INDUSTRIAL CONTROL TECHNOLOGY. A Handbook for Engineers and Researchers. Peng Zhang. Beijing Normal University, People's Republic of China

Transcription

1 INDUSTRIAL CONTROL TECHNOLOGY A Handbook for Engineers and Researchers Peng Zhang Beijing Normal University, People's Republic of China Ш I William I Andrew Norwich, NY, USA

2 Contents Preface 1 Sensors and Actuators for Industrial Control 1.1 Sensors Bimetallic Switch Operating Principle Basic Types Application Guide Calibration Color Sensors Operating Principle Basic Types Application Guide Calibration Ultrasonic Distance Sensors Operating Principle Basic Types Application Guide Calibration Light Section Sensors Operating Principle Application Guide Specifications Calibration Linear and Rotary Variable Differential Transformers Operating Principle Application Guide Calibration Magnetic Control Systems Operating Principle Basic Types and Application Guide Limit Switches Operating Principle Basic Types and Application Guide Calibration xix Vll

3 CONTENTS Photoelectric Devices Operating Principle Application Guide Basic Types Proximity Devices Operating Principle Application Guide Basic Types and Specifications Scan Sensors Operating Principle Basic Types Technical Specifications Force and Load Sensors Operating Principle Basic Types Technical Specifications Calibration 86 Actuators Electric Actuators Operating Principle Basic Types Technical Specification Application Guides Calibrations Pneumatic Actuators Operating Principle Basic Types and Specifications Application Guide and Assembly on Valve Hydraulic Actuators Operating Principle Basic Types and Specifications Application Guide Calibration Piezoelectric Actuators Operating Principle Basic Types Technical Specifications Calibration Manual Actuators 141

4 CONTENTS IX 1.3 Valves Control Valves Basic Types Technical Specifications Application Guide Self-Actuated Valves Check Valves Relief Valves Solenoid Valves Operating Principles Basic Types Technical Specifications Float Valves Operating Principle Specifications and Application Guide Calibration Flow Valves Operating Principle Specifications and Application Guide Calibration 180 Computer Hardware for Industrial Control Microprocessor Unit Chipset Microprocessor Unit Organization Function Block Diagram of a Microprocessor Unit Microprocessor Internal Bus System Memories Input/Output Pins Interrupt System Microprocessor Unit Interrupt Operations Interrupt Process Interrupt Vectors Interrupts Service Routine (ISR) Microprocessor Unit Input/Output Rationale Basic Input/Output Techniques В asic Input/Output Interfaces Microprocessor Unit Bus System Operations Bus Operations Bus System Arbitration 222

5 X CONTENTS Interrupt Routing A A Configuration Registers Programmable Peripheral Devices Programmable Peripheral I/O Ports Programmable Interrupt Controller Chipset Programmable Timer Controller Chipset CMOS Chipset Direct Memory Access Controller Chipset Idle Cycle Active Cycle Application-Specific Integrated Circuit (ASIC) ASIC Designs ASIC Specification ASIC Functional Simulation ASIC Synthesis ASIC Design Verification ASIC Integrity Analyses Programmable Logic Devices (PLD) Field-Programmable Gate Array (FPGA) FPGA Types and Important Data FPGA Architecture FPGA Programming 255 System Interfaces for Industrial Control Actuator-Sensor (AS) Interface Overview Architectures and Components AS Interface Architecture: Type AS Interface Architecture: Type Working Principle and Mechanism Master-Slave Principle Data Transfer System Characteristics and Important Data How the AS Interface Functions Physical Characteristics System Limits Range of Functions of the Master Modules AS Interface in a Real-Time Environment 277

6 CONTENTS XI 3.2 Industrial Control System Interface Devices Fieldbus System Foundation Fieldbus PROFIBUS Controller Area Network (CAN bus) Interbus Ethernets/Hubs Interfaces PCI, ISA, and PCMCIA IDE SCSI USB and Firewire AGP and Parallel Ports RS-232, RS-422, RS-485, and RS IEEE Human-Machine Interface in Industrial Control Overview Human-Machine Interactions The Models for Human-Machine Interactions Systems of Human-Machine Interactions Designs of Human-Machine Interactions Interfaces Devices Tools Software Highway Addressable Remote Transducer (HART) Field Communications HART Communication HART networks HART Mechanism HART System HART System Devices HART System Installation HART System Configuration HART System Calibration HART Protocol HART Protocol Model HART Protocol Commands HART Protocol Data 411

7 Xll CONTENTS HART Integration Basic Industrial Field Networks Choosing the Right Field Networks Integrating the HART with Other Field Networks 420 Digital Controllers for Industrial Control Industrial Intelligent Controllers Programmable Logic Control (PLC) Controllers Components and Architectures Control Mechanism PLC Programming Basic Types and Important Data Installation and Maintenance Computer Numerical Control (CNC) Controllers Components and Architectures Control Mechanism CNC Part Programming CNC Controller Specifications Supervisory Control and Data Acquisition (SCADA) Controllers Components and Architectures SCADA Protocols Functions and Administrations Proportional-Integration-Derivative (PID) Controllers PID Control Mechanism PID Controller Implementation PID Controller Tuning Rules PID Control Technical Specifications Industrial Process Controllers Batch Controllers Batch Control Standards Control Mechanism Servo Controllers Components and Architectures Control Mechanism Distributed Servo Control Important Servo Control Devices Fuzzy Logic Controllers Fuzzy Control Principle Fuzzy Logic Process Controllers 564

8 CONTENTS хш Application Software for Industrial Control Boot Code for Microprocessor Unit Chipset Introduction Code Structures BIOS and Kernel Master Boot Record (MBR) Boot Program Boot Sequence Power On Load BIOS, MBR and Boot Program Initiate Hardware Components Initiate Interrupt Vectors Transfer to Operating System Real-Time Operating System Introduction Task Controls Multitasking Concepts Task Types Task Stack and Heap Task States Task Body Task Creation and Termination Task Queue Task Context Switch and Task Scheduler Task Threads Input/Output Device Drivers I/O Device Types Driver Content Driver Status Request Contention I/O Operations Interrupts Interrupt Handling Enable and Disable Interrupts Interrupt Vector Interrupt Service Routines Memory Management Virtual Memory Dynamic Memory Pool

9 XIV CONTENTS Memory Allocation and Deallocation Memory Requests Management Event Brokers Event Notification Service Event Trigger Event Broadcasts Event Handling Routine Message Queue Message Passing Message Queue Types Pipes Semaphores Semaphore Depth and Priority Semaphore Acquire, Release and Shutdown Condition and Locker Timers Kernel Timers Watchdog Timers Task Timers Timer Creation and Expiration Real-Time Application System Architecture Input/Output Protocol Controllers Server or Manager I/O Device Module Process Process Types Process Attributes Process Status Process and Task Process Creation, Evolution, and Termination Synchronization Mutual Exclusive Finite State Automata Models Designs Implementation and Programming 667

10 CONTENTS XV Data Communications in Distributed Control System Distributed Industrial Control System Introduction Opened Architectures for Distributed Control Closed Architectures for Distributed Control Similarity to Computer Network Data Communication Model for Distributed Control System Data Communication Models for Open Control Systems Data Communication Models for Closed-Control Systems Data Communication Basics Introduction Data Transfers within an 1С Chipset Data Transfers over Medium Distances Data Transfer over Long Distances Data Formats Bit Byte Character Word Basic Codeword Standards Electrical Signal Transmission Modes Bit-Serial and Bit-Parallel Modes Word-Parallel Mode Simplex Mode Half-Duplex Mode Full-Duplex Mode Multiplexing Mode Data Transmission Control Circuits and Devices Introduction Universal Asynchronous Receiver Transmitter (UART) Applications and Types Mechanism and Components Universal Synchronous Receiver Transmitter (USRT) 708

11 XVI CONTENTS Universal Synchronous/Asynchronous Receiver Transmitter (USART) Architecture and Components Mechanism and Modes Bit-Oriented Protocol Circuits SDLC Controller HDLC Controller Multiplexers Digital Multiplexer Time Division Multiplexer (TDM) Data Transmission Protocols Introduction Asynchronous Transmission Bit Synchronization Character Synchronization Frame Synchronization Synchronous Transmission Bit Synchronization Character-oriented Synchronous Transmission Bit-oriented Synchronous Transmission Data Compression and Decompression Loss and Lossless Compression and Decompression Data Encoding and Decoding Basic Data Compression Algorithms Data-Link Protocols Framing Controls High-Level Data Link Control (HDLC) Synchronous Data Link Control (SDLC) Error Controls Error Detection Error Correction Flow Controls Stop-and-Wait Sliding Window Bus Arbitration Sublayers Logic Link Control (LLC) Media Access Control (MAC) 762

12 CONTENTS xvn 6.6 Data Communication Protocols Client-Server Model Two and Three-Tier Client-Server Message Server Application Server Master-Slave Model Master Slave Producer-Consumer Model Designs Implementations Remote Procedure Call (RPC) 770 System Routines in Industrial Control Overview Power-On and Power-Down Routines System Hardware Requirements Low Voltage Power Supply Circuit (LVPSC) Basic Input and Output System (BIOS) System Power-On Process ' System Power-On Self Tests When Does the POST Apply? What does the POST do? Who Does the POST? System Power-Down Process Install and Configure Routines System Hardware Requirements PCI Address Spaces PCI Configuration Headers PCI I/O and PCI Memory Addresses PCI-ISA Bridges PCI-PCI Bridges PCI Initialization The PCI Device Driver PCI BIOS Functions PCI Firmware System Devices Install and Configure Routine System Configure Routine 803

13 XVlll CONTENTS 7.4 Diagnostic Routines System Hardware Requirements Device Component Test Routines System NVM Read and Write Routines Faults/Errors Log Routines Change System Mode Routines System Modes List System Modes Transition Calibration Routines Calibration Fundamentals Calibration Principles Calibration Methodologies Simulation Routines Modeling and Simulation Process Models Process Modeling Control Simulation Methodologies and Technologies Manufacturing Process Modeling and Simulation Computer Control System Modeling and Simulation Simulation Program Organization Simulation Routines for Single Microprocessor Control Systems Simulation Routines for Distributed Control Systems Simulation Routine Coding Principles Simulators, Toolkits, and Toolboxes MATLAB SIMULINK SIMULINK Real-Time Workshop ModelSim Link for ModelSim 849 Index 853