Home

1.0 INTRODUCTION - EngineeringEdu.org

1. PLC IO Table PLC 10 Table A Initialise CPU Bus settings Yes No A Are you sure you want to create the IO Table Yes No CHM CPU11 Program CJIM CPU11 Program PLC IO Table NewPLC1 PLC IO Table NewPLC1 BE Hele Z eaa Hele siy malela Fi CJ1M CPU11 fl CJ1M CPU11 4 Inner Board 4 Inner Board H Transfer from PLC Transfer from PLC Select the transfer target data and press the Transfer utton Comment information is deleted if IO T able is transferred Transfering iv IO Table v SIO Unit Parameters Cancel CJIM CPU11 Program CJIM CPU11 Program Figure 8 7 Demonstration of Create PLC IO Table in CX Programmer The status of the data transfer from PLC to computer will be shown when the Transfer Result dialog shows up If it is successful the dialog will write Transfer Success 1 Unit and Transfer Unsuccessful 0 Unit Press OK button to close the dialog Meanwhile in PLC IO Table dialog under the 0000 Main Rack the relevant unit of the PLC are all set as shown in the Figure 8 7 80 iH PLC 10 Table NewPLC1 File Edit View Options Help el allel dale a gt Bl Al x qe CILM CPU11 tig Inner Board g 00001 Main B na 1525 C1 W ETNZ1 ETNz21MadeXEthernet Unit Unit 01 0000 CJ1W ID211 DcC Input Unit 02 0001 CJ1W Ocz11 Relay Output Unit 03 0002 Empty Slot 04 0002 Empty Slot o5 0002 Empty Slot o6 0002 Empty Slot oF
2. L NO Figure 2 14 Star connected topology 17 A star connected topology is designed in the way that with each node example file server workstations and peripherals connected directly to a central network hub switch or concentrator 17 Data on a star network passes through the hub switch or concentrator before continuing to its destination The hub switch or concentrator manages and controls all functions of the network It also serves as a repeater for the data flow This configuration is common with twisted pair cable however it can also be used with coaxial cable or fibre optic cable 17 The IEEE 802 3 standard also states the data frame format that 1s required for all MAC implementations including optional formats that are used to expand the basic capability of the protocol The 7 field data frame format structure is illustrated in Fig 2 15 26 C13 ele 2 risoome a Figure 2 15 IEEE 802 3 data frame format Fig 2 16 illustrates the MAC frame for the transmission rates with Gigabit carrier extension field 7 1 6j 6 2 Variable 4 variable Figure 2 16 MAC frame with Gigabit carrier extension 2 5 IP Address Every machine interfaced to a router or host in a network has a unique identifying number called an IP address IP Address is the acronym for Internet Protocol address 14 18 Example below illustrates how IP address looks like 192 168 1 45 An IP add
3. 0002 Empty Slot o8 0002 Empty Slot 09 0002 Empty Slot CJ1M CPLI 1 Program Figure 8 8 Succesfully created PLC IO Table in CX Programmer Then double click the CJIW ETN21 ETN21 Mode Ethernet Unit so that the CJIW ETN21 ETN21 Mode Edit Parameters dialog will appear Make the configuration as demonstrated in Figure 8 8 then left click the Transfer PC to Unit button and the PLC will restart CJ1W E1TN21 ETN21Mode Edit Parameters Setting FINS TCP DNS SMTP POP Mail Address Mail Send Mail Receive Clock Auto Adjustme 4 gt Broadcast FINS UDP Port FINS TCP Port TCP IP keep alive All1 4 3BSD f Default 9600 Default 9600 o min 0 default 120 C All0 4 2BSD C User defined C User defined o mM Destination IP address v Change to dynamic IP Address Conversion Baud Rate 10 1 135 46 Auto dynamic Auto C Auto Static C 10BASE T Sub net Mask C Combined 255 255 252 Q0 C IP address table IP Address T able Login AT 010 001 136 045 ll Password ica Port No fo 0 Default 21 Transfer Unit to PC Transfer PC to Unit Compare SoftSw Restart Set Defaults Cancel Figure 8 9 CJIW ETN21 Configuration in CX Programmer 81 If the error alarm indicator in the PLC is light up restart the PLC by turn off and turn it on again Once the error alarm is off left click the amp button again to disconnect the connection Then right cli
4. Device Manager The Device Manager lists all the hardware devices installed on your computer Use the Device Manager to change the properties of any device ev j Driver Signing lets you make sure that installed drivers are compatible with Windows Windows Update lets you set up how Windows connects to Windows Update for drivers Hardware Profiles Drivers 2 Hardware profiles provide a way for you to set up and store za different hardware configurations Hardware Profiles System Properties window in Windows XP For Windows XP select the Hardware tab and left click the Device Manager Meanwhile for Windows Vista look at the top right of the window under the Task left click the Device Manager Figure 8 2 Afterwards expand the Ports COM amp LPT and select the relevant port The actual port is used in this project COM35 however the COM1 will be used as demonstration purpose only Figure 8 2 76 Device Manager File Action View Help E amp HD m m Computer S Disk drives 2 Display adapters 3 DVD CD ROM drives a Human Interface Devices 3 IDE ATA ATAPI controllers Se Keyboards Mice and other pointing devices Monitors BB Network adapters BB Broadcom NetLink TM Gigabit Ethernet B Cisco Systems VPN Adapter Y Ports COM amp LPT 9 ECP Printer Port LPT1 SB Processors Sound video and game controllers Se Storage volumes System devices Un
5. button again Let the Optimisation Method to be default which is Write only latest value for all tags and the Duty Cycle is 10 writes for every read Click Next button and let the port number remain as 9600 Click Next button again and follow by Finish button to close this window as demonstrated in Figure 8 15 Now the channel had been successfully setup 86 New Channel Network Interface x New Channel Write Optimizations x equivalent C Write all values for all tags Write only latest value for non boolean tags Write only latest value for all tags Duty Cycle Perform fio 4 writes for every 1 read lt Back wel c9 99 oem we c n9 New Channel Communications Parameters New Channel Summary x If the following information is correct click Finish to save the settings for the new channel Default Write Optimization Write only latest value for all tags 10 writes per read Port Number 9600 lt Back Rs Cancel He Figure 8 18 Demonstration of New Channel setting up in NI OPC Servers After that create the device by left click the Click to add a device link Name the device depend on the user preference which in this project the name is CJIM CPU11 ETN21 Then perform the configuration as illustrated in Figure 8 16 The Device model is CJ series Since the IP address of the PLC is 10 1 136 46 the device ID should be identical with it and the Destination Node Number wi
6. i ut raft ined 3 steer bed ocean utut rlontedubrory ntdbrry 3 ssmssss Figure 8 27 Multiple Variable Editor window 94 Once the shared variables had been successfully created the list of OPC tags will be shown in the Project Explorer window under the Untitled Library 5 library as illustrated in Figure 8 25 Fille Edit View Project Operate T EF E My Computer d Untitled Library 1 BE OPCI jJ 9a inputbiti a nouti outputbit1 1 putputbit5 9 outputbite 2 J 9 outputbit m Dependencies Build Specifications 93 outputbitz Ta Figure 8 28 Project Explorer with shared variables in LabVIEW In order to use the shared variable in the VI firstly create the new VI by right click on the My Computer and then select New VI then Front Panel window will pop up Then drag the relevant shared variable into the Front Panel window For example in this case the inputbitl had been dragged and put into the Front Panel Do notice that the inputbitl appear as push button in the Front Panel as illustrated in Figure 8 26 95 Figure 8 29 VI Front Panel with shared variable push button in LabVIEW In order to open the Block Diagram window press Ctrl E in keyboard The inputbitl appeared as Boolean input in Block Diagram as shown in Figure 8 27 Untitled 1 Block Diagram on Untitled Project 1 My Computer Figure 8 30 VI Bl
7. demonstrates the step by step configuration and setup of the NI OPC Server Before performing the configuration below it is important to ensure that the LabVIEW Datalogging and Supervisory Control Module had been installed properly in the computer The demonstration in this chapter is performing under the Windows Vista Basic operating system and the LabVIEW used is LabVIEW 2009 Therefore the explanation might be slightly different if the users are using other operating system in their computer Firstly launch the NI OPC Server by left click Start gt gt All Programs gt gt National Instruments gt gt NI OPC Servers gt gt NI OPC Servers Then left click the File tab and select the New option Double click the Click to add a channel link and the New Channel Identification will show up as illustrated in Figure 8 15 New Channel Identification X channel name can be from 1 to 256 Channel name Channel lt Back Net gt Cancel Hep Figure 8 16 New Channel naming in NI OPC Servers 85 Left click Next button to continue Select the device driver to Omron FINS Ethernet as demonstrated in Figure Figure 8 4 New Channel Device Driver i X ct the device driver you want to assign to channel The drop down list below contains the names of Figure 8 17 Device driver selection in NI OPC Servers Left click Next button to continue Let the Network Adapter as default then click Next
8. devices microwave devices etc Meanwhile topology refers to physical layout of devices The network topology can have a significant effect on the performance and efficiency of the network and growth potential Whereas protocols are the set of rules that are agreed to enable communication between devices Whilst operating systems are the software running on the background managing the sharing of equipment and data between the network nodes 11 Communication process between two devices A to B 1s illustrated in Figure 2 10 11 Network software Network software Protocol Interface Interface ali tit Medium of communication Figure 2 10 Process of communication of networked devices 11 17 2 4 2 Overview of Protocols Protocol is a set of rules that are agreed by related authorities in order to allow successful communications between devices Protocols are created according to the Open System Interconnection OSI reference model The seven layers of OSI reference model are illustrated in Figure 2 12 12 OSI Layer Common Protocols Application Presentation HTTP FTP SMTP DNS Session Transport Network Data Link Ethernet Physical Figure 2 11 Seven Layers of OSI Reference Model 12 The seven layers of the OSI reference model can be divided into lower layers 1 4 and upper layers 5 7 The lower layers focus on data transport functions while the upper layers focus on the applications 1
9. if a gt 49 Else if a is more than or equal to 49 then x equals to 1 y xz y 1 z 1 equals to 1 and z equals to 1 else Or else x equals to 0 y equals to 0 and z equals to O x 0 y 0 z 0 Table 4 3 below explained the relationship between the multi step speed references through 3 and frequency references 1 through 8 54 Table 4 3 Relationship between multi step speed references and frequency references 5 Frequency reference Multi step speed Multi step speed Multi step speed reference 1 reference 2 reference 3 Set value 6 Set value 7 Set value 8 Frequency reference 1 Frequency reference 2 Frequency reference 3 OFF OFF The concept of frequency varying in Table 4 3 1s crucial as the PLC communicate with the variable frequency drive in Boolean format The value of each frequency reference can be set in the function parameters of the variable frequency drive refer to Table 3 1 In this thesis the value of each frequency reference had been tabulated in both Table 3 1 and Table 4 4 Table 4 4 Conditions of Input Frequency in LabVIEW for varying frequency reference Frequency Multi step Multi step Multi step Output Frequency Input Range speed speed speed of Squirrel Cage in LabVIEW reference 1 reference 2 reference 3 Induction Motor Outputbit5 Outputbit6 Outputbit7 55 By referring to Table 4 4 as long as the user had set the input frequency according to any of the conditio
10. in LabVIEW Now user can draw a wire from nputbit1 into Outputbitl without showing any error as illustrated in Figure 8 30 Project Untitled Project 1 B 3 Untitled Library 1 i Untitled Library 2 Figure 8 33 Wire the input and output shared variable in LabVIEW 98 Next in order to ensure the program run continuously until the user pressed the stop button a While Loop execution control function is needed In LabVIEW this can be done by simply right click anywhere in the Block Diagram window and the Function Palette will appear In the Function Palette under the Express tab choose Execution Control gt gt While Loop as demonstrated in Figure 8 31 P Untitled 1 Block Diagram on Untitled Project 1 My Computer Ele Edit View Project Operate Tools Window Help e je gl olet Sea 5 x G o Real ti WhileLoop FlatSequence Case Structure x CRI al Time Delay Elapsed Time Figure 8 34 Create While Loop in LabVIEW Part 1 After that drag the mouse from left side to cover the whole program as demonstrated in Figure 8 32 99 Untitled 1 Block Diagram on Untitled Project 1 My Computer File Edit View Project Operate Tools Window Help Sme valet iss Sea Figure 8 35 Create While Loop in LabVIEW Part 2 Now the demonstration of using shared variable in LabVIEW had done User can test the program by run the software and control it in F
11. it 19 31 2 Human Machine Interface HMI Human machine interfaces HMI are graphical representations of a system that consist of system configurations alarms data collection and trend logging capabilities The HMI is usually hosted in the computers of the master station where it can remotely monitor and control processes and field devices with the click of a button HMIs can also be configured to remotely monitor and control plant processes or field devices from other computers within a plant Ethernet network or the Internet However it is advisable that user monitoring and control permissions as well as control time granted to the user s to be restricted to a certain period and group This is to ensure that control is given to the appropriate user to avoid unauthorized action that can affect the system s operability 14 32 3 0 PROJECT DESIGN CONFIGURATION amp PREPARATION 3 1 NI OPC Server NI OPC Server was used in this project as it has OMRON FINS Ethernet driver that allow the communication between OMRON CJIM CPUIT ETN21 PLC with LabVIEW OMRON originally supplies their customers with FINS gateway interfacing software that communicates with the PLC and its proprietary software OMRON CX Programmer over the Ethernet network 14 With the OMRON FINS Ethernet driver in NI OPC users can setup the server by just a few simple setups and create variable tags that can be links directly to the PLC s registers These ta
12. left and Rotor Construction right Stator windings which are positioned around the rotor will generate rotating magnetic field as they move quickly over the rotor when supplied with three phase power From this process current is induced in the rotor conductors and when it interacts with the rotating magnetic field by the stator caused the rotating movement of the rotor 5 The speed of the motor which is known as the synchronous speed can be expressed by the following formula 10 120f xd Equation 1 Where Ns synchronous speed of the motor f frequency of the power supply P number of poles of the motor 11 Equation 1 shows that the speed of the motor is proportional to the frequency of the power supply which explains the concept at the output part of the project 1 e controlling induction motor by altering the frequency of the power supply However according to the load torque induction motor never runs at synchronous speed but slightly less The difference in these two speeds is the slip of the motor usually expressed in percent and is given by o NN Ne 7 gilt ead Ug REPRE Equation 2 Where S c slip Ns synchronous speed of the motor N rotating speed of the motor 12 2 4 Ethernet 2 4 1 Overview of Instrumentation Networking Communication 1s one of the essential tools 1n monitoring and control system as the data transfers between the control units and the
13. network chap5 chap5 htm 18 How Stuff Works 2001 January What is an IP Address Online http computer howstuffworks com internet basics question549 htm 19 National Instruments What is OPC Online http zone ni com devzone cda tut p id 7451 20 National Instruments LabVIEW FAQs Online http www ni com labview fag htm 21 National Instruments Getting Started with LabVIEW National Instruments 373427F 01 2009 22 National Instruments Connect LabVIEW to Any PLC Using OPC Online http zone ni com devzone cda tut p id 7450 23 National Instruments Using the LabVIEW Shared Variable Online http zone ni com devzone cda tut p id 4679 24 OMRON Industrial Automation SYSMAC CJ Series Programmable Controllers Operation Manual W393 E1 14 2009 25 OMRON Industrial Automation CJ1M CPU Units with Ethernet Functions Operational Manual 2005 26 OMRON Industrial Automation Sysdrive 3G3MV Multi function Compact Inverter User Manual 2001 Online http www limasoft eu omron pdf 3G3MV en manual pdf 27 National Instruments Basic TCP IP Communication in LabVIEW Online http zone ni com devzone cda tut p id 2710 28 National Instruments Connect LabVIEW to Any Industrial Network and PLC Online http zone ni com devzone cda tut p id 5407 29 National Instruments Controlling a 3 Phase A C Motor Using LabVIEW and FieldPoint Online http zone ni com devzone cda tut p id 4
14. octet from 1 to 126 are part of this class The other three octets are used to identify each host This means that there are 126 Class A networks each with 16 777 214 27 2 possible hosts for a total of 2 147 483 648 2 unique IP addresses Class A networks account for half of the total available IP 28 Loop Back Class B Class C addresses In Class A networks the high order bit value the very first binary number in the first octet is always 0 Net Host or Node 115 24 53 107 The IP address 127 0 0 1 1s used as the loop back address This means that it is used by the host computer to send a message back to itself It is commonly used for troubleshooting and network testing Used for medium sized networks A good example is a large college campus IP addresses with a first octet from 128 to 191 are part of this class Class B addresses also include the second octet as part of the Net identifier The other two octets are used to identify each host This means that there are 16 384 2 Class B networks each with 65 534 2 2 possible hosts for a total of 1 073 741 824 2 unique IP addresses Class B networks make up a quarter of the total available IP addresses Class B networks have a first bit value of 1 and a second bit value of O in the first octet Net Host or Node 145 24 53 107 This class is commonly used for small to mid size businesses IP addresses with a first octet from 192 to 223 are pa
15. the situation in Figure 5 11 and Figure 5 12 respectively Tag Name Outputbit1 i Tag Name Outputbit6 PLC Address Q1 01 PLC Address Q1 06 Connected to VFD S1 Connected to VFD S6 Figure 5 11 PLC Output for forward direction and frequency 14 Hz Figure 5 12 VFD frequency meter for forward direction and frequency 14 Hz 63 If the user increases the input frequency range to a value that is within 21 Hz and less than 28 Hz then the outcome that can be seen in the PLC and the VFD frequency meter will be identical with the situation in Figure 5 13 and Figure 5 14 respectively Tag Name Outputbit1 PLC Address Q1 01 Connected to VFD S1 Tag Name Outputbit5 PLC Address Q1 05 Connected to VFD 5 Tag Name Outputbit6 PLC Address Q1 06 Connected to VFD S6 Figure 5 13 PLC Output for forward direction and frequency 21 Hz Figure 5 14 VFD frequency meter for forward direction and frequency 21 Hz 64 If the user increases the input frequency range to a value that is within 28 Hz and less than 35 Hz then the outcome that can be seen in the PLC and the VFD frequency meter will be identical with the situation in Figure 5 15 and Figure 5 16 respectively Tag Name Outputbit1 Tag Name Outputbit7 PLC Address Q1 01 PLC Address Q1 07 Connected to VFD S1 Connected to VFD S7 Figure 5 15 PLC Output for forward direction and frequency 28 Hz Figure 5 16 VFD fre
16. virtual instrument design and the description of the program Is for Testing and Verification It shows the testing outcome of the project implementation This section is Conclusion summarises the overall project Is the Recommendations It describes the future recommendation that can be implemented in the system demonstrated in this thesis 2 0 BACKGROUND 2 1 Programmable Logic Controller PLC 2 1 1 Overview of PLC PLC is industrial computer in which the hardware and software had been specially designed to adapt in the industrial environment PLC can be used to monitor inputs and depending upon their state make decisions based on its program or logic to control turn on off its outputs to automate a machine or a process 1 They are used in many applications such as material handling machining packaging automated assembly and countless other industries Before the automotive industry discovered the advantages of PLC the process of modifying relay circuitry was a headache process In the past annual car model changes forced plant engineers to constantly modify production equipment managed by relay circuitry In some cases the engineers had to scrap entire relay controlled panels and replace them with completely redesigned systems which are costly troublesome and not environmental friendly 2 Now with the PLC been introduced to the world 1n 1968 3 it allows engineers to implement numerous manufacturing c
17. x 1 y 1 z 0 else if a 228 amp amp ac35 1 x 0 y 0 z 1 While Loop h else if a2 235 amp amp ac42H x y 0 z 1 else if a2 242 amp amp ac49 1 x 0 y 1 z 1 _ a Formula Node x 1 y l 2 1 h else 1x 0 y 0 z 0 prchinfyp lvproj My Computer 4 Figure 4 4 VI Block Diagram 51 By referring to the Figure 4 4 the red colour square box with dot lines are the VI components that are visible in both Front Panel and Block Diagram Example the push buttons knob light indicator Meanwhile the red colour square box without dot lines are the VI component that is visible in Block Diagram but they are not visible in Front Panel which are essential VI to structure the program For example shared variables formula node number to boolean converter consist of number to boolean array and index array and the While loop The While loop which is similar concept with the While loop in C Programming is used in this VI to ensure the program execute continuously until the stop button had been triggered The VI block diagram consist of two parts of program First part of the program is to allow user to switch on either Forward or Reverse direction of the squirrel cage induction motor And the second part of the program is to vary the frequency of the motor by changing the knob value Shared variables Shared variables Write Mode ds TF Forward Figure 4 5 VI Block Diagram Program Motor Orientatio
18. 002 73 30 CISCO 2010 Ethernet A Brief History Online http www cisco com en US docs internetworking technology handbook Ethernet html wp1020560 31 Wikipedia 2010 September Industrial Ethernet Online http en wikipedia org wiki Industrial Ethernet 32 Wu Y C Chang W F Chiu C W and Yu W C 2006 October Feng Chia University Online http dspace lib fcu edu tw bitstream 2377 2285 1 ce07ics002002000276 PDF 33 National Instruments Connecting LabVIEW to an OPC Server through a DataSocket Connection Online http zone ni com devzone cda tut p id 3978 34 National Instruments DataSocket Tutorial Online http zone ni com devzone cda tut p id 3224 35 National Instruments DataSocket Simplifies Live Data Transfer for LabVIEW Online http www ni com pdf datasocket us datasocketarticle pdf 36 National Instruments Integrating the Internet into Your Measurement System Datasocket Technical Overview Online http www ni com pdf wp wp1680 pdf 37 Nader Nassif Barsoum PLC Inverter Fed Induction Motor Curtin University Sarawak Campus Miri Undergraduate Thesis 2007 38 Omron 2001 Sysdrive 3G3MV Multi function Compact Inverter User Manual Online http www limasoft eu omron pdf 3G83MV en manual pdf 39 TECO Three Phase Squirrel Cage Induction Motor Catalogue Online http www teco co th admin2 images e catalog Catalogue 20AEEB pdf 40 Solomon S Turkel 199
19. 02 Multi function input 1 Forward Stop Multi function input 2 Reverse Stop outputbit CIO0001 06 outputbit7 CIO0001 07 i r m vi Front Panel on prchinfyp lvproj My Computer Multi function input 6 Multi step speed reference 2 Multi function input 7 Multi step speed reference 3 outputbit 5 CIO0001 05 S5 Multi function input 5 Multi step speed conf 50 By referring to Figure 4 3 the green push button is the switch to determine the motor is turning in forward direction Meanwhile the orange push button is the switch to determine the motor is turning in reverse direction Both green and orange light indicators at the right hand side shows whether the push button had been switch on And then the knob labelled as frequency is the key program to control the frequency as well as the speed of the motor The push button labelled stop function to stop the program execution Figure 4 4 illustrate the VI Block Diagram which the programming part of the VI fypprogram vi Block Diagram on nrchinfvn lvnroi Mv Computer Shared variables Shared variables F ros Buton gifs Write Mode Foni Read Mode M PEL Lenis b Ry outputbitd Bq outputbit2 MAT Light indicator It Bacco Ec el Number to Boolean if gt 7 amp amp a lt 14 Converter Bassin else if A gt 14 amp amp ac21 4 x 0 y 1 z 0 1 else if a 221 amp amp ac28 1
20. 1 0 INTRODUCTION 1 1 Project Overview In the past engineers had been designing the engineering systems that requires a lot of hardwares It is merely impossible to design distance control of the system as more hardwares and wiring were needed In addition if engineers wish to improve the design all the unrelevant hardwares need to be scrap away which is not environmental friendly costly and not sustainable With the rise of the technology programmable logic controller PLC had ease the engineering design and less materials are needed as all the design are implemented in software through programming PLC had been commonly used in the industry including controlling induction motor inverter fed variable drive system Design a distance control machinery is now possible even by using Ethernet as the communication device between the computer and the PLC The convenient part of PLC is apart of design the program structure by its own propietary software it is also assessible and controllable by other software provided the software has the driver of the PLC Therefore engineers can use LabVIEW which has various types of industries applications that is in virtual instrument VI instead of the real and heavy instrument to control the PLC 1 2 Project Objectives The main objective of this project is to implement the Programmable Logic Controller PLC by using LabVIEW 2009 via LAN Ethernet for motor control system The project must a
21. 16 JChannel1 CJ1M CPU11 ETN21 0utputbit7 11 08 24 816 Tags status in real time in NI OPC Quick Client Time Event 11 08 25 AM The OPC Quick Client will run for 2 hours before automatically shutting down 11 08 25 AM Connected to server National Instruments NIOPCServers 11 08 25 AM Added group System to National Instruments NIOPCServers 11 08 25 AM Added 18 items to group System 11 08 25 AM Added group Channeli System to National Instruments NIOPCServers 11 08 25 AM Added group Channel1 CJ1M CPU11 ETN21 System to National Instrument 11 08 25 AM Added 4 items to group Channel1 System 11 08 25 AM Added group Channel1 CJ 1M CPU11 ETN21 to National Instruments NIOPCS 11 08 25 AM Added 13 items to group Channel1 CJ1M CPU11 ETN21 System Figure 3 1 NI OPC Servers with NI OPC Quick Client The setup and configuration of NI OPC Servers is demonstrated in Appendix B 34 3 2 LabVIEW 3 2 1 Overview LabVIEW is the acronym for Laboratory Virtual Instrumentation Engineering Workbench and is a graphical development environment for generating flexible and scalable design control and test applications rapidly at minimal cost With LabVIEW engineers and scientists are able to interface with real world signals analyse data for meaningful information and share results through intuitive displays reports and the Web Regardless of programming experience LabVIEW makes development fast
22. 3 e Level 1 Physical Layer This layer divides the transmission data into frames and manages to make it ready for the interface to the network medium A typical example of a physical layer protocol and hardware is the RS 23 12 e Level 2 Data Link Layer Outgoing messages are pulling together into data frames and acknowledgements from the receivers are scheduled for each message transmitted Data integrity 1s 18 checked and error detecting and error correcting codes are issued There are many examples of hardware and software operating at this level such as the Binary Synchronous Communications Protocol BIS YNC X 25 12 Level 3 Network Layer This layer deals with addressing of the messages for delivery and converts logical network addresses into their physical counterparts Physical network addresses are known as the Media Access Control MACSs addresses MAC decides how to rout the transmission from sender to receiver It deals with packet switching data routing and congestion control of the network 12 Level 4 Transport Layer This layer manages the transportation of data from sender to receiver across the network This layer is crucial to ensure the flow control by making sure that the recipient of the transmitted data 1s not overlapped with the capacity of the data that it can handle Long data payloads are fragmented into fractions matching the maximum packet size that can be suitable by the network medi
23. 9 x 1 y 1 z 1 else x 0 y 0 z 0 Figure 3 2 Three main elements of LabVIEW software 3 2 3 Shared Variables Project Library Shared variable is a library function variable that allows sharing of data between applications or different data sources across a network There are many existing data sharing method in LabVIEW such as UDP TCP LabVIEW queues and Real Time FIFO Compared to Datasocket Communication using shared variable is user friendly as the configuration can be done by simple setup in the library instead of writing URL and perform more wiring in Datasocket Communication 14 23 The demonstration of setting up shared variable in LabVIEW is further explained in Appendix C 37 3 3 Programmable Logic Controller PLC 3 3 1 PLC Setup The PLC used in this project is OMRON CJ series There are 4 units used in this PLC which are Power Supply Unit CPU Unit with Ethernet function Basic Input Unit Basic Output Unit Figure 2 3 shows the dimension of the Power Supply Unit which is CJIW PA202 Meanwhile Figure 2 4 shows the dimension of the CPU Unit which is CJ1M CPUII ETN21 Then Figure 2 5 shows the dimension of the Basic Input and Output Unit which are CJIW ID211 and CJIW OC211 with 18 terminal blocks IL c m E Figure 3 3 Dimension of CJ1W PA202 Module 24 38 PERIPHERAL Figure 3 5 Dimension of the ID211 and OC211 18 termi
24. 9 April Understanding Variable Speed Drives Part 2 Online http ecmweb com mag electric understanding variable speed 3 index html 41 University of Koblenz 1999 April Chapter 7 Ethernet IEEE 802 3 Online http www uni koblenz de ros Rechnerorganisation ethernet pdf 74 8 0 Appendix Appendix A Ethernet Configuration in CX Programmer In order to use the Ethernet Module of the OMRON CJIM CPU11 PLC the configuration needs to be done through CX programmer in order to set the unit number and IP address of the PLC Before setting up the configuration user has to make sure that the correct version of CX Programmer which is compatible with the PLC had been installed properly in the computer The demonstration in this section is performing under the Windows Vista and Windows XP operating system Therefore the explanation might be slightly different 1f the users are using other operating system in their computer Before started it is important that the PLC had been turned on and identify the correct serial communication port in the computer For laptop additional hardware might be is needed which is FTDI USB Serial Port Converter Cable In Windows Vista and Windows XP left click Start and then select and right click My Computer gt gt Properties and then the System Properties window will appear 75 System Properties Figure 8 1 Advanced Automatic Updates Remote General Computer Name Fardwere ardware
25. B is used the OMRON FINS Ethernet driver must be developed using the MS Comm function and this would require more time to develop the code 14 22 LabVIEW has front end interface applications that allow user to design and then use for controlling application systems In general LabVIEW has three main elements the front panel the block diagram and the connector panel The front panel allows the user to build the controls and indicators The controls are including knobs push buttons dials and other input mechanism Indicators are graphs LEDs and other output display Meanwhile the block diagram let user to add code using Vis and structures to control the front panel objects The connector panel allows user to represent a single VI as a sub VI icon that can be called in another VI The elements are illustrated in Figure 3 2 36 P fypprogram vi Front Panel on prchinfyp lvproj My Computer j lol xj Ee Edit View Project Operate Tools Window Heb Connector Panel ee an set Application Font 87 227 e fypprogram vi Block Diagram on prchinfyp lvproj My Computer View Project Operate Tools Window Help Frequency else if a 14 amp amp a 21 y 1 z 0 else if a gt 21 amp amp a lt 28 x 1 y 1 z 0 else if 4 gt 28 amp amp a lt 35 x 0 y 0 z 1 else if a 235 amp amp a lt 42 x 1 y 0 2 1 else if a 242 amp amp a lt 49 x 0 y 1 z 1 else if a gt 4
26. LC will be turned on This turn on process allow the 3G3MV Inverter Variable Frequency Drive to operate the Three Phase Squirrel Cage Induction Motor according to the input data given by the user In addition 3G3MV Inverter Variable Frequency Drive also serve as inverter between the power supply unit and the motor as the input power is single phase power while the Squirrel Cage Induction Motor is operate in three phase power 4 2 Implementation of VI Design The objective of the VI program in this thesis 1s to allow user to make the decision of the start and stop operation of the motor either in forward or reverse direction and varying the speed by changing the frequency of the motor by perform two simple step Firstly select the turning direction by press the push button in the VI Front Panel which 1s either forward or reverse Secondly vary the speed by turning the frequency knob to the value of the frequency that the user desire Figure 4 3 illustrate the VI Front Panel Before running the VI make sure all the hardware had been switched on and configured correctly and launch the NI OPC Quick Client so that the OPC tags can be browsed by the shared variables in this VI 49 There are 5 OPC tags had been created and used in this project and the details of the tags had been tabulated 1n Table 4 1 below Table 4 1 The details of OPC tags and its connection to 3G3MV Inverter outputbit CIO0001 01 outputbit2 CIOO0001
27. Modbus Modbus Slave is Communicate with OPC OLE for Process Control me cmm orm Figure 8 23 Creating New I O Server OPC Client in LabVIEW Next the Configure OPC Client I O Server window will show up So under the Settings tab change the Update rate ms into 100 and under the Registered OPC servers left click the National Instruments NIOPCServers follow by left click the OK button Figure 8 21 Once this step had been performed the Untitled Library I will appear in Project Explorer window Expand it and the OPCI will turn up gt Configure OPC Client I O Server Update rate ms Browse Machine 100 Deadband 95 E lb Project Untitled Project 1 o 5 E Emm Reconnect poll rate s o Prog ID Instruments NIOPCServers Figure 8 24 Configuration of OPC Client I O Server 92 After that create a new library in the Project Explorer window under the My Computer icon This step can be performed by right click the Untitled Library I and select New gt gt Library which is illustrated in Figure 8 22 left Next create the bound variables by right click the newly created library called Untitled Library 2 and select Create Bound Variables option as illustrated in Figure 8 22 right P Project Explorer Untitled Project 1 File Edit View Project Operate Tools Window Help heiHglxiuoxeqlis kt ne E Pr
28. and easy for all users 14 20 3 2 2 Programming Style The programming style used in LabVIEW is G programming which is abbreviation for graphical programming It is also known as dataflow programming as it is depending on the structure of the graphical block diagram to execute the user designed program Compared to text based programming LabVIEW is user friendly as the user can design the program by simply arrange and wiring the relevant icons together 14 20 LabVIEW programs are named as virtual instruments or VI because their appearance and operation mimic the physical instruments such as oscilloscope and multimeters 21 Similar to other conventional programming LabVIEW has standard features such as looping structures data structures event handling object oriented programming LabVIEW also has an extensive library of math functions similar to MATLAB libraries and also formula 35 nodes that allow text based programming for certain sections of the code that require complex logical structures Besides that LabVIEW also has networking library functions that can easily allow users to reference 14 Compared to other softwares like Microsoft Visual Basic LabVIEW is a better option as it comes together with a library of functions included Shared Variables Project Library which is bound to the OPC tags that allow server and client communication by connecting relevant icons with the Shared Variables If Microsoft Visual Basic V
29. and the VFD frequency meter will be identical with the situation in Figure 5 21 and Figure 5 22 respectively Tag Name Outputbitl Tag Name Outputbit5 PLC Address Q1 01 PLC Address Q1 05 Connected to VFD S1 Connected to VFD S5 Tag Name Outputbit6 PLC Address Q1 06 Connected to VFD S6 Tag Name Outputbit7 PLC Address Q1 07 Connected to VFD S7 Figure 5 21 PLC Output for forward direction and frequency 49 Hz Figure 5 22 VFD frequency meter for forward direction and frequency 49 Hz 68 6 0 Conclusion amp Recommendation 6 1 Conclusion In conclusion the objective and the scope of the project had been achieved AII the basic requirements of the projects had been achieved But there are imperfections in this project Firstly there 1s a delay of time during the project execution which every decision made by the user through LabVIEW will takes about 30 seconds in average to send the signal to the PLC The delay mainly cause by the poor specification of the laptop in this project that lead the LabVIEW takes long time to execute the program and generate the Boolean data to send to the PLC Secondly the Ethernet connectivity between the laptop and the PLC is easily disconnected This problem arises also due to the poor specification of the laptop used in this project This problem happen when the laptop had used up too much memory causing the laptop lag and unable to use temporary Therefore user cann
30. b and under the Connection category change the Port Name to the suitable port and which in this demonstration is COM 1 Make sure the Data Format shown in this dialog is identical with the port setting in Figure 8 5 78 Network Settings SYSMAC WAY Mehwork Driver Modem Connection Data Format Pot Mame PNT Data Bits Baud Hate 3800 ki Parity Li Stop Bits Make Default Cancel Help Figure 8 6 Network Settings of SYSMAC WAY in CX programmer Once all the previous steps had been correctly done go back to the CX Programmer and left click the online icon to connect the PC with the PLC And then the Connect to PLC notification dialog will pop up Left click Yes button to continue Figure 8 6 Once the computer is connected to the PLC configuration can be done much easier by changing from Running Mode into Program Mode So right click the NewPLCI CJIM Running Mode which is located at the project window Then select Operating Mode gt gt Program After that double click the IO Table and Unit Setup in the project window then the PLC IO Table will pop up Left click the Option tab and select Create to create the I O Table automatically And then perform the actions as demonstrated in Figure 8 6 79 PLC IO Table NewPLC1 PLC IO Table NewPLC1 zi Z A f CJiM CPU11 Inner Board 4 0000 Main Rack fl CJ1M CPU11 4 Inner Board 0000 Main Rack
31. ber of bits transmitted per second Baud rates and bit rates are the same 1f only one bit 1s assigned per symbol 11 Digital information is generally transmitted in data frames Data frame is collection of characters Figure 2 6 that convey a complete message that can be understood by the transmitting and receiving devices 11 Start Destination Source Information Frame bits address address check Figure 2 6 Digital data transmission in frames 11 When data frames are used the information rate is not the same as bit rates or bauds since it contains overhead data addresses error checks start and stop information and so on The type of information in the frames is governed by protocols and standards 11 Data from one device to other are transmitted in serial or parallel forms 11 Figure 2 7 and 2 8 explaine the difference between the serial and parallel data transmission 14 Transmit Tx Receiver Rx PTT TEE eN Shift register Shift register Figure 2 7 Serial Data Transmission 11 Transmit Tx Receiver Rx or Figure 2 8 Parallel Data Transmission 11 In general there are 3 modes of channel operation 11 Simplex operation transmission can take place only in one direction from one device to another Half duplex operation transmission can take place in either direction but only one direction at a time Full duplex operation transmission takes place in both dir
32. borq oo1z 000 c 92uoa19Jos Aouonbodq 00fl 000 T 9ouoad9Jos Aouonborq 00L 000 92uo19jow Kouonboiq 000 009 SUJ mepa SV Occ PNAU AWE DE ur UONeINSTJUOD si pue s1ojeuredeq UOTIOUN JO 3srT ALL V uorpesuoduroo di s pue juejsuoo O1nuoo 10799A se posn JOJ JOS SI Iojouremed SUL uornesuoduioo di s pue juejsuoo oJjuoo 103294 s posn SI ZH Ww ps di s 10j0u1 poires 8 usano soouaiojos Aouonboug p s 0 JOS oue s eusis dS oouonbos 2aJIA 7 ur pueuruioo UOIn Ol 9SI9A9I pue pIeMIO SUIJLOYIOAO WOJ IOJOU dy 312910Jd 0j sonsuojoeeuo pwy amono ou ourulojop O pue ju jsuoo ONUOD 10 29A S ISN JOJ 19S SI JULINO Jo3oui pIJ 20001 Se JUNNI JOJOU poje1 oq uo poseq Jas sr osn ur 1070W 3y JO Juano peo ou sy J JAS ST SN UI JO OUI y JO on eA dijs payer OY c 92uaJI9Jol p ds dojs n n q T 9ouoioJol poads dojs n n q 9 uaiojol p ds dojs n n q pe qeuo sr uoroung dojg es1oAosq pe qeuo st uonounj dois pieMioj7 ojepdoureu 1070W au UO UAOUS jUOIInO 1070W pow og oj GSurpioooe JOS SI uonoojop PPOTIOAO IOJOU JO JUNI 92U9J9 OI yor JUSTIN IOJOU podyel ou oq JO posn st uonenby Ajyroedeo Sunjes Jojoy I ym quano peo ou JOjJOJA 056 S LA 66 010 uonenby Ajyroedeo Jew 94 YIM ZH 0 07 SUINAS di s 1070W powy SIEN 01 0 0 LS L mdu cc pue amp arerp uorbung nnpq ve STI 9S 9 1ndu eVSIp uorbu
33. chieve the ability on controlling the following aspect Start e Stop Speed Control e Forward Reverse Position Control The start and stop actions can be control directly through the status change of the PLC output Meanwhile the speed and forward reverse position control can be controlled by the PLC through the Variable Frequency Drive VFD 3G3MV inverter All the controlling process must be done by using the main computer that is connected to the PLC using LabVIEW 2009 The Local Area Network LAN is needed in order to have connection between main computer and PLC Thus the Ethernet Module is involved in the PLC 1 3 Thesis Outline The outline of the thesis is divided into seven main sections as listed below Section 1 This is an Introduction It introduces the overview and objectives of the thesis It includes the brief explanation of the project Section 2 Section 3 Section 4 Section 5 Section 6 Section 7 Is the Background This section explaines the overview of PLC and its operation and structure variable frequency drives VFD squirrel cage induction motor Ethernet OPC and Human Machine Interface HMD It is for the Project Design Configuration and Preparation that explaines NI OPC Servers LabVIEW the configuration of the PLC Ethernet Unit and the function parameters setting of the VFD This is the Project Implementation It shows the implementation process and LabVIEW
34. ck the NewPLCI in the project window and select Change in order to change the network type to Ethernet FINS TCP as illustrated in Figure 8 9 Change PLC Device Name NewPLC1 Device Type CM Settings Network Type Settings Comment Cancel Help Figure 8 10 Change PLC dialog in CX Programmer Ethernet FINS TCP Next left click the Setting button and the Network Settings Ethernet FINS TCP dialog will shows up Change the FINS destination Address according to the decimal number set in the PLC node number and this number determine the IP address of the PLC Then left click the Driver tab and insert the IP address Once it is completed left click the OK button to close the dialog Figure 8 110 and Figure 8 11 82 Network Settings Ethernet FINS TCP Network Diver FINS Source Address Network n E FINS Destination Address Network n Made E Ex Frame Length Response Timeout s 2000 zal Cancel Help Figure 8 12 Network Settings Part 1 of Ethernet FINS TCP in CX programmer Network Settings Ethernet FINS TCP Network Driver Workstation Made Number W Auto negotiatiorn IP Address Port Number 9600 Cancel Help Figure 8 13 Network Settings Part 2 of Ethernet FINS TCP in CX programmer Now the Ethernet configuration in CX programmer had been done In order to test whether it is working properly connect the Eth
35. cy of the motor However this project is not a supervisory control and data acquisition SCADA system since there is no practical data measurement acquire from the actual output of the motor This project has three layer network architecture illustrated 1n Figure 4 1 Layer 1 User User Control Remote Control System Layer 2 OPC Operation Management Ethernet Communication Protocol PLC Layer 3 Variable Frequency Drive Machinery Operation Squirrel Cage Induction Motor Figure 4 1 Three Layer Network Architecture 47 8v UOD InSITUO YIOMION enjoy c p enar uidi gop peedg UAS ZH 05 Aouonborq dH 44 190d p so od J030 A uoronpug 9687 3 I HI DS IBY d A Otc uN Ajddng Imod 9seugd I SUIS aM o qeo PUNYA OV 2PON 0 ON uN OCS SST SSC oUuqns weisold ONUOS ou 9p 9 T TOL dI pue 1oumueIS0Jg X 2 OdO IN MATAT sunsoH Jo1nduiro 0 cScC SSC Sec ouqns Ly 9 T TOL dI sog doydvT mi 4 1 1 Mcz re EES Ld ts gt ec Sess lt lI TCTTMT X As illustrated 1n Figure 4 2 user gets the authority to control through the host computer which is laptop in this thesis Then the input data by the user will convert into Boolean data and send to CJI M CPUI ETN21 Programmable Logic Controller through Ethernet cable and router Once the Boolean data had been processed by the PLC the relevant address in the basic output of the P
36. d PERIPHERAL TOUBASE TX Figure 3 8 CJ1W CPU11 ETN21 Ethernet Module Hardware Configuration Node No x 16 is the most significant bit MSB of the node address whereas x16 is the least significant bit LSB of the node address IP addresses are in decimal form therefore any reference made to the DAI of the PLC Ethernet module in software configurations must be in decimals To convert any hexadecimal number to decimal the following example can be applied 14 41 MSB LSB 2 E N 14 x 16 2x 16 46 In this project the PLC is given the IP address 10 1 136 46 The router is for personal home network therefore the IP addresses associated with the devices in the network 1s classified under Class C The hardware configuration of this PLC Ethernet module unit is associated with the software configuration in CX programmer which will be further explained in Appendix A 42 3 4 Variable Frequency Drive OMRON SYSDRIVE 3G3MV A2007 inverter 1s a variable frequency drive used in this project to alter the frequency of the electrical power supplied to the motor so in order to change the motor speed 5 The SYSDRIVE 3G3MV A2007 inverter is suitable for a variety of applications as it incorporates many convenient controls and I O functions that are easy to use as well as open loop vector control function The advantages of vector control function are that it ensures a torque output that is 150 of the rated motor torque at a
37. d direction and frequency 0 Hz Figure 5 6 VFD frequency meter for forward direction and frequency 0 Hz 60 Meanwhile if the user set the orientation of the induction motor into forward direction the outcome that can be seen in the PLC will be identical with the situation in Figure 5 7 Similarly if the input frequency set by the user is less than 7 Hz the VFD frequency meter will indicate 0 Hz and the motor will remain idle in Figure 5 8 Tag Name Outputbit2 PLC Address Q1 02 Connected to VFD S2 Figure 5 7 PLC Output for reverse direction and frequency 0 Hz Figure 5 8 VFD frequency meter for reverse direction and frequency 0 Hz 61 When user decided to set the coast of the induction motor in forward direction and the input frequency range is from 7 Hz until less than 14 Hz the outcome that can be seen in the PLC and the VFD frequency meter will be identical with the situation in Figure 5 9 and Figure 5 10 respectively Tag Name Outputbitl Ae Tag Name Outputbit5 PLC Address Q1 01 PLC Address Q1 05 Connected to VFD S1 Connected to VFD S5 Figure 5 9 PLC Output for forward direction and frequency 7 Hz Figure 5 10 VFD frequency meter for forward direction and frequency 7 Hz 62 If the user increases the input frequency range to a value that is within 14 Hz and less than 21 Hz then the outcome that can be seen in the PLC and the VFD frequency meter will be identical with
38. devices such as sensors creates the objectives of the system The link between the devices and softwares are named as network and the process of the communication named as networking Networking of hardware and software resources is crucial for 11 Bringing multiple devices together for exchange of information and joint operations Sharing of functions of equipment and devices Data sharing which allows a group of users to exchange information among each other on periodical or regular basis Routing data from one network element to another Coordination of activities of equipment and devices in plant and production Monitoring the status of equipment and devices Monitoring and taking corrective actions on safety issues Production planning configuring and reconfiguring There are three types of networks which are 11 Wired networks devices are connected by wires hence fixed in space Wireless networks devices are connected wirelessly hence can move in space and 13 Hybrid networks devices are connected in which both wired and wireless connections are used in combination Meanwhile data is collection of alphabetic numeric or special function characters that are appropriately grouped in binary format to form words messages or information Data is measured in baud rates or bit rates Baud rate specify the number of symbols transmitted in a unit time or per seconds While bit rate specify the num
39. ections simultaneously Figure 2 9 expresses the 3 modes 15 Simplex Half duplex Figure 2 9 Three Modes of Channel Operations R Full duplex In networks the transmission 1s recognized by using various channels A channel may be defined as a single path on a line trough which signals flow Lines are defined as the components and parts that extend between the terminals of the communicating devices 11 There are a variety of forms of networks depending on the number of network elements and their spatial distributions Local area network LAN is a system for interconnecting data communicating components within a comparatively detain space While wide area networks WANs extent into greater geographic distances linking two or more separate LANS 11 There are many other terms used apart of LANs and WANS such as metropolitan area networks MANSs personal area networks PANs and so on but these are basically LANs or WANs with varying sizes The major point of networks is to share resources by connecting network elements called nodes In order to connect nodes four elements are 16 needed 1 the transmission medium 2 the network topology 3 the protocols and 4 the network operating system 11 Transmission medium can be defined as the physical path between nodes of the network Physical path may be cables fibres radiofrequency
40. ernet cable from the PLC to the router Ethernet port and the LNK indicator light in the PLC will light up Click the amp button to connect the computer to the PLC If it is connected no errors will shows up 83 Additionally user can test the PLC and computer connection by using Command Prompt Firstly launch the Command Prompt by left click Start gt gt All Programs gt gt Accessories gt gt Command Prompt Then in command prompt type ping lt PLC IP address gt If the Ethernet configuration had been correctly configured the output of the pinging should be appearing as the result illustrated in Figure 8 12 Command Prompt Microsoft Windows AP Version 5 1 2600 LG Copyright 1985 20661 Microsoft Corp G Documents and Settings curtin ping 180 1 1356 46 Pinging 16 1 136 46 with 32 bytes of data 1H 1 136 46 bytes 32 timet ims TTL 255 1H 1 136 46 bytes 32 time lt ims TTL 255 1H 1 136 46 bytes 32 timet ims TTL 255 Reply from 186 1 136 46 hytes 32 timetims TTL 255 Ping statistics for 18 1 136 46 Packets Sent 4 Received 4 Lost A CH loss Approximate round trip times in milli seconds Minimum Ams Maximum Ams Average Bms C Documents and Settings curtin Figure 8 14 Testing Connectivity using Command Prompt in Window XP Otherwise troubleshoot the problem by refer back to the step by step approach all over again 84 Appendix B Setting Up NI OPC Server This section
41. graduate Thesis 2009 6 Clive Maynard PLC Structure Online http kernow curtin edu au www plc 2STRUCT HTM 7 Siemens Basic PLC Operation Online http sea siemens com step templates lesson mason plcs 1 2 2 8 Joliet Technologies What is a Variable Frequency Drive Online http www joliettech com what is a variable frequency drive htm 9 Yarn Spinning Technology Induction Motor Online http textiletechnology bravehost com spinning inductionmotor htm 10 Nader Nassif Barsoum 2007 April AC Motor Online http www engineeringedu org cources units es 2a pdf 11 Halit Eren Instrumentation Network Curtin University Instrumentation and Control 402 Lecture Notes 4 6 12 University of South Florida 2009 Chapter 2 Protocol Online http fcit usf edu network chap2 chap2 htm 13 CISCO 2010 April CISCO Online http www cisco com web strategy docs manufacturing industrial ethernet pdf 14 Nader Nassif Barsoum Ethernet LabVIEW Control Curtin University Sarawak Campus Miri Undergraduate Thesis 2010 72 15 Search Networking com 2000 August What is Ethernet Online http searchnetworking techtarget com definition Ethernet 16 Javvin Network Management and Security Ethernet IEEE 802 3 Local Area Network LAN protocols Online http www javvin com protocolEthernet html 17 University of South Florida 2009 Chapter 5 Topology Online http fcit usf edu
42. gs are named as OPC tags The NI OPC Servers also have NI OPC Quick Client that enable users to monitor the status of the PLC in real time 14 As long as the OPC tags had been created the communication between the LabVIEW and PLC had been simplified as the driver can automatically apply the relevant FINS commands provided the tags are correctly configured 14 Meanwhile in LabVIEW the program can be design by using Shared Variables which is link to the OPC tags Figure 3 1 shows the layout of both NI OPC Servers and NI OPC Quick Client 33 NI OPC Servers C Program Files National Instruments Shared WI OPC Servers Projects prchinfyp opf a a File Edit View Users Tools Help Dae k VMhog ot sexlee Channel Tag Name Address Datatype ScanRate Scaling Description mq SES E coam cpuii1 ETN21 P CIO0000 01 None C1O0000 02 CIO0001 01 Tags created in NI CIO0001 02 CIO0001 05 OPC Servers CIO0001 06 CIO0001 07 OPC Quick Client Untitled File Edit View Tools Help D c Exi ck ed Flt BEX National Instruments NIOPCServers System Channel 1 CJ1M CPU11 ETN21 inputbit1 11 08 24 816 Channel1 System Channel 1 CJ1M CPU11 ETN21 inputbit2 11 08 24 816 a C Channel 1 CJ1M CPU11 ETN21 outputbiti 11 08 24 816 Gil Channeli CHM CPULLETM2L System Hl channel 1 CJ1M CPU11 ETN21 outputbit2 11 08 24 816 CjChannel1 CJ1M CPU11 ETN21 outputbit5 11 08 24 816 C Channel 1 CJ1M CPU11 ETN21 0utputbit6 11 08 24 8
43. hanges with relative ease which reduces changeover costs and downtime 2 The first PLCs were introduced in order to eliminating the large cost involved in replacing the complicated relay based machine control systems into US car manufacturer Bedford Associates Bedford MA proposed something called a Modular Digital 4 Controller MODICON to a major US car manufacturer The MODICON 084 brought the world s first PLC into commercial production in the mid70 s 4 The programmable logic controller is becoming a very crucial tool in most industrial automations today as it 1s rugged and designed to withstand vibrations temperature humidity and noise Plus PLCs have interfacing for inputs and outputs already inside the controller In addition PLCs are easily programmed and have an easily understood programming language 1 Apart of that PLC systems also have many other advantages which include 5 Better and more reliable performance with easy maintenance Much smaller physical size thus easier installation even at very limited area Cost effective for controlling complex systems Flexible and can be changed to other control systems quickly and easily Allowed more complicated controls Reduced downtime with more efficient troubleshooting function and help 2 1 2 PLC Operation The PLC operates internally in a way which is identical to normal computers The inputs are continuously monitored and copied from the I O
44. he computer The demonstration in this section is performing under the Windows Vista Basic operating system and the LabVIEW used is LabVIEW 2009 Therefore the explanation might be slightly different if the users are using other operating system in their computer Firstly launch the LabVIEW software by click Start gt gt All Programs gt gt National Instruments gt gt LabVIEW 2009 gt gt LabVIEW Once the LabVIEW window had been launched the Getting Started window will appear Under the New title left click the Empty Project to open a new project The new Project Explorer will show up Next under the Item tab right click the My Computer icon and select New gt gt I O Server which had shown in the Figure 1 below left side Now left click the I O Server and then the Create New I O Server window will appear There are many types of I O server under the Create New I O Server window but in this project the scope will only focus on the selection of OPC Client as the objective of the configuration 1s to allow the user computer to connect to the PLC by bounding with OPC tags So under the Create New I O Server window left click the OPC Client and press Continue to proceed Figure 8 20 91 Project Explorer Untitled Project 1 mja x Elle Edit View Project Operate Tools Window Help I O Server Type Alarm Printer Custom VI On Input Change Custom VI Periodic Data Set Marking EPICS Client EPICS Server
45. hese messages always use the IP address 255 255 255 255 30 2 6 OLE for Process Control OPC OLE for Process Control OPC which is the short form for Object Linking and Embedding for process control 1s a standard interface between various data sources including devices on a factory floor laboratory equipment test system fixtures and databases in a control room 19 OPC allows device side server and application software which are two separate processes to communicate with each other through Microsoft COM DCOM interface COM is abbreviation for Component Object Model and meanwhile DCOM is Distribution COM COM provides an interface communication layer that allows local and remote procedure calls to be made between processes DCOM is the natural extension of COM to support communication among objects on different computers i e on a LAN WAN or the Internet 19 OPC was designed to be a layer of abstraction between the specific device and the program that needs to acquire information or control that device The OPC standard specifies the behaviour that the interfaces are expected to provide to the clients who use them and the client receives the data from the interface using standard function calls and methods As a result any computer analysis or data acquisition program can communicate with any industrial device as long as that program has an OPC client protocol and the device driver has an OPC interface associated with
46. ing voltage of 5 volts and the external processes usually require higher powers and currents the I O modules are optically or otherwise detached The typical I O operating voltages are 5V 240 V dc or ac and currents from 0 1A up to several amperes The I O modules are designed in this way to minimize or eliminate the need for any intermediate circuitry between the PLC and the process to be controlled small PLC units would have around 40 I O connections with larger ones having more than 128 with both local or remote connections and extensive upgrade capabilities 6 Programming devices are essential components of the PLC systems Since they are used only in the development and testing stage of a PLC program they are not permanently connected to the PLC The program in a ladder diagram or other form can be designed and usually tested before downloading to the PLC The Programming devices can be a dedicated device such as Hand held Programming Consoles or a personal computer It allows the graphical display of the program ladder diagram Once the device connected to the PLC it can read the program and allows for the real time monitoring of its operation to assist debugging Once the program is found to operate as required the programming device is disconnected from the PLC which continues the operation 6 2 2 Variable Frequency Drive 2 2 1 Overview of Variable Frequency Drive VFD There are 2 ways to alter the speed of an induction mo
47. iversal Serial Bus controllers Figure 8 3 Device Manager window in Windows XP Double click the COMI and the properties dialog will appear Left click the Port Settings tab and make configuration as demonstrated below The configuration in Port Settings must follow and identical with the CX programmer Network Settings SYSMAC WAY dialog shown in Figure 8 3 Communications Port COM1 Properties General Port Settings Driver Details Resources Bits per second 9600 v Data bits Zz Parity Stop bits Flow control None v Restore Defaults Figure 8 4 Communication Port Properties window and its configuration 77 Firstly launch the CX Programmer by left click the Start gt gt All Programs gt gt OMRON gt gt CX One gt gt CX Programmer gt gt CX Programmer Then left click the File gt gt New or press Ctrl N to open a new blank document and the Change PLC dialog will appear In this dialog change the Network Type into SYSMAC WAY as illustrated in Figure 8 4 Change PLC Device Name INewPLET Device Type EJIM Settings Network Type OY S MAD WATY Settings Comment Cancel Help Figure 8 5 Change PLC dialog in CX Programmer SYSMAC WAY Next left click the Settings button which is right hand side of the Network Type and the Network Settings SYSMAC WAY dialog will appear Left click the Driver ta
48. le if the data acquired from the sensor indicates that the temperature of the motor is too high user can immediately get warning from the system and stop the motor from running LabVIEW has the data acquisition NI DAQ toolkit that allow the acquire data from the motor to be processed and become useful signal that 1s readable by the user Additionally CJ1 series PLC has the MAD 42 unit that allow the analogue signal from the sensor to be process by the PLC by simply connect the relevant sensors to the MAD 42 unit 70 Furthermore by using LabVIEW internet toolkit the remote control system can be upgraded into web based control Other computers can have the access to control of the VI the system provided they had installed the NI Runtime RT engine plug in that has similar version with the main user computer Microsoft Silver light plug in is also required to view the embedded VI java script on the web 71 7 0 Bibliography 1 PLC Manual Introduction to PLCs Online http www plcmanual com 2 Suffolk Automation 2005 December Basic of Programmable Logic Controller Online http www suffolk automation co uk uploads pdfs LOGIC CONTROLLERS pdf 3 PLC Manual PLC History Online http www plcmanual com plc histor 4 Phil Melore PLC History Online http www plcs net chapters history2 htm 5 Nader Nassif Barsoum PLC Humidity Control Inverter Fed Induction Motor Curtin University Sarawak Campus Miri Under
49. ll be 46 Meanwhile as the IP address of the user computer is 10 1 136 47 the Source Node Number will be 47 87 New Device Name New Device ID our documentation for the device may refer to this as Network ID or Network Address Enable auto device demotion on communication failures Demote after E successive failures 10000 milliseconds Discard write requests during the demotion period Demote far New Device FINS Network Configuration New Device Summary the FINS network configuration parameters me TET cm o the request size in bytes This determines maximum number of bytes the driver can in a transaction Request Size EN Bytes X If the following settings are correct click Finish to begin Name CJ1M CPU11 ETN21 Model CJ1 Request size in bytes 512 Source Network Address Number 0 zj me E ce oo Figure 8 19 Demonstration of creating New Device in NI OPC Servers 88 Now the device had been successfully configured Next create the tags by left click the Click to add a static tag link and the Tag Properties dialog below will appear Perform the configuration as demonstrated in Figure 8 17 x General Scaling Identification Data type Boolean ag Client access Read Write v Scan rate 100 H milliseconds Figure 8 20 Create Tags in NI OPC Servers Once the configuration is complete the tag and it
50. medium for frames to travel Ethernet is a widely installed local area network LAN technology 14 It was formerly developed by Xerox from an earlier specification called Alohanet for the Palo Alto Research Center Aloha network and then developed further by Xerox DEC and Intel An Ethernet LAN typically uses coaxial cable or special grades of twisted pair wires 15 Ethernet was named by Robert Metcalfe from Xerox for the passive substance called Iuminiferous light transmitting ether that was previously thought to spread through the universe carrying light throughout Ethernet was named in this way in order to describe the way that cabling also a passive medium could equally carry data everywhere throughout the network 15 According to Cisco Systems Ethernet is the favorite protocol to be used because e Relatively easy to understand implement manage and maintain e Allows low cost network implementations e Provides extensive topological flexibility for network installation e Guarantees successful interconnection and operation of standards compliant products regardless of manufacturer 22 There are two types of operation in the Ethernet standard which are half duplex and full duplex modes In the half duplex mode data are transmitted using the popular Carrier sense Multiple Access Collision Detection CSMA CD protocol on a shared medium The main weaknesses of the half duplex are the efficiency and distance li
51. mitation in which the link distance is limited by the minimum MAC frame size This limitation reduces the efficiency severely for high rate transmission Therefore the carrier extension technique is used to ensure the minimum frame size of 512 bytes in Gigabit Ethernet to attain a reasonable link distance 16 In today s technology there are 4 types of Ethernet 13 16 10 BASE T Ethernet IEEE 802 3 This 1s a traditional type of Ethernet which delivers performance of up to 10 Mbps over twisted pair copper cable Fast Ethernet IEEE 802 3u Fast Ethernet delivers a speed which is 10 times the IOBASE T Ethernet specification 100 Mbps while preserving many of Ethernet s technical specifications These similarities allow organizations to use IOBASE T applications and network management tools on Fast Ethernet networks Gigabit Ethernet IEEE 802 3z This Ethernet delivers a speed which is tenfold over Fast Ethernet to 1000 Mbps or Gbps Because it is based upon the current Ethernet standard and compatible 23 with the installed base of Ethernet and Fast Ethernet switches and routers network managers can support Gigabit Ethernet without need to retrain or learn a new technology 10 Gigabit Ethernet IEEE 802 3ae 10 Gigabit Ethernet endorsed as a standard in June 2002 in which it is an even faster version of Ethernet It can support intelligent Ethernet based network services interoperate with existing architect
52. module into RAM memory which is divided into the input and output sections The Central Processing Unit CPU steps through the control program in another section of the memory and fetches the input variables from the input RAM Depending on the program and the state of inputs the output RAM is filled with the control variables which are then copied into the I O module where they control the processes 6 Figure 2 1 shows the basic PLC operation process Central Processing Programming Operator evice Module Figure 2 1 Basic PLC Operation Process 7 2 1 3 PLC Structure The CPU used in PLC system is a standard CPU present in many other microprocessor controlled systems The choice of the CPU depends on the process to be controlled In general 8 or 16 bit CPUs fulfil the requirements sufficiently 6 The memory in a PLC system is separated into the program memory which is usually stored in EPROM ROM and the operating memory The RAM is essential for the operation of the program and the temporary storage of input and output data Typical memory sizes of PLC systems are about 1 kb for small PLCs few kb for medium sizes and more than 10 20 kb for larger PLC depending on the conditions Many PLC would support easy memory upgrades 6 Input Output modules are the boundary between the internal PLC systems and the external processes to be monitored and controlled Since the PLC is a logic based device 6 with a typical operat
53. n the number will be converting into Boolean in which it will arrange according to the relevant Multi step speed reference Then this Boolean number will trigger the variable frequency drive and determine the frequency and as well as the speed of the squirrel cage induction motor according to the output condition listed in Table 4 4 For example if the user set the input as 8 Hz in which the input range of this value is within 7 x lt 14 Therefore the Boolean number of Multi step speed reference 1 is 1 and the rest are 0 And this signal triggers the variable frequency drive to deliver the frequency of 7 Hz 56 5 0 Testing and Verification After the implementation test 1s performed in order to verify that the project is working smoothly Before implement the test process it 1s important to refer and follow the checklist tabulated in Table 5 1 If problem s arise during the execution of the project revise the checklist to troubleshoot the problem s and identify the suitable solution s Figure 5 1 and Figure 5 2 shows the overview of the project Table 5 1 Checklist before project testing Make sure all the hardware had been switched on User Computer Ethernet Router PLC VED Make sure all the wiring of the hardware had been connected properly LAN cables PC to PLC Wires PLC to resistors Wires resistors to VFD been configured correctly been configured correctly setup and configured c
54. n Switching Part By referring to Figure 4 5 if user had switch on the Forward button the signal will be transmitted to the outputbit1 shared variable which is in write mode 1 e the signal will 52 be write into the PLC Then once the signal had been successfully write to the PLC the output address 1 01 of the PLC will light up and as well as the Forward light indicator in the LabVIEW Front Panel This process identical to the reverse direction as well Number to Boolean Converter Formula node if a gt 7 amp amp ac 144 x 1 y 0 z 0 else if a gt 14 amp amp ac21 x 0 y 1 z 0 1 else if a gt 71 8 amp a lt 28 ai Shared x y 1 z 0 a i T n a gt Variables else if a gt 28 amp amp a lt 35 Write Mode x 0 y 0 z 1 e else if a2 235 amp amp a lt 42 X 1 y 0 z 1 else if a2 242 amp amp as AH x 0 y 1 z 1 else if a 49 4 x l y 1 z l else 1 x 0 y 0 z 0 Figure 4 6 VI Block Diagram Program Motor Frequency Varying Part By referring to the Figure 4 6 the red colour square box indicate the VI named formula node where the language used in the formula node is C programming after the user set the value of the frequency by turn the Frequency Variable knob the value will send to the formula node where it is denoted as a The explanation of the C programming language inside the formula node is shown in Table 4 2 The ou
55. n output frequency of 1 Hz allows powerful revolution at low frequencies and restrains the revolution fluctuation caused by the load 5 Table 3 1 tabulated the list of function parameters of the 3G3MV inverter that need to be configured in order to control the 3 phase squirrel cage induction motor effectively 43 S92uaJojJo1 poads dojs n nur 10 posn pue jos ale 9 Yysnoly soouarmsjor AOuanbaly pe qeuo st 19319AUT ou 0 JUSS pue ululoo UOIJejOl ISIOADY opoui Jowa ut poj129 es oq 0 soouaJoJal ouonbojg Jo poypu jndur y so qeua uomnounj sm Opou OMUOD 101224 0 19S SI I93J9AU Y JOJ opoui o3juoo au SI9joure Ted Jo asuvl JOWUOU y ogueugo Jo sJIojoureged Jos UNUM oq 0 Siojoured Hqrqoid ssumes ynepp 0 SIojoureTed ozi eriur O sr uonoung sy suljqeua Jo asodind oy Jos JIB SODUDIOJOI Aouanbaly euru pe qeuo SI UONeIOI lt dISIOADY 9 qeue st p cQu avua Kouonboi doo uado opour onuoo 10 09A poyojruour pue JOS SI saurngos p usnoig sdnois uonounj 21 6LTu 01 QQu uoi oguel e uym SIojoureJed y SUnjos Jumo Jo uonouny VV L IWIJI Kouonborq uonoo es 11qrqoud UOI LIJOY 9SI9A9M uonoo os 92U9JI9JOI KAouonbod UOT9 es opoui 0 guo UoHesST ET TUT JojoureJeduonoo os yqryosd IMIM IojoureJeq g o2uo19Jo3 Loun b y 006b 000 00 9 o ouodoJos Aouonborq cose 000 K b ooua19 os Aouonbou4 OUsSc 000 und p 9ouo19jow Kouon
56. nal blocks 24 There is an End Cover for the PLC unit All these units can be connected by assembled them together and lock the sliders by moving them towards the back of the units The End Cover must be connected on the far right hand side of the PLC Otherwise fatal error will occur Figure 3 6 demonstrate the typical connection of the PLC units 5 39 Dx O9 G OS a8 BS Co em t Power Supply CPU r VO in Unit E Y nd Unit VO Units 10 max included with CPU Unit Figure 3 6 Typical Connection of PLC Units 5 Figure 3 7 demonstrate the arrangement of the PLC units in this thesis 0i a Oooiii oT ooo 0 0o oiai O oooo on o o oiciOOO0o0o Power Supply Unit CPU11 ETN21 Unit I O Units P NE Figure 3 7 Connection of PLC Units for CJ1M CPU11 ETN21 with I O Units 40 3 3 2 CJ1W ETN21 Hardware Configuration In order to let the PLC to operate through the Ethernet the PLC must be given an IP address with a destination node number DA1 that is not a duplicate of DAIs of other IP addresses in the network The destination node number is also known as the last octet of an IP address The PLC node number is configured by turning the dials on the CJ1W ETN21 module as illustrated in Figure 3 8 the PLC must also be given a unit number in the network besides a destination node address DNA 14 All node dials are 1n hexadecimal with a range of 0 to F e
57. ng nnpi SS 1ndu pensSIp uoroung n np cS c 1ndu Qe rp uoroung nnpq IS 1 1ndu eVSIp uoroung nnpq IIAU og Jo JULINO Ayoedeo jndino OU YIM S N A SUIS p Jo Jua LImno JOJOUL PILY 950S 950 oru i The rated motor slip value is calculated from the rated frequency Hz and rpm on the motor nameplate by using the following formula 5 26 Given that rated frequency 50Hz rated rpm 1390 number of poles 4 Srated Sratea Nratea X T oro Equation 3 4 XxX J 0 50 1390 120 3 66790 Where Srated Rated slip value Srateq Rated frequency Hz Nrated Rated rpm P Number of poles The motor no load current is set in percentage based on the rated current of the Inverter as 100 5 26 With no load current at 50Hz 0 7794 9 x 100 38 95 x 39 Equation 4 Motor no load current 46 4 0 PROJECT IMPLEMENTATION 4 1 Implementation Process The Ethernet control systems presented in this thesis 1s to control squirrel cage three phase induction motor In order to achieve the objectives of this project the establishment of the communication between PLC and LabVIEW is crucial as LabVIEW is 3 party software instead of using the software implemented in the PLC itself Thus the project used LabVIEW to perform the start and stop operation of the motor either in forward or reverse direction and varying the speed by changing the frequen
58. ock Diagram with shared variable Boolean input in LabVIEW 96 Next with the purpose of controlling the output of the PLC the Outputbitl need to be used by drag the Outputbitl icon from Project Explorer window into Block Diagram window which is illustrated in Figure 8 28 Project Explorer Untitled Project 1 l0 xi gt Untitled 1 Block Diagram on Untitled Project 1 My Computer File Edit View Project Operate Tools Window Help Pe rere eee sca el seat le Project Untitled Project 1 Ej M My Computer Untitled Library 1 i k uM OPC1 i Untitled Library 2 i By inputbiti Sa inputbit2 p Ra outputbit2 Shared Variable Read Mode Figure 8 31 VI Block Diagram with input and output shared variables in LabVIEW For now the Outputbitl is in Read mode in order to control the PLC the Outputbitl must be in Write mode Therefore in order to change the mode right click the Outputbitl and select Change To Write option Notice that once the previous step had been performed the Outputbitl icon had changed as shown in Figure 8 29 97 Project Explorer Untitled Project 1 E ni x Untitled 1 Block Diagram on Untitled Project 1 My Computer Elle Edit View Project Operate Tools Window Help Project Untitled Project 1 Untitled Library 1 i gl OPC1 Shared Variable Write Mode Figure 8 32 Change the output shared variable into write mode
59. oject Untitled Project 1 EF My Computer WI E E Untitled Library 1 zx Miia i gi OPCI Eq y Contro 32 EIE A NN GY Dependencies Find Project Items Variable i ie Build Specificatic Open I O Server AUN Find k XControl Add Find Project Items Save r Find r Show Error Window Multiple Variable Editor Create Variables Create Bound Variables Figure 8 25 Creating New Library and Bound Variables in LabVIEW Once the previous step had been performed the Create Bound Variables window will show up At the left hand side of the window expand all the icons until the relevant OPC tag shown Then left click the Add button in the middle of the window to add all the OPC tag into Added variables list follow by left click the OK button This step had illustrated in Figure 8 23 93 3H R Project Untitled Project 1 Add gt gt E My Computer Eig Untitled Library 1 0 Addrmess E M OFC1 HE System Custom base name Bo Channel outputbit HE system ERG CHM CPULLET m gn Copy properties from inputbit1 inputbitz outputbit1 outpu thit2 Mid Figure 8 26 Add variables in Create Bound Variables dialog in LabVIEW Next the Multiple Variable Editor window will pop up From this window the details of the variables are clearly shown Refer to the Figure 8 24 for further details Then left click the Done button to close the window pA Hultiple Variable Editor x
60. orrectly E ens e Pt e MO e m ioraa Client Make sure the LabVIEW shared variables are configured correctly 57 Figure 5 1 Side view of the project Squirrel Cage Three Phase Induction Motor PLC with Ethernet EL ee i de MM acr deed RUM OBI T lee s Lite eerie a EN Figure 5 2 Front view of the project 58 If all the tasks in Table 5 1 had been performed correctly run the project VI in LabVIEW Figure 5 3 shows the PLC Ethernet Module light indicators that light up when the project VI is executing And Figure 5 4 shows the snapshot of the Squirrel Cage Three Phase Induction Motor when it is running I RUN ERC SO RO 1 CPUTT ETN 100M ERH TCR FTP HOSI PROGRAMMABLE CONTROLLER OPEN SW SETTING M zn 2 nn mot ety ttt ret Pela j k d Figure 5 4 Squirrel Cage Three Phase Induction Motor running in forward direction a LUN 1 z P 1 gt Y Ms z E Si tix XY TAE Y z e ES d H KS amp T as oF F V AED zb NOEL a Es 59 If the user set the orientation of the induction motor into forward direction the outcome that can be seen in the PLC will be identical with the situation in Figure 5 5 And if the input frequency set by the user is less than 7 Hz the VFD frequency meter will indicate 0 Hz and the motor will remain idle in Figure 5 6 Tag Name Outputbitl PLC Address Q1 01 Connected to VFD S1 Figure 5 5 PLC Output for forwar
61. ot make too many actions and changes at the same time as it will crash the program Thirdly there is limitation in the speed control as there are only 3 multi step references in the VFD The frequency changes in this project cannot perform in smaller steps unless there are additional multi step references provided But in overall choosing LabVIEW as the human machine interface of this project 1s a correct decision as it has various types of applications and functions that are easy to understand and use Additionally this approach is more economical as the objectives of 69 the project had achieved with only basic functionality of the LabVIEW toolkit used which are shared variables and NI OPC Servers OMRON CJI series PLC is easy to install and setup Both hardware and software configuration can be easily done It can carry out additional functions by simply add more units with various functions which in this project is the Ethernet unit The 3G3MV inverter is a user friendly VFD that allows the user to configure the function parameter easily and the circuit wiring can be completed easily 6 2 Recommendation Ethernet control of the squirrel cage induction motor is not consider as a perfect distance remote control system as it 1s not a supervisory control and data acquisition SCADA system It 1s crucial to acquire data from the induction motor so that user can make decision according to the current status of the motor For examp
62. ouonbaly qene A pue QTd Jo Weiseiq 312177 9c 9 o1nSrq era Bung ili m gt T at a5 e eI AP ERI AT 22 2 ACS c el 69 ele alae c Die e EEN EZA eom pee EZAN ZNT DOGGIE ej TJI TOE ooo a5 elle indjno 10104 qddns jc ORS lt ZEER VE e loll vJl i BEZE LL 9 TANAN eue c0 ooo o o o IO iom iio o o o moo ci ooo 8 C l A ouenboauJ ajqeueA pue 54d JO wepe n3119 Jj xipueddy Figure 8 37 Internal Circuit of the 3G3MV Inverter 104
63. plication session and presentation layer of the OSI model Examples of these layers are e mail remote login network management and file transfer protocol FTP 14 Level 2 Transport Layer This layer is identical to the transport layer in the OSI model It has two types of protocol which are Transmission Control Protocol TCP and User Datagram Protocol UDP TCP is connection oriented i e the receiving device allows to send byte stream data or to send data in an orderly form This allows the retransmission of the corrupted data on upon the request from the receiver On the other hand UDP is a connectionless transfer of individual messages and provides no mechanism or error recovery and flow control This makes UDP less reliable and more suitable for quick data transfer that does not contain secure files 14 Level 3 Internet Layer This layer corresponds to the network layer of the OSI model and uses the Internet Protocol IP to transfer data packets In this layer transfers of information across networks are performed via gateways and routers Network failure can be rectified around the point of failure without correcting the overall system connection 21 e Level 4 Network Interface Layer This layer combines the physical and data link layer of the OSI model and manages the exchange of data between networks via routers and gateways 2 4 3 Overview of Ethernet Ethernet is the hardware part of a network which acts as a
64. quency meter for forward direction and frequency 28 Hz 65 If the user increases the input frequency range to a value that is within 35 Hz and less than 42 Hz then the outcome that can be seen in the PLC and the VFD frequency meter will be identical with the situation in Figure 5 17 and Figure 5 18 respectively Tag Name Outputbitl PLC Address Q1 01 Connected to VFD S1 Tag Name Outputbit5 Tag Name Outputbit7 PLC Address Q1 05 PLC Address Q1 07 Connected to VFD S5 Connected to VFD S7 Figure 5 17 PLC Output for forward direction and frequency 35 Hz Figure 5 18 VFD frequency meter for forward direction and frequency 35 Hz 66 If the user increases the input frequency range to a value that is within 42 Hz and less than 49 Hz then the outcome that can be seen in the PLC and the VFD frequency meter will be identical with the situation in Figure 5 19 and Figure 5 20 respectively Tag Name Outputbitl u B r ag Name Outputbit6 PLC Address Q1 01 PLC Address Q1 06 Connected to VFD S1 Connected to VFD S6 Tag Name Outputbit7 PLC Address Q1 07 Connected to VFD S7 Figure 5 19 PLC Output for forward direction and frequency 42 Hz aN om cns cape a t eia Figure 5 20 VFD frequency meter for forward direction and frequency 42 Hz 67 If the user increases the input frequency range to a value that is equal or more than 49 Hz then the outcome that can be seen in the PLC
65. r is the most common type of three phase alternating current AC motor used in the industries today The reasons are shown below 9 Cheaper price compared to other types of motors Simple and rough construction More dependable High efficiency Able to alter the speed easily Does not require starter to have starting torque A three phase induction motor consists of two members stator and rotor A stator is the stationary part with winding and a rotor is the moving part with winding or bars of copper If the rotor is wounded with copper wires it is called wound rotor motors and if the rotor is constructed of solid copper bars welded together at both ends the motor 1s known as squirrel cage rotor motor figure 2 3 10 End Bracket Hearing Housing End Bracket Bearing Housing Figure 2 3 Squirrel Cage Three Phase Induction Motor 9 For squirrel cage induction motor the stator 1s a core made up of hundred thin laminations stacked together to form a cylinder and with coils of insulated wire inserted into slots of the core figure 2 4 As for the rotor it is constructed of steel laminations piles with evenly spaced aluminium conductor bars cast in the slots of the rotor core around the boundary and welded together at both ends figure 2 5 5 Figure 2 4 Stator Lamination left and Stator Construction right 9 10 Steel Laminations Conductor Bars End Ring Figure 2 5 Rotor Lamination
66. ress is 32 bits long in another words it has 2 possible combinations of IP addresses An IP address is the combination of 4 decimal notations separated by a period Each decimal can have a number in the range of O to 255 IP addresses are written in decimal notation so that it is readable by humans but its actual form is binary as computers can only read information in binary notation For example the given IP address above has a binary notation given in Figure 2 17 14 27 1 1000000 10101000 00000001 00101110 4 h 8 bits or 1 byte 32 bits or 4 byte Figure 2 17 Binary representation of an IP address Each section has an 8 bit decimal representation equivalently 1 byte or an octet where the minimum can be 0 2 and the maximum number can be 255 2 The above example is a representation of an IPv4 address There are other types of IP address versions available such as IPv6 anticipated to compensate for the exhaustion of Pv4 address 1 e running out of space for IPv4 address However it is not be included in this thesis as the project uses an IPv4 type address 14 There are 5 IP classes plus certain special address illustrated in Table 2 1 Table 2 2 Five types of IP Classes and Special Addresses 18 Default Network The IP address of 0 0 0 0 1s used for the default network Class A This class is for very large networks such as a major international company might have IP addresses with a first
67. ront Panel If the program is correctly configured output light of the PLC will turn on when the input had been triggered and the small triangle of the input push button will light on when the VI is running which indicate the connection between the computer and PLC is valid Otherwise troubleshoot the configuration by ensure all the steps above had been followed correctly and the NI OPC Servers configuration especially IP address had been configure correctly 100 Appendix D Hardware Specification OMRON CJ1M CPUI11 ETN21 Programmable Logic Controller PLC Name Specifications CJIM CPU Unit CJIM CPUII ETN21 I O bits 160 Program capacity 5 Ksteps Data Memory 32 Kwords DM 32 Kwords EM None CJ Series Power CJIW PA202 100 to 240V AC Output Capacity 2 8A at Supply Unit Mi 5V DC DC Input Unit CJIW ID211 Terminal block 24V DC 16 inputs Relay Output Unit CJIW OC211 Terminal block 250V AC 0 6A 8 points End Cover CJIW TEROI Must be connected to the right end of the CPU Rack A fatal error will occur if the End Cover is not connected Table 8 1 Specifications for each unit in CPU Rack 101 TECO Motor Type AEEB Squirrel Cage Three Phase Induction Motor V2 HP Power Input Voltage 220 240 V Delta Input Current 2 02 1 85 A Output Voltage 380 415 V Wye Output Current 1 17 1 07 A Table 8 2 The Specification of the Three Phase Squirrel Cage Induction Motor TECO 102 cOL Anq A
68. rt of this class Class C addresses also include the second and third octets as part of the Net identifier The last octet is used to identify each host This means that there are 2 097 152 22 Class C networks each with 254 25 2 possible hosts for a total of 536 870 912 2 unique IP 29 Class D Class E Broadcast addresses Class C networks make up an eighth of the total available IP addresses Class C networks have a first bit value of 1 second bit value of 1 and a third bit value of O in the first octet Net Host or Node 145 24 53 107 Used for multicasts Class D 1s slightly different from the first three classes It has a first bit value of 1 second bit value of 1 third bit value of 1 and fourth bit value of 0 The other 28 bits are used to identify the group of computers the multicast message is intended for Class D accounts for 1 16 268 435 456 or 2 5 of the available IP addresses Host or Node 24 53 107 Used for experimental purposes only Like Class D it is different from the first three classes It has a first bit value of 1 second bit value of 1 third bit value of 1 and fourth bit value of 1 The other 28 bits are used to identify the group of computers the multicast message is intended for Class E accounts for 1 16th 268 435 456 or 2 of the available IP addresses Net Host or Node 240 24 53 107 Messages that are intended for all computers on a network are sent as broadcasts T
69. s details will appear in the table as illustrated in Figure 8 18 NI OPC Servers untitled opf File Edit View Users Tools Help D cw Bie idmo mes m amp xio E P Channeli Tag Name Address DataType sScanRate _ Scaling Hf CJM CPU11 ETN21 Figure 8 21 NI OPC Servers with a input OPC tag 89 Launch the OPC Quick Client by left click the icon It is necessary to launch the OPC Quick Client so that the tags can be browsed by the LabVIEW If the connection between the user computer and PLC 1s successful the outcome of the OPC Quick Client should be identical with the Figure 8 19 which is the part crop from the demonstration OPC Quick Client OPC Quick Client Untitled File Edit View Tools Help Dc E xicke im sex Eg National Instruments NIOPCServers pe ave System 3Channeli CJ1M CPU11 ETN21 inputbiti Boolean 0 13 00 24 393 mj Channeli System E EChanneli C 1M CPU11 ETN21 Channel1 CJ1M CPU11 ETN21 System Good 1 Figure 8 22 NI OPC Quick Client Now the demonstration of the NI OPC Configuration had been completed The OPC tags are now can be used in the LabVIEW 90 Appendix C Setting Up LabVIEW Shared Variables This section demonstrates the step by step configuration and setup of the shared variable in LabVIEW Before performing the configuration below it is important to ensure that the LabVIEW Datalogging and Supervisory Control Module had been installed properly in t
70. tor either changing the slip of motor or by changing the frequency of the motor Slip can be alter depends on the load on the shaft which also can be controlled by lower down the voltage applied to the motor or even increasing the rotor resistance in the rotor windings 5 In this project variable frequency drive will be acting as the speed controller and as well as the inverter VFDs are used in many different types of applications for various reasons For example they are effective in term of energy saving in pump and fan applications In addition they enhance process operations particularly where flow control is involved VFDs provide soft start capabilities which decrease electrical stresses and line voltage sags associated with full voltage motor start ups especially when comes to drive high inertia loads 8 Figure 2 2 shows the rectifier inverter of VFD The drive consists of rectifiers in three phase diode bridge or in controlled rectifier circuits and inverter switching circuits most commonly used device is insulated gate bipolar transistor IGBT The rectifiers convert AC input power to DC intermediate power then the inverters will convert the resultant to quasi sinusoidal AC power as shown in Figure 2 2 5 Input Converter DC Bus Output Inverter Diode Bridge Filter IGBT Figure 2 2 Internal Circuit of a Variable Frequency Drive Sketch using PSIM 2 3 Squirrel Cage Three Phase Induction Motor Induction moto
71. tput of the formula node had been divided into x y and z in which the number is either O or 1 In order to be readable by the shared variables it is necessary to convert the number into boolean format And once the signal is in boolean format and send to the 53 shared variable the information will be write into the PLC and the output address 1 05 1 06 1 07 of the PLC will light up according to the desired output Table 4 2 VI Formula Node C Programming and its Explanation C Programming Code if a gt 7 amp amp a lt 14 If ais more than or equal to 7 AND less than 14 then x x 1 y 0 z 0 equals to 1 y equals to 0 and z equals to 0 j else if a gt 14 amp amp a lt 21 If a 1s more than or equal to 14 AND less than 21 then x x 0 y 1 z 0 equals to 0 y equals to 1 and z equals to 0 j else if a gt 21 amp amp a lt 28 If a 1s more than or equal to 21 AND less than 28 then x xz y 1 z 0 equals to 1 y equals to and z equals to 0 j else if a gt 28 amp amp a lt 35 If a is more than or equal to 28 AND less than 35 then x x 0 y 0 z 1 equals to 0 y equals to O and z equals to 1 j else if a gt 35 amp amp a lt 42 If a is more than or equal to 35 AND less than 42 then x x 1 y 0 z 1 equals to 1 y equals to 0 and z equals to 1 j else if a gt 42 amp amp a lt 49 If ais more than or equal to 42 AND less than 49 then x x 0 y 1 z 1 equals to 0 y equals to 1 and z equals to 1 else
72. um and the recipient 12 Level 5 Session Layer This layer set up the system to system connection across the network and letting two parties to hold ongoing communications called a session This layer has many roles such as setting up the session monitoring session identification 19 process offering security in data flow continuity in exchanging data and messages and terminating the session 12 Level 6 Presentation Layer This layer deals with data formatting For the outgoing messages it converts data into generic formats so that they can pass through the transmission 12 Level 7 Application Layer Application layer is the top layer of the OSI reference model This is the level that can be seen by the individual users and it provides a set of interfaces for applications in order to gain access to network services At this layer the network transparency is maintained by hiding the physical distribution of resources from the users However the conventional OSI model is more likely an academic guideline as the real world applications have the combination of multiple OSI layers into a single layer The commonly used alternative model in the networking industry is the TCP IP model Figure 2 12 illustrates the TCP IP architecture 14 Application Layer Transport Layer Internet Layer Network Interface Figure 2 12 TCP IP Model 20 Level 1 Application Layer This layer combines the ap
73. ures and minimize users learning curves Its high data rate of 10 Gbps makes it a good solution to deliver high bandwidth in WANs and metropolitan area networks MANS In general the Ethernet system consists of three basic elements 16 The physical medium used to carry Ethernet signals between computers A set of medium access control rules embedded in each Ethernet interface that allow multiple computers to fairly arbitrate access to the shared Ethernet channel An Ethernet frame that consists of a standardized set of bits used to carry data over the system As with all IEEE 802 protocols the ISO data link layer is divided into two IEEE 802 sub layers the Media Access Control MAC sub layer and the MAC client sub layer The IEEE 802 3 physical layer corresponds to the ISO physical layer 16 Figure 2 13 shows the relation between Ethernat and ISO IEEE802 24 IEEE amp cp 3 reference model Application Presentation i protexols Transport Media Access MAC IEEE ace 3 specific Figure 2 13 Ethernet logical relationship to the ISO reference model The configuration of cables computer and other peripherals are defined as the physical topology of a network In general there are 3 types of physical topologies 17 e Linear Bus e Star e Tree or Expanded Star The star connected topology is the most commonly used Ethernet configuration The Figure 2 14 illustrates the network configuration 25

1.0 INTRODUCTION - EngineeringEdu.org

Contents

Download Pdf Manuals

Related Search

Related Contents