar to the Level 2 implementation you must decompose the given mechanism into individual states The SDS instruction monitors the mechanism s input for transition and uses the SDS instruction to control the mechanism s outputs while it is in a given step Upon an invalid transition of a mechanism s input the instruction generates a fault message Changes that affect the control of a mechanism also update that mechanism s diagnostics Using Level 3 the following is true the SDS instruction is used to control the machine s outputs diagnostics and control are integrated you should use the DFA instruction for discrete fault annunciation Figure 2 4 DDMC Implementation Level 3 Level 3 The SDS controls outputs and monitors inputs for disagnostic detection and automatic message generation vla TI 6 M Advance Request 1 WA Return Request SDS Advance Request Advance Solenoid Return Request il Return Solenoid O Advanced Light Advanced LS Returned Light Returned LS 2 4 Implementing for Operator Guidance Messaging Chapter 2 Implementing DDMC to a Specific Level In addition to implementing DDMC at various levels you can implement the instructions to provide operators with messages that guide them to perform sequential steps For example when a machine f
62. d to know the physical and logical inputs and outputs controlling the operation of the slide Refer to Figure 5 3 for locations of devices The physical inputs or sensors needed by the state logic to sense the motion position states or conditions of the devices are brake contactor energized feed motor started energized rapid advance motor started energized rapid return motor started energized returned position limit switch advanced position limit switch feed position limit switch torqued limit switch rapid advance return motor overloads feed motor overloads The logical input requests internal ladder logic or other SDS instructions to the state logic are brake release request feed request rapid return request rapid advance request reset overloads request The physical outputs used by the state logic to control the output devices are brake release command feed advance command rapid advance command rapid return command The logical output indications internal ladder logic needed by the state logic to synchronize with other state and ladder logic are brake release indication advanced indication returned indication in feed area indication overloads okay indication 5 7 Chapter 5 Organizing a Transfer Line Application Organizing the Logic Associating Motions with SDS Instructions 5 8 To reduce complexity and programming time eval
63. drill machine example we defined 11 states Each diagnostic segment derived from the decomposition process has its own SDS instruction on a rung of ladder logic Each SDS instruction contains screens for entering the I O states and transitions from the state diagram and state table Refer to the DDMC User s Manual publication 6401 6 5 1 for more information on the instruction s configuration screens Figure 4 9 shows the state configuration for station 1 of the two station drill machine in a step description worksheet The SDS instruction uses the term step to refer to states For example in our drill machine example we have 11 steps We have provided blank worksheets in appendix B if you would like to use them when configuring your instructions 4 17 Chapter 4 Organizing a Drill Machine Application Figure 4 9 Step DescriptionWorksheet for Station 1 of the Drill Machine STEP Returned amp Ready TIMER 0 00 sec STEP MESSAGES ON OFF No Input ID Equation Destination No Output ID State Advanced LS OFF gt ON STEP 10 Reverse Motor Full Depth LS OFF gt ON STEP 10 Advance Command OFF gt ON STEP Ready to Advance TIMER 20 00 sec STEP 10 MESSAGES ON OFF No Input ID Equation Destination No Output ID State Returned LS OFF gt ON STEP 3 Forward Motor ON 1 1 2 Advanced LS OFF gt ON STEP 10 2 Reverse Motor OFF 3 3 Full Depth LS OFF gt ON STEP 10 Dri Motor OFF 4 Advance Co
64. e SDS instruction s step table Edit Step screen using the combinatorial feature Figure 1 2 shows a step table with transitional structure each input transition sends the instruction to a unique state for those conditions For more information about the SDS configuration utility and steps for configuring the instruction refer to the DDMC User s Manual publication 6401 6 5 1 Figure 1 1 SDS Instruction showing combinatorial function Edit Step Screen 1 untitled TIMER 5 00s STEP 11 suec No Input ID No Output ID State Equation Destination 0 PART IN POSITION ON gt OFF ERSTEP 10 1 VALVE 4 OFF 1 CLAMP LS1 01 5 9 2 CLAMPS OPEN ON 2 CLAMP LS2 01 5 9 3 CLAMPS CLOSED OFF 3 CLAMP LS3 01 5 9 4 SOLENOID LAST 4 CLAMP LS4 0 5 9 5 LIGHT LAST 5 HAND EQ2 STEP 5 6 MOTOR 2 ON 6 AUTO 7 406 PB 2 5 5 8 PERMISSIVE ON gt OFF STEP 2 Press a function key Enter destination step number or INIT Prog edit mode 5 25 Addr 5 SDSTEST Equatn Display Step Step Edit Step Msg Equatn Output Marked List Symbol Name Type Step Timer Off Editor State Exit Fl F2 F3 F4 FS F6 EI F8 F9 F10 Figure 1 2 SDS Instructions showing state transitional function Edit Step Screen ds 1 READY TIMER 0 0s DISABLED MSG OFF No Input ID Equation Destination No Output ID State 0 RET D LS OFF 0N STEP 4 0 FORWARD MOTOR 1 OFF 1 ADV D LS OFF 0N STEP 10 1 REVERSE MOTOR 1 OFF 2 FULL DEPTH LS OFF gt ON STEP 4 2
65. e Transition Conditional Logic Programming 3 6 Table 3 A Truth Table for Motor Inputs Outputs Switch Motor 1 1 0 0 In this example the number of possible states equals the number of practical states Setting up a State Transition Diagram A state diagram graphically represents the control or operation of a machine in a state transition format A state diagram consists of states and transitions States are often represented as bubbles Transitions are often represented as arcs with arrows pointing in the appropriate direction between bubbles When defining states in a state diagram label the state with the state number on the edge of the bubble put the name of the state inside the bubble Important When naming states choose the name that most accurately describes what is happening at that particular state When you begin using state names to diagnose machine faults it is imperative that the state name clearly identifies the state at which the fault is occurring When defining transitions in a state diagram label the input causing the transition at the edge of the arc transition below or beside the input Figure 3 5 shows a state diagram for the motor example Chapter 3 Geting Started with State Transition Conditional Logic Programming Figure 3 5 State Diagram of Motor 1 witch On Motor Off 2 Motor On Switch Off Setting up a State Table A state table combines information from the trut
66. e s mode of operation These interlocks are provided to protect the machine from damage whether the machine is in automatic or manual mode For example a critical interlock might be a spindle or lube OK condition required before a tool can advance into a piece of work In most cases these conditions must be satisfied regardless of the mode of operation that is don t close the door until all fingers are out of the way or don t move the transfer mechanism until all heads are returned and all stations are unclamped You can include critical interlocks in the same SDS instruction used for controlling a mechanism but the instruction could contain a large number of steps We recommend including critical interlocks in a second SDS instruction to provide a permissive to the SDS that controls the mechanism Summary Chapter 7 Applying DDMC Instructions for Operator Guidance Constantly Monitored Interlocks Constantly monitored interlocks are commands that are required regardless of a machine s mode of operation or its position within a sequence These interlocks are provided to protect the operator in case of machine failure Examples of constantly monitored interlocks include air pressure OK emergency stop guards closed You can place these interlocks in ladder logic and monitor them with the DFA instruction to provide the operator with startup manual operation and diagnostics information if the machine fails Process I
67. ells readers where machinery may be damaged or economic loss can occur if procedures are not followed properly Warnings and Cautions Identify a possible trouble spot Tell what causes the trouble Give result of improper action Tell the reader how to avoid trouble Important We recommend you frequently backup your application programs on appropriate storage medium to avoid possible data loss 1991 Allen Bradley Company Inc PLC is a registered trademark of Allen Bradley Company Inc Summary of Changes Summary of Changes New Information in this This release of the publication contains the following new information Publication In this release a new 14 step detented value SDS instruction replaces the SDS shown in the previous version of this manual see page 6 6 of Applying SDS Instruction to a Machine Clamp The new SDS instruction includes changes that have been made to eliminate processor scan dependencies These changes include swapping the request and memory I O addresses in the input table other step transition changes throughout the SDS New or changed information is noted with a revision bar as shown in the margin Table of Contents Summary of Changes 1 1 New Information in this Publication 41 1 Using this Manual P 1 Manual Objectives P 1
68. equest 9 rapid return request 10 rapid advance motor starter energized 7 rapid advance command 11 feed position limit switch 8 in feed area indication 12 rapid advance request 13 rapid advance return motor overloads 9 overload okay indication 14 feed motor overload 15 reset overload request 5 Organizing a Transfer Line Application Table 5 C shows the SDS block decomposed into two motions brake engage advance return By decreasing the number of inputs in each section of the block we have simplified our SDS instructions Table 5 C View 1 of SDS Block Brake Engage Advance Return Inputs Outputs 1 brake contactor energized 1 brake release indication 2 brake release request 2 brake release command 3 feed motor starter energized 3 feed advance command 4 rapid return motor starter energized 4 rapid return command 5 returned position limit switch 5 returned indication 6 advanced position limit switch 6 advanced indication T torqued limit switch 8 feed request 9 rapid return request 10 rapid advance motor starter energized 7 rapid advance command 11 feed position limit switch 8 in feed area indication 12 rapid advance request 13 rapid advance return motor overloads 9 overload okay indication 14 feed motor overload 15 reset overload request 5 10 5 Organizing a Transfer Line Application Table 5 D shows the SDS block decomposed into three
69. est 10 rapid advance motor starter energized 7 11 feed position limit switch 8 12 rapid advance request brake contactor energized 1 Outputs brake release indication brake release command feed advance command rapid return command returned indication advanced indication rapid advance command in feed area indication 13 rapid advance return motor overloads 9 overload okay indication 14 feed motor overload 15 reset overload request Important When using the approach at 4 be certain that the desired coupling between the control and the diagnostics is not lost Table 5 G shows the estimated number of normal states for the views shown in Table 5 B through Table 5 F Table 5 H contrasts Table 5 G with the number of possible states for each view 5 13 5 Organizing a Transfer Line Application Developing State Diagrams and State Tables 5 14 Table 5 G Number of Normal States for Each View View SDS 1 SDS 2 SDS 3 SDS 4 Big block View View 2 View 33 View 44 8 1 Table 5 H Number of Possible States for Each View View 05 3 SDS 4 Big block View 1 View 2 128 View 3 128 View 4 8 2 After evaluating the complexity of each view we pick the most feasible view that is the one with the fewest inputs per SDS and develop state diagrams and state tables From Table 5 G view 4 looks like the best choice since it has 38
70. estart the motor by pressing the START PB 4 When the STOP PB is pressed the motor starter turns off Figure 3 6 illustrates the above operation in a relay logic diagram Figure 3 7 shows the PLC ladder logic for the same operation Figure 3 6 Relay Logic Diagram of Drill Motor Starter Operation Start PB MS Overload Stop PB Motor Starter 2 MS Auxiliary Contact Figure 3 7 PLC Ladder Logic of Drill Motor Starter Operation Start PB MS Overload Stop PB i C a MS Auxiliary Contact m Decomposing the Drill Motor Motor Starter Because the drill motor is a fairly simple operation with 4 inputs and 1 output and one basic motion we need not decompose it further 3 8 Chapter 3 Geting Started with State Transition Conditional Logic Programming Setting up a Truth Table Using the formula 2 we can determine that we have 16 possible states since we have four inputs Table 3 C shows the truth table which confirms this Table 3 C Truth Table of Possible States for Drill Motor Inputs Outputs Start PB Auxiliary Contact Stop PB Motor Overload Motor Starter o was nm aps ruptum spes Tut truth table shows all of the possible
71. eturned LS OFF gt ON State 25 Advanced Indication OFF Advanced LS OFF gt ON State 15 Returned Indication OFF Torqued 15 OFF gt ON State 25 Feed Motor Starter ON gt OFF State 19 Return Motor Starter OFF gt ON State 25 15 Feed Request OFF gt ON State 5 Feed Adv Command OFF Return Request OFF gt ON State 25 Rap Ret Command OFF Returned LS OFF gt ON State 25 Advanced Indication OFF Advanced LS ON gt OFF State 25 Returned Indication ON Torqued LS OFF gt ON State 6 Feed Motor Starter ON gt OFF State 20 Return Motor Starter OFF gt ON State 25 16 Feed Request OFF gt ON State 25 Feed Adv Command OFF Return Request OFF gt ON State 9 Rap Ret Command OFF Returned LS OFF gt ON State 25 Advanced Indication ON Advanced LS OFF gt ON State 25 Returned Indication OFF Torqued 15 ON gt OFF State 17 Feed Motor Starter Return Motor Starter ON gt OFF State 6 17 Feed Request OFF gt ON State 25 Feed Adv Command OFF Return Request OFF gt ON State 10 Rap Ret Command OFF Returned LS OFF gt ON State 25 Advanced Indication OFF Advanced LS ON gt OFF State 18 Returned Indication OFF Torqued 15 OFF gt ON State 25 Feed Motor Starter OFF gt ON State 25 Return Motor Starter ON gt OFF State 20 18 Feed Request OFF gt ON State 25 Feed Adv Command OFF Return Request OFF gt ON State 11 Rap Ret Command OFF Returned LS OFF gt ON State 12 Advanced Indication OFF Advanced LS OFF gt ON State 25 Returned Indication O
72. ew Rapid Advance A and Rapid Return R Motor Sheave e Chapter 5 Organizing a Transfer Line Application Figure 5 4 Slide Mechanical Drawings continued Sheave Feed Advance Motor k Planetary Gear Cage Assembly end view V belt Sheave ZZZZZZZZZZZ d Feed Advance Worm Gear 17637 To detail the slide further we need to get an overview of its operation Table 5 A Reference letters from components in Figure 5 2 and Figure 5 3 are shown in parentheses Table 5 A Overview of Slide Operations Type of Operation Step Description System Initialization Turn on the rapid advance motor A Turn on the feed motor B When the rapid advance motor A is turned on the input sun gear C turns the planetary gears D G Sequence of Operation The planetary gears D G turn the output sun gear H The output sun gear H turns the ball screw I 4 The ball screw I moves the ball nut J forward 5 The slide K is then carried forward by the ball nut J 6 When the feed motor B is turned on the feed motor B drives the worm gear L 7 The worm gear L then drives the surfaces of the gearbox cage M This affects the slide K speed 5 5 5 Organizing a Transfer Line Application Table 5 A Overview of Slide Operations continued Type of Operation Step Description 8 In about 8 seco
73. first 13 words of the local data table to contain the information which will be sent in your message You may want to change the radix to ASCII to make editing simpler To edit the data table do the following 1 Access data table at the data file address for the message instruction 2 Enter information into words 0 12 as shown below Note that you configure words 0 6 by editing the data table directly words 7 12 need to be supplied by the ladder programming when an error is detected WORD 0 15 14 18 12 11 10 09 08 07 106 05 04 0 02 01 00 CLASS TYPE PLCTYPE UNUSED Message class C fault 0 PLC 5 1 clear 4 PLC 5 250 2 8 2 Chapter 8 Logging IMC Faults Sent as Messages by the PLC 5 Processor WORDS 1 4 PROCESSOR NAME entered in ASCII WORD 5 15 14 13 12 11 10 09 08 07 06 05 0 03 02 01 00 RACK GROUP Rack number of IMC device Group number of IMC device WORD 6 15 14 12 11 10 09 08 07 06 05 04 0 02 01 00 SLOT IMC TYPE Slot number of IMC device IMC 120 1 IMC 121 2 123 3 WORD 7 IMC Error Code from IMC program WORDS 8 12 IMC to PLC Block Zero information words 2 6 Figure 8 2 shows the data table at the message instruction control file address configured with information 8 3 Chapter 8
74. g messaging capabilities when a fault occurs An instruction that resides in ladder logic providing state machine control and up to date diagnostics for your machine The conditions of the outputs of a machine at a point in time An input change from ON to OFF or OFF to ON associated with a single input A diagnostic technique that incorporates a timer to monitor sequencer event A real or storage output used to coordinate sequences P 3 Preface Using this Manual Related Publications For more information about DDMC components see the following publications Publication Title Publication Number DDMC User Manual PLC 5 Processors 6401 6 5 1 1785 6 6 1 1785 6 2 1 5000 6 2 1 PLC 5 Programming Software Documentation Set 6200 8 001 PLC 5 Programming Software Installation and Configuration 6200 6 4 6 PLC 5 Programming Software Programming User s 6200 6 4 7 Manual PLC 5 Programming Software Instruction Set Reference 6200 6 4 11 PLC 5 Programming Software I O Configuration Software 6200 6 4 12 PLC 5 250 Programming Software Documentation Set 6200 N8 002 5000 6 4 7 1785 PLC 5 Family Programmable Controllers Installation Manual 1785 PLC 5 Programmable Controller Design Manual Pyramid Integrator Design Manual PLC 5 250 Programming Software Installation and Configuration 5000 6 4 8 5000 6 4 11 5000 6 4 12 PLC 5 250 Programming Software Programming Manual PLC 5 250 Programming Softw
75. ger 8 5 Chapter 8 Logging IMC Faults Sent as Messages by the PLC 5 Processor BEGIN FOR ir 1 max_splocs DO Ssploc ir 0 ENDFOR ir 1 WHILE dequeue err true ir lt max splocs DO sploc ir err ir 1 ENDWHILE put plc 6 abort flag false enable condition 2 END output errs s START_OF_PROGRAM BEGIN ouput errs IF UNINIT ABORT FLAG THEN ABORT FLAG FALSE ENDIF IF ABORT FLAG THEN OUTPUT ERRS ENDIF 8 6 Chapter 8 Logging IMC Faults Sent as Messages by the PLC 5 Processor CONDITIONS CONDITION 1 WHEN ENDCO CONDITION 2 ERROR RET_VAL DO ENQUEUE SERROR SIGNAL EVE T 1 ABLE CO DITIO WHEN EVENT ENDCO DITIO CONDITION 3 WH ENDCO DITION ENABL OUTPUT 1 EN ABORT DO ABORT FLAG TRUE DITION DO ERRS 1 CONDI ION 1 ENABLE CONDI ION 2 ENABL CONDI ION 3 ws The actual motion program is placed here This simple program moves single axis back and forth while toggling a single output e value to indicate direction AXIS2 SSPEED WHILE ON DO FOUT 1 ON 152 BY 10 FOUT 1 OFF MOVE 152 BY 10 ENDWHILE AXIS2 STERMTYPE NOSETTLE
76. ginal request as an input to the SDS instruction 4 and 5 The circuit shown by these rungs is used to create a pulsing output called flash that toggles on and off This output is used to drive all flashing instructions A 4 second timer is used to turn the light off every 2 seconds You may choose other alternatives such as flip flops to achieve this flashing condition The logic in rungs 1 through 3 must be repeated for each request signal and indicator light pair 9 9 Appendix SDS Instruction Worksheets Appendix Overview This appendix provides the following worksheets I O Data Worksheet Step Description Worksheets two versions Use the I O Data Worksheet to help you address your I O Use the Step Description Worksheets to help you program steps into the SDS instruction Appendix SDS Instruction Worksheets Data Worksheet RACK ADDRESS GROUPING PAGE OF _ DATE _ DESIGNER Address Symbolic Name Description Appendix SDS Instruction Worksheets Step Description Worksheet 1 STEP TIMER sec STEP MESSAGES ON OFF Equation Destination State STEP 5 MESSAGES ON OFF Equation Equation No State STEP Equum panem A 3 Appendix SDS Instruction Worksheets Step Description Worksheet 2 STEP STEP STEP STEP STEP STEP TIMER STEP STEP STEP
77. h table with information from the state diagram A state table contains output states input conditions input transitions actions to be taken The state table is a helpful tool when you are ready to enter data into the SDS instruction You can also take information directly from the state table and plug it into the fill in the blank configuration templates at the programming terminal Table 3 B shows a state table for our simple motor Table 3 B State Table for Motor Input Description Input Transition or Output Description Output Status Conditions On Off switch OFF gt ON OFF ovo 7 Chapter 3 Geting Started with State Transition Conditional Logic Programming A Drill Motor Example The first motor example was helpful in showing how to use the tools in developing a state application In the following example we have a drill motor with one device a motor starter and four inputs We use the same tools to develop a state transition application for the drill motor The following sequence of operation explains how the motor starter reacts to the different inputs 1 When the START PB is pressed the motor starter turns on 2 When the motor starter turns on the MOTOR STARTER AUXILIARY CONTACT closes turns on sealing the circuit 3 Ifthe motor starter has a current overload the MOTOR STARTER OVERLOAD CONTACT opens turns off When the motor starter contact resets itself then you can r
78. hapter 1 Understanding DDMC Instructions and their Purpose Keep in mind that you want to use the SDS for a particular motion or mechanism Any other information related to that motion but not part of that motion can be handled more easily with conventional ladder logic like full depth information or in a separate SDS instruction if you want messages generated This information could include Information Operating Mode Full Depth Motor Starter Overloads Manual Inputs Description Including operating mode in your SDS only increases the number of steps required in the instruction thus increasing the difficulty of the instruction lt is not necessary that the SDS instruction know why the axis it controls is being requested to move only that it must behave a certain way when it is requested to do so When you configure an SDS instruction for a motion it is likely that you include the inputs and outputs required to generate a full depth condition Even so we recommend keeping full depth logic out of the SDS because canceling the full depth signal requires including additional inputs complicating the configuration Internal storage points or logical conditions are more easily suited for ladder logic For example a full depth condition usually includes latches and unlatches both easily handled by ladder logic When you program an SDS instruction to go to a fault step upon seeing an overload trip the instructi
79. hapter 5 Organizing a Transfer Line Application Figure 5 7 State Diagram for SDS 3 Rapid Advance 0 Initialization Step 1 2 Advance Req Off i Advancing amp Feed me Not in Feed Area ee eturn Advance Req On Advance MS On Return Req On Advance Req Off Advance MS Off Feed LS On Advance MS On Advance Req On LS On 4 Return Req Return Req On RJA Motor Off Between Advance Confirmed Feed amp Return Rapid Advance Error 24774 Advance MS Off Req On 2 150 Advance 5 Feed n Feed LS Off Advance MS On Advance Req On Feed LS Off R A Off for Feed Off R A Motor Not Confirmed at Feed Return Req Off Advance MS Off RIA Off at Feed LS 5 Organizing a Transfer Line Application Table 5 K State Table for SDS 3 Rapid Advance State Input Description Input Transition Next State Output Description Output Status 1 Advance Request Advance Command OFF Return Request In Feed Area Ind OFF Feed LS Advance Motor Starter 2 Advance Request Advance Command ON Return Request In Feed Area Ind OFF Feed LS Advance Motor Starter 3 Advance Request ON gt OFF Advance Command ON Return Request OFF gt ON In Feed Area Ind OFF Feed LS OFF gt ON Advance Motor Starter ON gt OFF 4 Advance Request Advance Command OFF Return Request OFF gt ON State 8 In Feed Area Ind ON Feed LS Advance Moto
80. hat transition the DFA instruction generates a fault message Machine control logic fault detection logic and fault annunciation logic are not integrated Using Level 1 the following is true ladder logic controls the machine diagnostics are not updated with control logic changes diagnostic detection relies on ladder logic Figure 2 2 shows an example of Level 1 implementation Figure 2 2 DDMC Implementation Level 1 Level 1 Traditional Control Logic Conventional ladder logic is used for both control and fault detection The DFA monitors the ladder logic fault bits and HE generates messages Advance Solenoid cla vla Pd NY cL cl T rd B P RS S Returned Solenoid is Advance Light Returned Light vig 7 RS Fault Detection Logic Ht 1 1 t Station Fault Ht y Coolant Fault DFA Station Fault 1 E o j Coolant Fault 2 2 Implementing for Messaging and Diagnostics Level 2 Level 2 Conventional ladder logic is used to control outputs The SDS instruction monitors inputs and conditions to detect faults and generate messages Chapter 2 Implementing DDMC to a Specific Level Level 2 implementation of the DDMC uses the SDS instruction to decompose a mechanism into individual states based on the inputs or conditions that relate to the given
81. hin the SDS instruction HAND PB OK COMMAND REQUEST New Logic 14 TRIGGER E Vt CH CYC PB1 CYC PB2 CYCLE H HAND lE ji t Control SDS Instruction SDS JE Trigger t Condition monitoring SDS Instruction SDS Condition 1 Condition 2 Condition 3 Chapter 7 Applying DDMC Instructions for Operator Guidance Figure 7 2 State Diagram for Condition monitoring SDS Instruction Trigger OFF gt ON Timer Warning Output OFF Waiting for Trigger 2 Waiting for Output OFF Trigger Conditions ON OFF Cond 1 Trigger or ON gt OFF Cond 2 Cond 1 Cond 2 Cond 3 nditions OK Conditions 0 Output ON Table 1 A Step Tables for Condition monitoring SDS Instruction STEP 1 WAITING FOR TRIGGER TIMER 0 00 sec DISABLED MESSAGE OFF No Input ID Transition Destination No Output ID State 0 TRIGGER gt 0 STEP 2 0 1 COND 1 2 COND 2 3 COND 3 STEP 1 WAITING FOR CONDITIONS TIMER WARNING MESSAGE OFF No Input ID Transition Destination No Output ID State 0 TRIGGER ON gt OFF STEP 1 0 OK OFF 1 COND 1 OFF gt ON INPUT 2 2 COND 2 OFF gt ON INPUT 3 3 COND 3 gt 0 5 3 STEP 1 WAITING FOR TRIGGER TIMER 0 00 sec DISABLED MESSAGE OFF No Input ID Transition Destination No Output ID State 0 TRIGGER ON gt OFF STEP 1 0 OK ON 1 COND 1 ON gt OFF STEP 2 2 COND 2 ON gt OFF S
82. ilities For example suppose you have a machine that operates in two modes automatic and manual You would need two SDS instructions to account for the operation in each mode By keeping the auto manual permissive in the ladder program you need only one SDS instruction You can optimize your programming if you use the SDS instruction for Outputs to be controlled inputs or signals you want to diagnose a devices that provide feedback what information and use ladder logic for Serial permissives combinatorial logic why and when information For example in our drill machine example we will not develop state logic for the clamp because we do not receive feedback from the clamp to determine if it closed properly In most real world examples there would be an input to make this determination Using the SDS Instruction Chapter 4 Organizing a Drill Machine Application DDMC state logic resides in ladder logic in the form of an SDS instruction Within this one instruction is all of the logic from the state diagram and state tables described earlier The SDS instruction is very powerful in the PLC 5 250 processor it can contain up to 255 states or steps In the PLC 5 processor the instruction can contain 76 steps with 8 inputs 45 steps with 16 inputs or 23 steps with 32 inputs You determine the number of states per SDS instruction through the decomposition process In our two station
83. ill need to analyze your application a bit further Figure 2 6 shows the basic mode of thinking you must go through to prepare a DDMC application of Level 2 or greater Much of this requires a good understanding of your machine or line and the motions it goes through to complete an operation Figure 2 6 Requirements for applying DDMC Decompose Your Machine Define States U Define Inputs and Outputs Define Transitions and or Conditions Develop State Diagrams and Tables Develop Your Program Ladder and DDMC Instructions Configure DDMC Instructions amp System if required Summary This chapter explained the various levels of DDMC implementation Read chapters 3 5 for examples on performing the steps shown in Figure 2 6 2 7 Chapter Objectives Decomposing Your Machine Getting Started with State Transition Conditional Logic Programming State transitional programming has several advantages This approach lets you represent machine functions in a step by step manner parallel to the way the control system operates combine the machine control program and the diagnostic program Read this chapter to learn techniques used to develop a state transition conditional logic application Some of the topics you must understand to develop your application include decomposing your machine developing a truth table developing a
84. ine 4 11 for a drill motor 3 11 for transfer line brake 5 16 feed advance rapid return 5 18 motor overload monitor 5 26 rapid advance 5 24 step description worksheet 4 18 3 A4 T terms and conventions P 3 transition 3 4 truth table 3 5 W WARNINGS and CAUTIONS 3 worksheets data 4 14 step description 4 18 ALLEN BRADLEY AROCKWELLINTERNATIONAL COMPANY With offices in major cities worldwide WORLD EUROPE MIDDLE HEADQUARTERS EAST AFRICA Allen Bradley HEADQUARTERS 1201 South Second Street Allen Bradley Europe B V Milwaukee WI 53204 USA Amsterdamseweg 15 Tel 1 414 382 2000 1422 AC Uithoorn Telex 43 11 016 The Netherlands FAX 1 414 382 4444 Tel 31 2975 43500 Telex 844 18042 FAX 31 2975 60222 Publication 6401 6 4 1 November 1992 Supersedes 6401 6 4 1 October 1991 As a subsidiary of Rockwell International one of the world s largest technology companies Allen Bradley meets today s challenges of industrial automation with over 85 years of practical plant floor experience More than 11 000 employees throughout the world design manufacture and apply a wide range of control and automation products and supporting services to help our customers continuously improve quality productivity and time to market These products and services not only control individual machines but integrate the manufacturing process while providing access to vital plant fl
85. information you need to complete the decomposition process Defining States A state corresponds to the physical status of a machine and its components such as motor off or motor on States can be normal or in error state is normal when it follows the expected operation state is in error when it occurs outside normal operation In the following example we have a motor that is controlled by one input an on off switch Figure 3 2 shows the relay logic diagram of the motor example Figure 3 2 Relay Logic Diagram of a Motor Switch 7 a Motor T We have two normal states in our motor example motor on motor off Figure 3 3 shows a schematic of our two normal states 3 3 Chapter 3 Geting Started with State Transition Conditional Logic Programming Figure 3 3 Normal States for Motor Defining Transitions In this case a single transition is the condition that provides direction to move from one state to another Normally we think of these conditions as inputs that change state or state transition Transitions may be caused by actuators sensors or elapsed times Conditions may be represented by an equation In our motor example we have two states motor on and motor off We also have two state transitions a Switch ON OFF Switch OFF Figure 3 4 shows a schematic of input transitions between our two normal output states Figure 3 4 Transitions for Motor Switch Motor
86. ion Logic 1 Ready Initial Start PB On Stop PB On MS Overload On 2 5 MS Overload X Start 4 Error Stop Off Normal Stop MS Overload Off MS Auxiliary Contact On Stop PB Off Chapter 3 Geting Started with State Transition Conditional Logic Programming Setting up a State Table Table 3 E shows the state table for the drill motor Blanks in the input transition column and next state column mean the state is ignored Table 3 E State Table for Drill Motor State Input Description Next State Output Description Output Status 1 Start PB OFF gt ON Motor Starter Auxiliary Contact Stop PB Motor Overload 2 Start PB ON gt OFF Motor Starter Auxiliary Contact OFF gt ON Stop PB Motor Overload ON gt OFF 3 Start PB Motor Starter Auxiliary Contact Stop PB Motor Overload 4 Start PB Motor Starter Auxiliary Contact Stop PB OFF gt ON Motor Overload 5 Start PB Motor Starter Auxiliary Contact Stop PB Motor Overload OFF gt ON A Combinatorial Logic Approach Another more practical approach to the drill motor example would be to utilize the combinatorial functionality available in the SDS to reduce complexity based on individual transitions Figure 3 9 shows the state diagram for the drill motor Instead of five states using the state transition method using the combinatorial approach we have only three states to be concerned with 3 11 Chapter 3 Geting Started with State Transition Conditiona
87. ional and diagnostic messages with the instruction such as tool change messages and operating instructions Figure 1 5 shows an example of the DFA configuration template For more information about the DFA configuration utility and steps for configuring the instruction refer to the DDMC User s Manual publication 6401 6 5 1 Figure 1 5 DFA Instruction Message Screen DFA for DFA 1 AT N9 0 Input Message TOOL CHANGE REQUIRED 1 000 02 LUBE FAULT 2 I 000 01 LUBE LEVEL LOW 3 1 000 06 NO PARTS PRESENT 4 I B3 03 LOAD PARTS IN STA 5 5 I 000 04 PLACE MACHINE IN AUTO MODE 6 O 000 05 TIME TO CALL MAINTENANCE 7 5 1 MACHINE OVER CYCLE Press a function key or enter input number Rem Prog 5 25 Addr 5 Change Display Exit Input Edit Input Mode Symbol Monitor Message State Fl F2 F3 F5 F8 DB TEST Accept Edits F10 This chapter gave you an overview of DDMC instructions and what they are used for Read chapter 2 to learn methods for implementing these instructions into your program Implementing DDMC to Specific Level Chapter Objectives You can implement DDMC instructions at different operational levels depending on the amount of diagnostics and control that you need for your application Each level provides incremental increases in terms of diagnostic coupling with the control Figure 2 1 shows levels of implementation Table 2 describes the levels Figure 2 1 Levels of DD
88. itions leading to or from it This is because all states except state 11 lead to the error state The error state in turn leads back to an INITIALIZATION state The INITIALIZATION state is discussed in the DDMC User s Manual publication 6401 6 5 1 We chose to eliminate the transition arcs to the error state to keep the state diagram readable You may want to do this in similar cases also Setting up a State Table Table 4 C shows the state table for drill station 1 Table 4 C State Table for Drill Station 1 State Input Description Input Transition Output Description Output Status 1 Returned LS State 10 Forward Motor Advanced LS State 10 Reverse Motor Full Depth LS State 10 Drill Motor Advance Command State 2 Return Command 2 Returned LS gt Forward Motor Advanced LS OFF gt ON Reverse Motor Full Depth LS OFF gt ON Drill Motor Advance Command ON gt OFF Return Command 3 Returned LS ON gt OFF State 10 Forward Motor Advanced LS OFF gt ON State 4 Reverse Motor Full Depth LS OFF gt ON State 10 Drill Motor Advance Command ON gt OFF State 11 Return Command 4 Returned LS ON gt OFF Forward Motor Advanced LS ON gt OFF Reverse Motor Full Depth LS OFF gt ON Drill Motor Advance Command ON gt OFF Return Command 5 Returned LS ON gt OFF Forward Motor Advanced LS ON gt OFF Reverse Motor Full Depth LS ON gt OFF Drill Motor Advance Command Return Command OFF gt ON 4 11 Chapte
89. l Logic Programming Figure 3 9 State Diagram of Drill Motor Combinatorial Logic Start PB ON amp Motor 2 Overload OK amp Stop PB ON Motor On 1 Motor Off Stop PB UN OFF Auxiliary Con tact ON OFF 3 Seal On Motor Over load ON OFF In Figure 3 9 we don t care about the order in which the Start PB Motor Overload and Stop PB transition to ON We only care that they are all on at the same time for us to go to the Motor ON step Table 3 F shows the conditional logic for the drill motor in a table form The 175 and 0 represent the states that are applicable to the operation of the drill motor The dashes represent don t care states Compare this table to the truth table on page 3 9 Table 3 F Conditional Logic Table for Drill Motor Outputs Using the conditional approach the sequence of input transitions is not considered or checked The diagnostic accuracy desired may be a factor in when to use or when not use this approach For the above example the diagnostics should retain a high degree of accuracy since the probability of all three conditions failing at the same time is low With the combinatorial SDS instruction functionality you can configure messages to annunciate all missing conditions 3 12 Summary Chapter 3 Geting Started with State Transition Conditional Logic Programming This chapter described the concepts of state transitional programming by devel
90. lementations for operator guidance refer to chapter 6 Applying DDMC Instructions to Common Mechanisms 2 5 Chapter 2 Implementing DDMC to a Specific Level Figure 2 5 DDMC Implementation Operator Guidance HAND PB COND 1 COND 2 COND 3 COMMAND REQUEST Old Logic I jt 1r E J L AUTO e s aia a Conditions 1 2 and 3 permissives such as All Stations Returned or All Stations Clamped are placed as inputs within an SDS instruction An interlock called OK is controlled within the SDS instruction HAND PB OK COMMAND REQUEST New Logic lf H t AUTO CYCLE OK TRIGGER J J PB1 CYC PB2 CYCLE L d 2 HAND J E c SDS i Jir PE Trigger jt O OK Control SDS Instruction SDS Condition 1 Condition 2 Condition monitoring SDS Condition 3 1 Instruction Chapter 2 Implementing DDMC to a Specific Level Preparing to Apply DDMC Now that you have an understanding of the DDMC philosophy and the Instructions extent to which you can implement the DDMC instructions to provide diagnostics and messaging you can begin building your application If you are building messaging only application Level 1 you use the DFA instruction with your traditional ladder program application that contains diagnostics control or operator guidance you w
91. mechanism Refer to chapter 6 for examples of applying DDMC instructions to common mechanisms The SDS instruction monitors the mechanism as it cycles from state to state Upon an invalid transition of an input or when the SDS instruction exceeds a predefined time period for a given step the instruction generates a fault message that details the mechanism s state and the input that had the invalid transition The ladder logic is used to control the outputs of the machine Both fault detection and fault message annunciation are performed by the SDS instruction Using Level 2 the following is true ladder logic controls the machine SDS instruction performs diagnostics PLC processor control and fault diagnostics are not integrated you should use the DFA instruction for discrete fault annunciation Figure 2 3 DDMC Implementation Level 2 Te af 1 L lE RES 1 1 t Advance Solenoid ca ca mm La Returned Solenoid F Advance Light E 11 Returned Light ER SDS Advance Solenoid de d c DE Return Solenoid Hx 2 3 Chapter 2 Implementing DDMC to a Specific Level Implementing DDMC for The Level 3 implementation of the SDS instruction requires the instruction Messaging Diagnostics and to perform the machine output control fault detection and fault message Control Level 3 annunciation The control logic an
92. mmand ON gt OFF STEP 1 4 4 18 Integrating the SDS Instruction with Ladder Logic Chapter 4 Organizing a Drill Machine Application Figure 4 10 shows a ladder program for the two station drill machine We have incorporated the state logic we developed for drill station 1 in the SDS instruction at rung 2 7 As previously mentioned the clamps have been kept in ladder logic only because they do not contain feedback sensors to say we are clamped preventing us from diagnosing a fault As a contrast we kept the entire control for drill station 2 in ladder logic even though it and drill station 1 are identical We did this so that you could see the manipulations made in the ladder program to accommodate the SDS instruction Figure 4 10 Ladder Program for Two station Drill Machine 4 19 Chapter 4 Organizing a Drill Machine Application Figure 4 10 Ladder Program for Two station Drill Machine continued 4 20 Chapter 4 Organizing a Drill Machine Application Figure 4 10 Ladder Program for Two station Drill Machine continued 4 21 Chapter 4 Organizing a Drill Machine Application Summary 4 22 In this chapter we showed you how to decompose a machine into manageable segments so that you could set up a state application We also took one segment created by decomposition and defined states and transitions with a state diagram and state table Read chapter 5 to see how to apply DDMC spe
93. motions brake engage feed rapid advance rapid return By further reducing the inputs in each segment we continue to simplify the SDS instructions Table 5 D View 2 of SDS Block Brake Engage Feed Rapid Advance Rapid Return Inputs Outputs 1 brake contactor energized 1 brake release indication brake release request brake release command feed motor starter energized feed advance command returned position limit switch returned indication e ro 2 3 5 6 advanced position limit switch advanced indication 7 torqued limit switch 8 feed request 14 feed motor overload 15 reset overload request 9 overload okay indication 4 rapid return motor starter energized 4 rapid return command 5 returned position limit switch 5 returned indication 9 rapid return request 10 rapid advance motor starter energized rapid advance command 11 feed position limit switch in feed area indication 12 rapid advance request 13 rapid advance return motor overloads 5 11 5 Organizing a Transfer Line Application Table 5 E shows the SDS block decomposed to three motions different from those shown in view 2 brake engage feed advance rapid return rapid advance View 3 looks beyond the physical device at the optimum motion pair The order of inputs and outputs has been changed from view 2 View i sat SDS Block Brake Engage Feed Advance Rapid Return
94. nds the feed limit switch N is activated de energizing the rapid motor A and engaging the brake O 9 When the brake O is engaged the input sun gear C locks up 10 The slide K speed is reduced to the feed rate as the feed motor B is still spinning the gearbox cage M 11 This actuates the advanced limit switch P in about 8 seconds 12 When the slide K advances to a mechanical stop a torque spring actuates a piston operated limit switch Q in about 1 second 13 When the feed motor B is turned off there is a short dwell time of about one second to ensure that the drilling is complete 14 When the rapid return motor R is turned on the effect of driving the gearbox cage M backward against the worm gear L locks up the cage 15 The rapid return then occurs at the rapid rate actuating the returned limit switch S about 2 seconds later 16 This turns the rapid return motor R off Based on the methodology presented in chapter 3 and recalling examples we can associate states with different movements from the sequence of operation decompose the slide into the following movements brake engage brake disengage rapid advance slide rapid return slide feed advance slide We stop our decomposition at this point and set up our state application from this level 5 6 Detailing the I O Chapter 5 Organizing a Transfer Line Application To determine states for our example we nee
95. ng to steps 4 9 in the sequence of operation at Table 4 A we Operation can logically define states for drill station 1 Table 4 B shows the analysis you must go through to turn steps of the sequence of operation into states State names appear in all capital letters Some steps may contain more than one state if more than one input transition changes within that step 4 8 Chapter 4 Organizing a Drill Machine Application Table 4 B Analysis of Steps in Sequence of Operation Step from Figure 4 4 Corresponding States When all motors are off and station 1 is looking for a command the station is RETURNED AND READY When station 1 receives the advance command the station is READY TO ADVANCE As station 1 moves forward it de activates LS3 meaning the station is ADVANCING 5 Once station 1 actuates LS4 the station is ADVANCED At this point the drill motor comes on Station 1 is still moving forward When station 1 actuates LS5 it stops moving forward meaning the station is AT FULL DEPTH The drill motor is still turning When station 1 receives a return command or has met full depth conditions it remains in position for three seconds that is at FULL DEPTH DWELL letting the drill clean out any chips remaining in the part When the timer for the three second dwell goes off station 1 is at FULL DEPTH AND RETURNING When station 1 retracts past and de activates 155 the station is ADVANCED AND RETUR
96. nsition Next State Output Description Output Status ON 1 Rapid Advance Return Overload OK Ind Motor Overloads OFF gt ON State 2 Feed Motor Overload OFF gt ON State 2 Reset Overload Fault 2 Rapid Advance Return Overload OK Ind OFF Motor Overloads Feed Motor Overload Reset Overload Fault OFF gt ON State 0 After you develop state diagrams and state tables for your SDS instructions double check your tables to see if there are any redundant states If you find redundant states eliminate them from your state table and diagram Summary Chapters 3 and 4 showed you how to organize an application that uses the DDMC philosophy From our transfer line example you can see how complex a simple slide movement can be from a state programming point of view You can use the methods detailed in this chapter to setting up state transition applications for other machines or lines Read chapter 6 to see how to apply the SDS and DFA instructions to common mechanisms on your line or machine 5 26 Chapter Objectives Applying the SDS Instruction to a Hydraulic Slide STA 7 ADVANCE SLIDE PB STA 7 CYCLE STATION B3 Applying DDMC Instructions to Common Mechanisms This chapters shows how the SDS and DFA instructions can be used with common mechanisms on your line or machine to perform control and diagnostic functions We show examples for the following mechanisms a hydraulic slide 3 posi
97. nterlocks Process interlocks are commands or conditions required for a number of operations within a sequence You can include process interlocks in an SDS instruction similar to the way you handle critical interlocks However if a process interlock fails all of the instructions that were tied to it would each generate the same error messages for a single failure We instead recommend implementing process interlocks like constantly monitored interlocks actually performing the interlocking in ladder logic and generate diagnostics information with the DFA instruction In this chapter you read about using the SDS instruction to provide guidance to your operators In addition we described some of the terminology common to using DDMC instructions for operator guidance Chapter 8 contains application information for logging IMC faults sent as messages by the PLC 5 processor 7 5 Chapter Objectives Configuring the IMC Fault Message Type Logging IMC Faults Sent as Messages by the PLC 5 Processor A special message type has been defined for an IMC fault within the DDMC system By using the message instruction MSG in PLC 5 software you can log IMC faults and send them to an operator interface terminal This procedure simulates the diagnostic messages sent by the SDS instruction In addition you can use this same IMC message format as means of integrating other devices such as drives into the DDMC fault display and logging u
98. ommon Mechanisms 5 ND Sed 9 orc bed ed WDNR OC 6 4 STEP 5 ADVANCED TIMER Input ID Transition Destination STA 7 ADV SLIDE REQ OFF gt ON STEP 4 STA 7 RET SLIDE REQ OFF gt ON STEP 6 ADVANCED LS ON gt OFF ERSTEP 11 RETURNED LS OFF gt ON ERSTEP 11 RESET SLIDE FAULT STEP 6 ADVD amp RETURNING TIMER 1 00 Input ID Transition Destination STA 7 ADV SLIDE REQ OFF gt ON INITIALIZE STA 7 RET SLIDE REQ ON gt OFF STEP 5 ADVANCED LS ON gt OFF STEP 7 RETURNED LS OFF gt ON ERSTEP 11 RESET SLIDE FAULT STEP 7 RETURNING TIMER 5 00 Input ID Transition Destination STA 7 ADV SLIDE REQ OFF gt ON INITIALIZE STA 7 RET SLIDE REQ ON gt OFF STEP 10 ADVANCED LS OFF gt ON ERSTEP 11 RETURNED LS OFF gt ON STEP 8 RESET SLIDE FAULT STEP 8 RETD amp RETURNING TIMER 0 00 Input ID Transition Destination STA 7 ADV SLIDE REQ OFF gt ON INITIALIZE STA 7 RET SLIDE REQ ON gt OFF INITIALIZE ADVANCED LS OFF gt ON ERSTEP 11 RETURNED LS ON gt OFF ERSTEP 11 RESET SLIDE FAULT STEP 9 STOP D BTW ADV amp RET TIMER 0 00 Input ID Transition Destination STA 7 ADV SLIDE REQ OFF gt ON STEP 3 STA 7 RET SLIDE REQ OFF gt ON STEP 7 ADVANCED LS OFF gt ON ERSTEP 11 RETURNED LS OFF gt ON ERSTEP 11 RESET SLIDE FAULT STEP 10 COASTING TIMER 0 50 Input ID Transition Destination STA 7 ADV SLIDE REQ STA 7 RET SLIDE REQ ADVANCED LS RETURNED LS
99. on stops all motion and reports a fault message This is how the SDS instruction is supposed to react however while the SDS is in the fault step it cannot detect other faults If an input card or switch faults while the overload is tripped the SDS cannot detect the fault and flag it Rather than use the SDS in this case we recommend that you use the Diagnostic Fault Annunciator DFA instruction The DFA is described below Manual inputs include anything that does not control machine motion such as pushbuttons on off switches and dials 1 5 Chapter 1 Understanding DDMC Instructions and their Purpose Understanding the DFA Instruction DFA DIAGNOSTIC FAULT ANNUNCIATOR Control File N10 0 Length 124 No of I O 16 Prog file number 3 Summary 1 6 EN The Diagnostic Fault Annunciator DFA instruction is a monitoring only instruction that is it cannot control outputs You must define the inputs in the instruction that you want monitored Valid inputs can be Storage points such as binary bits a counter timer done bits Outputs real or logical any valid bit address lube or level indicators alarms fault bits set by another device such as an IMC motion controller or ladder logic If you currently have diagnostics programmed in ladder logic you can use the DFA instruction to generate messages when a fault occurs In addition you can create other types of operat
100. onitoring Conditioning these instructions gives you the ability to disable them preventing the instructions from detecting false errors The unconditional SDS monitors the Power OK signal and generates a message should power be lost On many machines it is desirable to provide operators with guidance as to which operation he she should perform next This is especially important on machines which have a hand or manual mode of operation with multiple choices In many cases the operator needs to know exactly which manual command to initiate to satisfy logic control requirements You can provide this guidance with lighted push buttons that flash to prompt the operator to perform a specific action For example if the machine is stopped in mid cycle should the operator press the advance or return manual push button A flashing push button could eliminate this decision meaning operators could perform their jobs with less training on the machine Figure 9 4 shows an example of a circuit for providing flashing push buttons Table 9 B following the figure explains each rung of the logic 9 Other Application Examples Figure 9 4 Ladder Logic for Flashing Lighted Push Buttons HAND PUSH BUTTON OTHER ORIGINAL REQUEST 1 4E qi zd B J L J L AUTO L REQUEST LS INDICATOR LIGHT 2 F ORIGINAL REQUEST H
101. ontrol File N34 0 Step Name 0 INITIALIZATION RETD amp ADVANCING ADVANCING ADVANCED amp ADVANCING ADVANCED amp RETURNING Outputs Step Description File Step Chapter 6 Applying DDMC Instructions to Common Mechanisms 5 6 7 8 N35 0 Step Name RETURNING RETURNED FAULT COASTING I O CROSS REFERENCE Input Logical Address Address Symbol Address Comment 0 B3 60 B3 60 ADVANCE REQUEST 1 1 067 01 I 067 01 RETURNED LS 2 067 00 067 00 ADVANCED LS 7 B3 69 B3 69 RESET FAULT Output Logical Address Address Symbol Address Comment 0 O 067 00 0 067 00 ADVANCE SOL 1 B3 62 B3 62 RETURNED 2 B3 63 B3 63 BETWEEN ADVD amp RETD 3 B3 64 B3 64 ADVANCED Step Tables STEP 1 RETD amp ADVANCING TIMER 0 00 sec DISABLED MESSAGE OFF No Input ID Transition Destination No Output ID State 0 ADVANCE REQUEST ON gt OFF STEP 8 0 ADVANCE SOL ON 1 RETURNED LS ON gt OFF STEP 2 1 RETURNED ON 2 ADVANCED LS OFF gt ON ERSTEP 7 2 BETWEEN ADVD amp RETD OFF 7 RESET FAULT 3 ADVANCED OFF STEP 2 ADVANCING TIMER 2 00 sec WARNING MESSAGE OFF No Input ID Transition Destination No Output ID State 0 ADVANCE REQUEST ON gt OFF STEP 8 0 ADVANCE SOL O 1 RETURNED LS gt ERSTEP 7 1 RETURNED OFF 2 ADVANCED LS OFF gt ON STEP 3 2 BETWEEN ADVD amp RETD Q 7 RESET FAULT 3 ADVANCED OFF STEP 3 ADVANCED amp ADVANCING TIMER 0 00 sec DISABLED MESSAGE OFF No Input ID
102. oor data that can be used to support decision making throughout the enterprise ASIA PACIFIC CANADA LATIN AMERICA HEADQUARTERS HEADQUARTERS HEADQUARTERS Allen Bradley Hong Kong Allen Bradley Canada Allen Bradley Limited Limited 1201 South Second Street Room 1006 Block B Sea 135 Dundas Street Milwaukee WI 53204 USA View Estate Cambridge Ontario NIR Tel 1 414 382 2000 28 Watson Road 5X1 Telex 43 11 016 Hong Kong Canada FAX 1 414 382 2400 Tel 852 887 4788 Tel 1 519 623 1810 Telex 780 64347 FAX 1 519 623 8930 FAX 852 510 9436 PN 95578101 Copyright 1991 Allen Bradley Company Inc Printed in USA
103. oping a small state application for a motor and a drill motor We also showed you tools to help you identify states and transitions for your application such as setting up a truth table State diagram State table Chapter 4 builds upon the concepts presented in this chapter by developing a state application for a larger example Chapter Objectives Becoming Familiar with the Drill Machine Organizing a Drill Machine Application Read this chapter to get a better understanding of developing a Level 3 state transition application The machine we describe in this chapter a drill machine is not technically a real world application however the procedure will help you better understand the concepts for implementing a Level 3 state transition application In this chapter we describe the two station drill machine decompose the two station drill machine into manageable segments prepare a state diagram and state tables for one of the two station drill machine segments Figure 4 1 shows a diagram of a two station drill machine and all of its devices We first decompose the drill machine into manageable segments then we set up a state application for one of the segments created by decomposition Figure 4 2 shows the operation of our drill machine in a relay logic diagram 4 1 Chapter 4 Organizing a Drill Machine Application
104. or guidance we recommend that you keep those actions related to the motion of the mechanism in a separate SDS instruction Information for analyzing expected conditions that are being monitored by the SDS instruction and allow the operator s request to be acted upon should be kept in another SDS instruction You do this to reduce the complexity in the instruction and to display messages different than those used to indicate control faults You use the configuration utility differently to configure operator guidance messages than to configure warning messages To configure operator guidance messages you first analyze existing or standard request logic and relocate the permissive and interlocks from the ladder logic and put them in their own SDS instruction as shown in Figure 7 1 The permissives in the request logic must not allow for parallel paths Figure 7 2 shows the state diagram for the SDS instruction that monitors the conditions The state or step tables follow the state diagram 7 1 7 Applying DDMC Instructions for Operator Guidance Figure 7 1 DDMC Implementation Operator Guidance HAND PB COMMAND REQUEST Old Logic A th ME di dE qup 1 L Conditions 1 2 3 permissives such as All Stations Returned or All Stations Clamped are placed as inputs within an SDS instruction An interlock called OK is controlled wit
105. r 4 Organizing a Drill Machine Application 4 12 State 10 11 Input Description Returned LS Advanced LS Full Depth LS Advance Command Return Command Timer Returned LS Advanced LS Full Depth LS Advance Command Return Command Returned LS Advanced LS Full Depth LS Advance Command Return Command Returned LS Advanced LS Full Depth LS Advance Command Return Command Returned LS Advanced LS Full Depth LS Advance Command Return Command Returned LS Advanced LS Full Depth LS Advance Command Return Command Table 4 State Table for Drill Station 1 cont Input Transition gt OFF gt OFF gt OFF gt OFF OFF gt ON gt OFF gt OFF OFF gt ON ON gt OFF OFF gt ON OFF gt ON OFF gt ON OFF gt ON Next State State 10 State 10 State 10 State 5 State 7 State 10 State 10 State 8 State 11 State 10 State 9 State 10 State 11 State 1 State 10 State 10 State 3 State 8 Output Description Forward Motor Reverse Motor Drill Motor Forward Motor Reverse Motor Drill Motor Forward Motor Reverse Motor Drill Motor Forward Motor Reverse Motor Drill Motor Forward Motor Reverse Motor Drill Motor Forward Motor Reverse Motor Drill Motor Output Status Once you have defined states and transitions for one segment of your state application you can do the same for each of the other segments you want to program with state
106. r Starter ON gt OFF State 5 5 Advance Request OFF gt ON State 8 Advance Command OFF Return Request OFF gt ON State 6 In Feed Area Ind ON Feed LS ON gt OFF State 8 Advance Motor Starter OFF gt ON State 8 6 Advance Request OFF gt ON State 8 Advance Command OFF Return Request ON gt OFF State 5 In Feed Area Ind ON Feed LS ON gt OFF State 7 Advance Motor Starter OFF gt ON State 8 7 Advance Request OFF gt ON Advance Command OFF Return Request OFF gt ON In Feed Area Ind OFF Feed LS OFF gt ON Advance Motor Starter ON gt OFF 8 Advance Request Advance Command OFF Return Request In Feed Area Ind OFF Feed LS Advance Motor Starter 5 24 Chapter 5 Organizing a Transfer Line Application SDS 4 Motor Overload Monitor The inputs and outputs for the motor overload monitor are Inputs rapid advance return motor overloads feed motor overload reset overload request Outputs overload okay indication Figure 5 8 shows the state diagram of motor overload monitor Table 5 L shows the state table of motor overload monitor Figure 5 8 State Diagram for SDS 4 Motor Overload Monitor Rapid Advance Return we Motor Overloads On 1 Slide Overload OK Feed Motor Overload Motor Overload Off Slide Overload Error 5 Organizing a Transfer Line Application Table 5 L State Table for SDS 4 Motor Overload Monitor State Input Description Input Tra
107. r logic you can prioritize instruction by using conditional logic external to the instruction You can also use sequential function charts to schedule when SDS instructions are activated 9 Other Application Examples Figure 9 1 shows an example of prioritizing SDS instructions by providing conditional logic Figure 9 1 Conditional Logic for Prioritizing SDS Instructions f COND 1 I 3 User defined COND 2 Logi E C 1 Highest Priority UNCONDITIONAL 505 SMART DIRECTED SEQUENCER I EN Control File N10 0 Step Desc File 10 102 5 Length 144 No of Steps 12 HER Position Step 0 No of I O 8 ES Prog file number 3 COND 1 SDS J SMART DIRECTED SEQUENCER EN Control File N20 0 Step Desc File N20 102 5 Length 144 of Steps 14 ER Position Step 0 No of I O 8 ES Prog file number 3 Lowest Priority COND 1 COND 2 SDS E E SMART DIRECTED SEQUENCER EN Control File N30 0 Step Desc File N30 102 ST Length 144 No of Steps 8 ER Position Step 0 No of I O 8 ES Prog file number 3 Chapter 9 Other Application Examples Adding Power Loss Detection and Management Logic The SDS instruction cannot differentiate between the loss of field power to an input and the transition of that same input from on to off This loss of field power can create or trigger false error mess
108. ribes how to apply Distributed Diagnostics and Machine Control DDMC specifically the SDS instruction to your application In this manual we provide a tutorial for implementing state transition conditional logic programming decomposing your machine or line into manageable segments defining states inputs and outputs transitions and conditions developing state diagrams and state tables developing a program that uses ladder logic and DDMC instructions application examples for common mechanisms application examples for providing operator guidance a sample program for logging IMC faults sent as messages from the PLC 5 processor other sample programs We assume that if you are using this manual you have read the DDMC User s Manual publication 6401 6 5 1 This means you are familiar with the following the SDS instruction configuration utility the DFA instruction configuration utility PLC 5 hardware and programming software 1771 Allen Bradley operator interface and programming terminals the line or machine for which you are developing the program P 1 Preface Using this Manual Specific Sections of the This manual is divided into two sections The first focuses on learning to Manual 2 Section 1 Application Concepts Section 2 Programming Techniques build an application with the SDS DFA instructions This is demonstrated with a conceptual example of a drill machine and a re
109. rned LS Advanced LS Torqued LS Feed Motor Starter Return Motor Starter Feed Request Return Request Returned LS Advanced LS Torqued LS Feed Motor Starter Return Motor Starter Table 5 J State Table for 505 2 Feed Advance Rapid Return Input Transition OFF gt ON ON gt OFF OFF gt ON OFF gt ON OFF gt ON OFF gt ON ON gt OFF OFF gt ON ON gt OFF OFF gt ON OFF gt ON OFF gt ON OFF gt ON ON gt OFF OFF gt ON OFF gt ON OFF gt ON OFF gt ON ON gt OFF OFF gt ON OFF gt ON ON gt OFF ON gt OFF ON gt OFF OFF gt ON Next State State 2 State 5 State 25 State 25 State 25 State 25 State 1 State 25 State 25 State 25 State 25 State 3 State 25 State 13 State 25 State 4 State 25 State 25 State 25 State 25 State 14 State 25 State 25 State 5 State 25 State 25 State 15 State 25 State 25 State 25 State 6 State 25 State 25 State 1 State 25 State 25 State 25 State 7 State 25 Output Description Output Status Feed Adv Command Rap Ret Command Advanced Indication Returned Indication Feed Adv Command Rap Ret Command Advanced Indication Returned Indication Feed Adv Command Rap Ret Command Advanced Indication Returned Indication Feed Adv Command Rap Ret Command Advanced Indication Returned Indication Feed Adv Command Rap Ret Command Advanced Indication Returned Indication Feed Adv Command
110. sage instruction 8 1 messages configured for DFA instruction 6 14 program sample for logging faults 8 5 motor starter overloads in SDS instruction 1 5 0 operating mode SDS instructions 1 5 operator guidance 7 1 stamp example 6 10 permissive terminology 7 4 logic providing logic for logging faults 8 4 possible number of states formula 3 5 power loss detection and management logic 9 4 prioritizing SDS messages 9 2 process interlocks 7 5 R related publications 4 S scan dependencies 9 1 SDS instruction applying to mechanisms 1 3 associating motions to 5 9 combinatorial logic 1 2 in hydraulic slide example 6 2 in machine clamp example 6 5 in mechanical slide example 6 15 in part stamp example 6 10 information to include 1 4 overview 1 1 transitional logic 1 2 SDS message prioritization 9 2 sections in the manual P 2 sketching sample SDS blocks 5 9 spindle example 6 13 spring return valve example 6 10 state definition of 3 3 state diagram description 3 6 for a drill machine 4 10 for a drill motor 3 10 for transfer line brake 5 15 feed advance rapid returm 5 17 motor overload monitor 5 25 rapid advance 5 23 state programming advantages 3 1 drill machine example 4 1 drill motor example 3 8 transfer line example 5 1 state table description 3 7 for a drill mach
111. second level for example operations of a station on a transfer line suboperations of a machine or process fourth level decompose according to the physical movements of third level components for example movement of a component or a subassembly Once you reach the level at which your segments become manageable you can determine states for each segment Figure 3 1 shows the decomposition process The top block or level represents the overall system Other blocks in the pyramid show successive levels of decomposition Figure 3 1 Decomposition Process Overall System Levels of Decomposition Chapter 3 Geting Started with State Transition Conditional Logic Programming Methods of Decomposition To decompose a machine accurately you must understand how the machine operates You can use several methods to gain a better understanding of the relationships between the machine components at each level of decomposition For example Sketch a block or physical diagram of the line machine or components refer to blueprints of the machine if available describe the sequence of operation detail each operation refer to or develop a timing diagram for each operation Apply these methods as needed to obtain the
112. state diagram developing a state table Decomposition is the act of breaking a line or machine into manageable segments so that you can define states or steps and transitions conditions that determine which state or step the machine should be in A large machine or transfer line consists of many states far too many to be considered manageable in one state instruction When setting up a state application for a machine you need to first decompose the machine so that segments are manageable In addition decomposition with individual SDS instruction for each part of the machine provides more accurate and precise messages Levels of Decomposition Decomposition is a logical process performed in levels These levels vary for each machine depending on its size and complexity To determine levels for decomposition it is imperative that you know how your machine operates In the decomposition process your first level is the overall system machine or line Subsequent levels are actions parallel to one another all smaller portions of the system until you achieve segments that are manageable 3 1 Chapter 3 Geting Started with State Transition Conditional Logic Programming Logical decomposition levels could be second level decompose along physical lines of your system for example stations of a transfer line major operations of a machine or process third level decompose along functional lines of your
113. states for drill motor Several of these states though probable are not practical for this application For example it is unlikely that you will press the START PB and STOP PB at the same time or that all four inputs will be false at the same time Likewise it makes little sense to worry about the START PB or the START AUXILIARY CONTACT when the motor overload is tripped since it overrides both Once you have developed a truth table for possible states you must evaluate each state for your application and narrow the truth table down to practical states As you do this think of the sequence of operation and try to put the states in order so you can develop your state diagram 3 9 Chapter 3 Geting Started with State Transition Conditional Logic Programming Table 3 D shows the truth table of practical states for the drill motor application Table 3 D Truth Table of Practical States for Drill Motor Inputs Outputs Start PB Auxiliary Contact Stop PB Motor Overload Motor Starter 2 Setting up a State Diagram Figure 3 8 shows the state diagram for the drill motor example Note that the diagram consists of only five states Our truth table of practical states contained seven In this case rows or states 3 and 4 and rows 6 and 7 in the table could be combined since the state of the START PB varied and did not change the operation Figure 3 8 State Diagram of Drill Motor State Transit
114. te 10 State 25 State 19 State 25 State 25 State 25 State 25 State 11 Feed Adv Command Rap Ret Command Advanced Indication Returned Indication Feed Adv Command Rap Ret Command Advanced Indication Returned Indication Feed Adv Command Rap Ret Command Advanced Indication Returned Indication Feed Adv Command Rap Ret Command Advanced Indication Returned Indication Feed Adv Command Rap Ret Command Advanced Indication Returned Indication Feed Adv Command Rap Ret Command Advanced Indication Returned Indication Organizing a Transfer Line Application OFF 5 21 5 Organizing a Transfer Line Application Table 5 J State Table for 505 2 Feed Advance Rapid Return cont State Input Description Input Transition Next State Output Description Output Status 25 Feed Request Feed Adv Command OFF Return Request Rap Ret Command OFF Returned LS Advanced Indication OFF Advanced LS Returned Indication OFF Torqued LS Feed Motor Starter Return Motor Starter State 0 SDS 3 Rapid Advance The rapid advance has four inputs and two outputs They are Inputs rapid advance motor starter confirmation feed position limit switch rapid return request rapid advance request Outputs in feed area indication rapid advance command Figure 5 7 shows the state diagram for the rapid advance Table 5 K shows the state table for the rapid advance 5 22 C
115. the Second Level Stations In a transfer line application decomposing to the second level requires dividing the system along physical lines By looking at the block diagram Figure 5 1 we see transfer and clamping mechanisms and a series of stations Therefore we can decompose the line into 27 separate stations the 25 stations on the line the transfer mechanism and the clamping mechanism Chapter 5 Organizing a Transfer Line Application Decomposing to the Third Level Operations Once you have determined the second level of decomposition stations you must decompose each of the stations to the next level in this case operations We have selected station 10 line bore and ream L H slide station to decompose to operations At this point we want to look at the subassemblies that make up station 10 If the subassemblies require further breakdown we will continue the decomposition process Several operations are performed at station 10 The subassemblies performing these operations are clamp lower lock line bore feed reamer feed slide index table a slide feed Because each subassembly contains several components we want to continue decomposing to determine manageable segments Decomposing to the Fourth Level Motions From station 10 we have selected the slide to decompose into motions To decompose the slide we must look very closely at the motions the slide components make through their
116. tilities Read this chapter to learn the techniques for logging this fault Important This procedure assumes you are familiar with programming 6200 Series software the message instruction function and structure and IMC MML programming To configure the IMC message type you must perform the following tasks configure the message instruction edit the data table provide PLC logic Configuring the Message Instruction To configure the message instruction do the following 1 Create a message instruction in your program 2 Configure the message instruction within the Message Instruction Data Entry screen as shown in Figure 8 1 8 1 Chapter 8 Logging IMC Faults Sent as Messages by the PLC 5 Processor Figure 8 1 Message Instruction Data Entry screen INSTRUCTION DATA ENTRY FOR CONTROL BLOCK 12 20 Communication Command Local Node Address Destination Data Table Address PLC 5 TYPED WRITE PLC 5 Data Table Address N12 0 Size in Elements 13 Local Remote LOCAL Remote Station N A Link ID N A Remote Link Type 77 IMC BLOCK SIZE 9 WORDS Press a key to change a parameter or lt ENTER gt to accept parameters gt Forces None Program Edits None 5 15 Addr 0 DDMCIMC Command PLC 5 Size in Local Remote Link Remote Local Destin Type Address Elemnts Remote Station ID Link Node Address Fl F2 F3 F4 FS F6 7 F8 F9 Editing the Data Table You must edit the
117. tion to a Hydraulic Slide Applying the SDS Instruction to a Machine Clamp Detented Valve Applying the SDS Instruction to a Part Stamp Spring Return Valve Applying the DFA Instruction toa Spindle Applying the SDS Instruction to a Mechanical Slide SUMMER M r Applying DDMC Instructions for Operator Guidance Chapter Getting Started with Providing Operator Guidance Understanding Interlock Terminology Summary Logging Faults Sent as Messages by the 5 Processor Chapter Configuring the IMC Fault Message Type Sample Motion Program Which Reports Errors Table of Contents ili Other Application Examples 9 1 Chapter Objectives 9 1 Accounting for Scan Dependencies 9 1 Prioritizing SDS Messages 9 2 Adding Power Loss Detection and Management Logic 9 4 Providing Flashing Push Buttons for Operator Guidance 9 7 SDS Instruction Worksheets Appendix Overview 1 Manual Objectives Audience Preface Using this Manual This manual desc
118. tion valve with 2 limit switches machine clamp detented valve part stamp spring return valve spindle mechanical slide For each example above we show ladder logic the SDS or DFA step directory for the mechanism number and names of steps the inputs and outputs defined for the instructions Step tables for each step The following three lines of logic are for a hydraulic slide From a request logic standpoint there is no apparent difference between this logic and the request logic for other types of slides The difference is in the SDS configuration The configuration for the hydraulic slide is set up for a 3 position valve Detented spring return or other types of valves would have a different configuration 5 7 5 7 CLAMP ISTA 7 SLIDE AUTO SS ADVANCED SLIDE REQ FAULT 1 066 B3 B3 N28 0 JZ p Sees a 07 54 41 12 ISTA 7 FULL DEPTH 0 066 eee 07 STA 7 ADV SLIDE REQ B3 6 1 6 Applying DDMC Instructions to Common Mechanisms The SDS instruction in this line of logic is used to control the hydraulic slide for station 7 POWER ON POWER HYDRAULIC DWELL CRM SLIDE 4 1 001 XSDSs 5 c 2 d Je SSS MET a SSS SMART DIRECTED SEQUENCER EN DN 00 Control File N28 0 Step Desc File N29 0 ST ILength 143 INo of Steps 114 IPosition Step 0 INo of I O 8 E
119. total states compared to 50 52 49 and 62 from the other views From Table 5 H view 4 is the clear choice when considering the total number of states that we must investigate when setting up a state application View 4 has 142 possible states while the others have 32 768 8196 260 and 260 View 4 provided us with the most manageable segments for setting up a state application In this section we set up a state diagram and state tables for each of the four segments that become our SDS instructions The four segments are brake feed advance rapid return rapid advance motor overload Chapter 5 Organizing a Transfer Line Application SDS 1 Brake The brake has two inputs and two outputs They are Inputs brake contactor energized brake release request Outputs brake release indication brake release command Figure 5 5 shows the state diagram for the brake Table 5 I shows the state table for the brake Figure 5 5 State diagram for SDS 1 Brake Release amp Brake Contactor Energized Off Release Req On Release Req Off 0 Initialization Step Brake Holding amp Collapsed Brake Contactor Energized On Brake Contactor Energized Off Brake Error Brake Releasing Collapsing Brake Contactor Energized Off Release Req Off Brake Contactor Energized On Release Req On Brake Released
120. uate which logic is handled best in ladder programming and which works best in state programming before setting up your SDS instructions With larger applications that require decomposing to the motion level you may want to associate the physical movements with SDS instructions This lets you determine how many instructions you need to achieve a manageable number of states per instruction You can do this by 1 sketching a sample SDS block of the operation 2 breaking the block into multiple SDS instructions 3 picking one view to develop into SDS instruction 5 Organizing a Transfer Line Application Sketching a Sample SDS Block Table 5 B shows the sample single SDS block with all physical and logical inputs and outputs Using the large block as one SDS instruction we have 215 32 786 possible states Because this is too complex to handle as one SDS instruction we want to decompose the large block into smaller blocks with fewer possible states Table 5 B Sample SDS Block of the Operation 15 Inputs and 9 Outputs Inputs Outputs 1 brake contactor energized 1 brake release indication 2 brake release request 2 brake release command 3 feed motor starter energized 3 feed advance command 4 rapid return motor starter energized 4 rapid return command 5 returned position limit switch 5 returned indication 6 advanced position limit switch 6 advanced indication 7 torqued limit switch 8 feed r
121. urned Indication Torqued LS OFF gt ON State 25 Feed Motor Starter OFF gt ON State 25 Return Motor Starter ON gt OFF State 25 11 Feed Request OFF gt ON State 25 Feed Adv Command Return Request ON gt OFF State 18 Rap Ret Command Returned LS OFF gt ON State 12 Advanced Indication Advanced LS OFF gt ON State 25 Returned Indication Torqued 15 OFF gt ON State 25 Feed Motor Starter OFF gt ON State 25 Return Motor Starter ON gt OFF State 25 12 Feed Request OFF gt ON State 25 Feed Adv Command Return Request Rap Ret Command Returned LS ON gt OFF State 25 Advanced Indication Advanced LS OFF gt ON State 25 Returned Indication Torqued LS OFF gt ON State 25 Feed Motor Starter OFF gt ON State 25 Return Motor Starter ON gt OFF State 1 5 19 5 Organizing a Transfer Line Application Table 5 J State Table for 505 2 Feed Advance Rapid Return cont State Input Description Input Transition Next State Output Description Output Status 13 Feed Request OFF gt ON State 3 Feed Adv Command OFF Return Request OFF gt ON State 25 Rap Ret Command OFF Returned LS ON gt OFF State 14 Advanced Indication OFF Advanced LS OFF gt ON State 25 Returned Indication ON Torqued LS OFF gt ON State 25 Feed Motor Starter ON gt OFF State 1 Return Motor Starter OFF gt ON State 25 14 Feed Request OFF gt ON State 4 Feed Adv Command OFF Return Request OFF gt ON State 25 Rap Ret Command OFF R
122. wo cylinders of equal length connected together to produce a three position shuttle The shuttle has three switches to indicate each of its three positions Figure 1 4 In this case the shuttle s movement is sequential each movement depends on the movement that just occurred In this situation a single SDS instruction would work well to diagnose faults accurately and provide precise messages Chapter 1 Understanding DDMC Instructions and their Purpose Figure 1 4 Three position shuttle with two cylinders and three switches Gylinder 2 L Cylinder 1 T i LS3 LS2 151 For more information on applying the SDS instruction to a particular mechanism refer to chapter 6 Applying DDMC Instructions to Common Mechanisms What Information Should the SDS Instruction Include The SDS instruction works with ladder logic to provide control and diagnostics for your application You can use the instruction to varying degrees to achieve your desired level of diagnostics and control Some instructions can become quite complex if you try to include too much information We provide the following recommendations for keeping your SDS instructions as simple as possible Limit inputs to motion requests from sequencing logic position indicators a fault reset request if applicable interlocks Limit outputs to motion actuator devices position indicating lights bits C

6401-6.4.1, Distributed Diagnostic and Machine Control, Application

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