Digital control devices. KON-C2004 Mechatronics Basics Tapio Lantela

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1 Digital control devices KON-C2004 Mechatronics Basics Tapio Lantela

2 Overview Programmable logic controllers Real-time control Digital communication

3 PLCs 3

4 The traditional logic controller: Electromechanical relays Still used for example in railway interlocking systems Robust, long lifespan Expensive special relays en.wikipedia.org/wiki/relay#mediaviewer/file:relay_room.jpg 4

5 The better way: Programmable Logic Controller (PLC) DIN rail mounting Resistant to - Electromagnetic interference - Dust, vibration, heat resistant Modular Off-the-shelf Easy and simple to set up - In comparson to a microcontroller system Higher voltage, better protected IO 5

6 PLC vs microcontroller PLC - Encased protected from environment - IO is protected? from high voltage, outputs more current does not break the whole device often based on relays - Modular add more io - Expensive (not very) - Programmed with IEC languages doable by an electrician Microcontroller - Unprotected prototyping board - For example 0-5 V low current I/O - Programmed with C - Extensions with communication bus and additional code - Very cheap 6

7 PLC vs PC PLC - Program once, run forever - Dedicated system - Cheaper - Programmable by electrician - Limited user interface (buttons, maybe a screen) - Built-in inputs PC - Lots of computing power - Often regular software updates - Display, flexible UI - Inputs with extension cards 7

8 PLC programming Programmed with a PC (Ethernet, serial bus etc.) Programming languages: IEC Ladder diagram (LD), graphical - Function block diagram (FBD), graphical - Structured text (ST), textual - Instruction list (IL), textual - Sequential function chart (SFC), has elements to organize programs for sequential and parallel control processing. 8

9 Ladder diagram Similar to relay schematics Understandable to electrical engineers without any programming skills By far the most used PLC language Also operators for - Mathematical operators - Analog operators - Timer operators etc. 9

10 Function block diagram 10

11 Structured text A bit like C or Pascal Familiar expressions - If, while, for, function calls 11

12 Instruction list A bit like Assembly V67KQWGCQC4/T30JnZx7saI/AAAAAAAAAcM/BygizcA-ASI/s1600/untitled.JPG 12

13 Ladder vs FBD vs IL 13

14 Soft PLC Example: Beckhoff industrial PCs 14

15 Real-time control 15

16 Real-time Guaranteed response from the control system in specified time frame Hard realtime - Delayed response leads to system failure Firm - Delayed result is useless but some delays are tolerated Soft realtime - Delay reduces the usefulness of the result

17 Need for real time control Control algorithms - Performance and stability Safety functions - Anti-lock braking etc. - Fly-by-wire Live video playback 17

18 Control system point of view Control algorithm often relies on constant update interval Too long delay -> unstable system Sampling rate - Time between two updates of the control signal Delay - Time from input sampling to output 18

19 Real-time operating system Definition: A real-time behavior of a software system requires that each process or task execution must satisfy bounded responsetime constraints or risk severe consequences, including failure. 19

20 Real-time operating systems FreeRTOS - Microcontrollers RTLinux Matlab xpc Target / Labview Real-Time - Measurement and prototyping on PCs and FPGAs Windows CE - Embedded devices (PCs etc.) Windows with real-time kernel extension 20

21 Microcontroller real-time operation Interrupt based scheduling Tasks - Control algorithm 1 - Control algorithm 2 - User input - Bus communication 21

22 Digital communication 22

23 Parallel vs serial communication Parallel - Bits transmitted simultaneously in parallel wires Serial - Bits sequentially in the same line 23

24 Serial and parallel buses Serial - USB (Universal Serial Bus) - Ethernet - PCI-e, SATA - RS I 2 C, SPI - CAN, Profibus, Fieldbus foundation, AS-interface Parallel - PCI - SCSI - IDE - Printer port 24

25 RS-232 Also known as Serial bus Voltage level 3-15 V - Negative = 1 - Positive = 0 - Also TTL (0-5 V) < 0.5 Mbit/s 25

26 Field buses AS-Interface Modbus Foundation Fieldbus Profibus Interbus EtherCAT 26

27 Industrial wireless communication Generic RF - <1 MHz Wifi - 2,4-5 GHz Bluetooth IEEE ,4 GHz - Wireless HART Zigbee, ISA100.11a RFID 27

28 Example: EtherCAT bus 28

29 Summary Microcontrollers are for hobby stuff and embedded devices PLC is the multipurpose logic tool of industry - Robust - Simple PC with a real time operating system gives computing power There is no universal digital communication standard 29

30 Mechatronic machine Communication Interface Sensors Actuators Signal processing Controller Input Output Controlling computer Process

31 The end Give feedback! It s the only way to direct the a process in the right direction.

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