1. BL40A2800 - Electrical Motion Control
Lectures /discussion/group works
Associate professor Tuomo Lindh room. 6409
3. period: Tuesdays , in room 7332
4. period: Tuesdays , in room 6216
Tutorials / group works assignments:
Researcher, Henri Montonen, (room 6416)
In laboratory of control engineering room 6316
Thursdays 12-14
Or somewhere else when informed

2. Course Content, period 3. period 4.
Automation, modelling servodrive, position control and trajectory tracking
period 4.
Modelling and identification. period 4.
Adaptive control

3. Discussions and demonstrations
P3.
Automation
Analog and digital communication techniques used in automation,
Digital control of mechatronic systems, field buses
Modelling servo drive
Controllers for position control and trajectory tracking
Work in group solving automation and control problems
P4.
Simulation of mechatronic systems,
Identification, Dynamical system models based on tests and measurements,
Observers and self-tuning controllers
Work in group solving automation and control problems.

4. contents
As drawn diagrams

5. Exercises Demonstrations /Lecture/ Exrcise
PLC systems, ABB AC500 PLC:s
Field buses,
Servo axle, dynamics of model (eigenvalues, step response etc.)
Electric drives, simulation
Beckhoff Industrial PC
System modelling,
Identification
Self tuning controllers

6. Exercise work 2-axis manipulator
Components
Models of manipulator
Rigid
Flexible
Position control
Trajectory tracking
Identification of one axis, (or ¼ -transit)
Detailed instructions will be available in Noppa

7. Hierarchy of automation Automation devices Programming
Lecture
Hierarchy of automation Automation devices
Programming

8. Components on different levels
Suuret teollisuuslaitoksen väylät ja tietojärjestelemät voidaan jakaa kuvan mukaisella hierarkialla
Eri tasoilla on erilaisia laitteisto ja väyläratkaisuja
Rajat eivät välttämättä ole selkeitä esim. kenttä- ja prosessinohjaustaso voivat olla limittäin ja tuotannonohjaustaso voi pienistä laitoksista puuttua.

9. Metso DNA

10. Simatic s7-400

11. From small PLC:s to factory scale
Valmistajat Prosessin hallinta
Loppukäyttäjät
I/O-laajuus
Ominaisuudet
Premium
Quantum
OEM / Laitevalmistajat
Momentum
Premium
Micro
Momentum
Magelis
Schneider Automation’s PLC range can be divided into two major segments: “PLCs for independent machine builders” and “PLCs for end users.” This positioning is not rules - most of our PLCs can technically fit most applications - but rather points you to the market segments where each PLC has been “optimized” for price/performance/application fit.
PLCs for machine builders
Micro and Nano are “optimized” for stand-alone machines because they provide a very compact mix of functions - in a low cost, small footprint package. They can also be used in some distributed applications.
Momentum has been optimized for distributed architectures where there are clusters of I/O. It is “optimized” for distributed clusters with 64 I/O points or less (two Momentum blocks max per cluster). It can be used in some stand-alone applications.
When a decentralized machine application has I/O clusters with greater than 64 points, or if specialty functions like motion, weighing, safety relays or specialized I/O is required, then the Premium is the “optimal” choice. It can handle large machines with up to 2,048 points. 64 point high density cards make it more cost effective for clusters >64 points.
PLCs for end users
Quantum can fit most end user applications, but it has been “optimized” for process applications with Concept FBD programming, S908, redundant MB+, hot-standby, conformal coating, and intrinsically safe I/O. It is our high end PLC platform.
Premium can fit most end user applications, but it has been “optimized” for discrete manufacturing applications with integrated motion, safety relays, superior FBD programming for sequential applications, memory backup, reflex I/O, and highly distributed architecture. It is our mid-range PLC platform.
The Momentum can be used in smaller distributed applications with Premium/Quantum as distributed I/O or as standalone processors. It is “optimized” for I/O clusters less than 64 points, or no more than 2 blocks per cluster.
The new Atrium processors fit a wide range of applications where users want the benefits of PC based control with the reliability of a PLC.
Strategic Positioning of PLC Platforms
Twido
Lähde: Scneider

12. Industrial PC E.g. Beckhoff See e.g.

13. Unitronics M90
ABB AC500

14. Modicon Quantum
Single-task: This is the more simple default structure, in which only the master task
is executed.
b Multitask: This structure, which is more suitable for high-performance real-time
events, consists of a master task, a fast task, periodic tasks, and high-priority
event-triggered tasks.
The master, fast and periodic tasks are made up of sections and subroutines. The
sections and subroutines can be programmed in any of the following languages:
Structured Text (ST), Instruction List (IL), Ladder (LD) or Function Block Diagram
(FBD) (1). The event-triggered tasks use the same languages. Sequential Function
Chart (SFC) or Grafcet language is reserved for master task sections.
The table below lists the possible program tasks for Atrium, Premium and Quantum
type processors respectively.

15. Siemens

16. Lähde: www.metsoautomation.com

17. Imatra paper factory, machine 5
operointiasemista OPS
Hälytysasemista ALP
Prosessiasemista PCS
Varmennusasemasta BU
Diagnostiikka asemasta DIA
Raportointiasemasta REP
Liityntäasemista
Prosessitietokoneille CIS
TARAP (XIS-järjestelmä)
PROMAS
Ohjelmoitaville logiikoille LIS
Selma, kartonkikoneen käyttöjen ohjausjärjestelmä, RS-232 liityntä
VIB-kostutuslaite, RS-232 liityntä
Sähköinfrat, RS-232 liityntä
Damatic järjestelmään DIS
Prosessinhallinta järjestelmistä XIS

18. PLC-programming
Tuomo Lindh

19. Programming environments
See
Codesys
TwinCat 3
(Unitronics)
IEC
Programming languages
(C,C++, Simulink)
IEC 61131

20. Environment Siemens IEC61131 programming, GUI Compiler and loader,
”On-line simulator”
Lähde: Kuvat Siemens

21. CodeSys and ABB AC500 Automation Builder Project tool
Creates definition files (electronic data sheets) of devices , fieldbuses, drivers etc.
CodeSys
IEC61131 programming
GUI
compiler and loader,
”On-line simulator”
Visualization, ’user interface’
Footer

22. PLC as real time operating system
See
Different types of tasks
Multitasking

23. Traditional PLC scheduling
Source: Siemens

24. Tasking - Pre-emptive tasks (Full codesys or non-pre-emptive tasks embedded codesys) - System events - Interrupt tasks
Which task is being processed?
For the execution, the following rules apply:
That task is executed, whose condition has been met; i.e., if its specified time has expired, or after its condition (event) variable exhibits a rising edge.
If several tasks have a valid requirement, then the task with the highest priority will be executed.
If several tasks have valid conditions and equivalent priorities, then the task that has had the longest waiting time will be executed first.
The processing of the program calls will be done according to their order (top down) in the task editor.
Depending on the target system PLC_PRG might get processed in any case as a free-wheeling task, without being inserted in the task configuration tree.
System Events
Instead of a "task" also a "system event" can be used to call a POU of your project. The available system events are target specific (definition in target file). The list of the standard events of the target may be extended by customer specific events. Possible events are for instance: Stop, Start, Online Change.
The assignment of system events to POUs is also done in the Task configuration editor. Use the dialog 'Events', which will be opened as soon as the entry " System-events" is selected in the task configuration tree:
Table for Assigning POUs to System Events
Footer

25. (Pre-emptive Rate-monotonic scheduling (RMS))

26. Beckhoff
” TwinCAT is a pre-emptive multitasking system” , [Source: Beckhoff Information System]

27. Step S7 Couple of cyclic tasks can pre-empty lower priority tasks
These are called cyclic interupts by Siemens

28. Programming model funktioiden suorituksen ohjaus
CONFIGURATION
RESOURCE
RESOURCE
TASK
TASK
TASK
TASK
PROGRAM
PROGRAM
PROGRAM
PROGRAM FB FB FB FB
GLOBAL and DIRECTLY
REPRESENTED VARIABLES
ACCESS PATHS
Communication function
IEC
muuttujan saantitie
muuttuja FB
toimintolohko, funktiolohko

29. IEC datatypes see e.g. http://en.wikipedia.org/wiki/IEC_61131-3
Elementary Data Types Data Type Size Description Range
BOOL 1 bit Boolean 0 to 1
BYTE 8 bits Unsigned Byte 0 to 255
BYTE 8 bits Signed Byte (SIMATIC mode for SHRB instruction only) to +127
WORD 16 bits Unsigned Integer 0 to 65,535
INT bits Signed Integer to
DWORD 32 bits Unsigned Double Integer 0 to
DINT 32 bits Signed Double Integer to
REAL 32 bits IEEE 32 bit floating point E-38 to E E-38 to E+38
derived types, structured types
Structured
TYPE MOTOR
STRUCT
ON_OFF: BOOL;
I_L1: ST_CURR;
I_L2: ST_CURR;
END_STRUCT
END_TYPE
Ohjelmoija voi määritellä rakenteellisia tietotyyppejä, joilla yhteenkuuluvat osat
saadaan yhdeksi kokonaisuudeksi. Esimerkiksi moottoriin liittyvät muuttujat voidaan
kaikki liittää yhteen Moottori-tyyppiin. (IEC 03)
Vrt. typedef ja struct
Johdetut ja rakenteelliset ei kovin yleisiä, muttei kannata hämääntyä jos näkee
TYPE
ST_CURR : REAL
END_TYPE

30. variables VAR_INPUT VAR_OUTPUT VAR_INPUT_OUTPUT VAR VAR_RETAIN
AT memory address
ROGRAM PLC_PRG
bitti1 AT %MX0.0.0: BOOL := 0; (*1. input *)
bitti_out AT %MX1.0.0: BOOL := 0; (*output bit*)
bitti2 AT %MX0.0.1: BOOL := 0; (*2. input *)
bitti_out2 AT %MX1.0.1: BOOL := 0; (*out 2*)
END_VAR
Footer

31. Programming languages
Ladder diagram (LD)
Function block diagram (FBD)
Structured text (ST)
Instruction list (IL),
Sequential function chart (SFC)
Continuous Function Chart (CFC). Extension to the IEC standard

32. IEC instructions IL

33. IEC instructions LAD

34. Structured text (ST) IF sw1FAULT OR sw2FAULT THEN state:=stateFAULT;
ELSIF sw1WARNING OR sw2WARNING THEN
state:=stateWARNING;
ELSIF NOT sw1OP_ENABLED OR NOT sw2OP_ENABLED THEN
STOP_START();
ELSIF ton1.Q THEN
state:=stateREADY;
(*CW1:=1151;
CW2:=1151;*)
END_IF

35. Continuous Function Chart
Instructions, Function blocks and functions with given execution order

36. POU program organization unit
POU can be
Program:
Executed once by event, sceduled ..
Function
Can be called
Function block
Footer

37. Example program
PROGRAM application1 VAR appData : REAL; END_VAR

38. Functions FUNCTION FunctionNameAsReturn :INT VAR_INPUT: X: INT;
Y: INT;
END_VAR
// function code
FunctionNameAsReturn =X+Y;
END_FUNCTION

39. Example Function
BODY
FUNCTION SlipRatioDtNeg : REAL VAR_INPUT LAMBDA_DT: REAL; END_VAR VAR RETVAL: REAL; SLOPE: REAL;
RETVAL := 0;
IF LAMBDA_DT < SlipRatioDtNegMax THEN
RETVAL := 1;
ELSE
IF ((LAMBDA_DT >= SlipRatioDtNegMax) AND (LAMBDA_DT <= SlipRatioDtNegMin)) THEN
SLOPE := (Ymin-Ymax) / (SlipRatioDtNegMin - SlipRatioDtNegMax);
RETVAL := LAMBDA_DT*SLOPE + (0-SlipRatioDtNegMin*SLOPE);
END_IF
SlipRatioDtNeg := RETVAL;

40. Function block example
FUNCTION_BLOCK AVGFILTER VAR_INPUT input: REAL; (* Incoming data *) length: INT; (* Length of the filtering array *) enable: BOOL; (* Enable / disable, if disabled, output := input *) inhibit: BOOL; (* If this is true, filter zeroes the array and outputs only zeros *) END_VAR VAR Staticvariable REAL; VAR_OUTPUT output: REAL; (* Output of the filter, average of the elements in the array*)

41. S7-200

42. function block ton1.IN:=(state=0); ton1.PT:=t#5s; ton1();
VAR_GLOBAL
send_ena: BOOL;
timer_ena: BOOL;
timer_counter: TIME;
timer_value: TIME;
END_VAR
VAR
ton1: TON;
END_VAR
ton1.IN:=(state=0);
ton1.PT:=t#5s;
ton1();
IF timer_ena=FALSE THEN
timer_ena:=TRUE;
send_ena:=FALSE;
END_IF
IF timer_value=T#100ms THEN
timer_ena:=FALSE;
send_ena:=TRUE;
Footer

43. Own function block Implementation FUNCTION_BLOCK FunktioLohkoEsim
VAR_INPUT:
X: INT;
Y: INT;
END_VAR
VAR_OUTPUT:
Z: INT;
VAR: % internal ’static’
ID: INT;
// function code
IF ID=0 THEN
ID=1;
ELSE
ID=0;
IF X=1 THEN
Z := X+Y+ID;
ELSEIF X=2 THEN
Z :=X-Y+ID;
END_IF
END_FUNCTION_BLOCK
VAR
tulos: int
END_VAR
Define instance
Inst11 : FunktioLohkoEsim
Inst11( X:=1,Y:=10) ;
read value
Tulos:= Inst11.z; or
LD 1
ST Inst11.X
LD 10
ST Inst11.Y