Abstract: Rockwell Automation PLC-5 programmable logic controller consisting of control systems, transformation of the ControlLogix system encountered technical problems and solutions.
Key words: ControlLogix DeviceNet program transformation
1 Introduction
Formosa Plastics Group thermoelectric (Ningbo) Co., Ltd in Taiwan by the Formosa Plastics Chemical Fiber Co., Ltd. Taiwan, Cayman Islands by the British-based Investment (Cayman) Limited, wholly-owned building. Formosa Petrochemical Zone of the self as a thermal power plant, equipped with 3 sets of 150 MW coal-fired generating units condensate pumping. Formosa Petrochemical Zone in order to meet production needs, each unit is equipped with steam boilers of 500 tons per hour and 150 MW generating units for the petrochemical zone in the various factories for production of steam, industrial water and electricity.
Indoor coal field is a large coal transfer station, the coal yard to provide 3,200 tons per day of coal combustion.
Into the coal from the coal yard, coal distribution, coal mining and the coal out of the four subsystems. ????? in coal: coal through a series of drive belts will dock at the pier s room from the delivery entrance to the indoor coal yard, while a large lump initial pulverization; ????? cloth Coal: The drive belt will be dozens of coal raised to room meters high, then fell to the ground along a particular funnel, piled into a pyramid shape, when the coal pile to the desired height, the funnel moved forward a distance from coal to cloth, finally, on the ground similar to the horizontal shape of Mitsubishi same Meishan feet; ????? dug: to the accumulation of forming the coal, according to a predetermined speed and direction of one level of Pa to the delivery belt; ????? out of coal: coal crushed further, the coal mining machine to the belt Pa on the combustion of coal transported to port.
The whole control system consists of SLC500, PLC-5 and the 1793 Remote I / O component, real-time monitoring systems through RSView32 coal field to achieve automatic unattended operation.
PLC-5 and the 1793 Remote I / O is the early products of Rockwell Automation, now discontinued, this has caused great difficulties for normal maintenance equipment. This requires the PLC-5 and the 1793 Remote I / O component of the system (Figure 1) transformation for the ControlLogix and 1794 I / O system (Figure 2). Figure 1 indoor coal yard control system (transformation of the former)
Figure 2 After transformation, the network equipment
2 project features and construction strategies
2.1 Project Characteristics
(1) on-site construction time is short
To ensure the normal power generation plants require days a week to complete the renovation project
(2) technology widely
Related to equipment Networking Technologies, SLC500, PLC-5, ControlLogix three types of PLC programming and PLC communication between, RSView32 host computer monitor and touch screen control technology.
2.2 Construction Policy
(1) Strategy 1: make a comprehensive, in-depth technical preparation
Simulator built in the laboratory, transformed all the procedures must be adopted simulation (including I / O testing, chain of test)
Use of spare parts (encoder, converter, etc.) in the laboratory equipment, network configuration, data mapping experiments
Familiar with PLC-5 and 1793 data modules based on the detailed site drawing process diagram wiring
(1) Strategy 2: unity of command, division of labor
Construction personnel will be divided into 2 groups, at the same time:
Group 1: Field wiring installation, Group 2: Control Room program and modify RSView32 graph control procedures.
As a result of these measures, so that the project successfully completed on schedule.
Three major technical problems
Replace the module in the choice of when to consider: the nature of sensor or load (poured and pulled out); public contacts; analog module s accuracy and resolution.
The original system RSLogix5 software development process, the first renovation project to convert PLC-5 program ControlLogix program, you can use RSLogix5000 own tools to complete the transformation [1], transformation correctness is yes. But the transformation is not complete, need to manually complete a number of important functions, such as I / O address mapping, device network address mapping, MSG instruction, etc. In addition, Logix5000 not found in the corresponding instruction (such as BTR, BTW, INV), need to According to logic itself.
With particular attention to: PLC-5 is 16-bit data format INT, ControlLogix is a 32-bit data format DI NT, in the programming note address offset.
3.1 I / O address mapping
Figure 1, PLC-5 1 / 2 slot addressing, the need to physical I / O mapping to transform the address to cloth Coal example, PLC-5 and 1756 blocks of I / O correspondence shown in Table 1, Ladder corresponding Figure 3,4. Table 1 I / O correspondence
Figure 3 will be the first one cloth Coal 1771-IBN mapped to the 1756-IB32
Figure 4 cloth Coal 1771-OBN mapped to the 1756-OB32
3.2 Net data mapping device
1771-SDN DeviceNet scanner module total of six input / output memory block [2], namely Block Xfer62 to Block Xfer57, a total of 357 input words and 357 output words. Shown in Table 2. Table 2 1771-SDN
This block using the Block Xfer62 storage, therefore, the input data mapped to the N10: 0 to N10: 61; output data mapped to the N11: 0 to N11: 61. Figure 5 (Note: touch screen using Block Xfer 61 storage blocks).
Figure 5 A network and the transformation of pre-B network input / output data mapping 1756-DNB DeviceNet scanner module input / output for the 124 pairs of words and 123 pairs of words were mapped to Local: 2: I. DATA [0] to Local: 2: I. DATA [123] and Local: 3 : O. DATA [0] to Local: 3: O. DATA [122] Figure 6,7,8 transformed data for the device network map Figure 6 A network input map after transformation Figure 7 A network output map after transformation
Figure 8 transformed B network input / output mapping
Network B under the equipment before and after transformation of data mapping, preparation of relevant transfer instructions shown in Figure 9:
Figure 9 will be dug machine 1794-IB16 data mapped to the N10 [20]
Figure 10, 11,12 was modified before and after the network.
Figure 10 pre-reform network
Figure 11 A network after transformation
798.jpg "border = 0> Figure 12 transformed B network
3.3 CPU communication between
Read the original process data communication between the various subsystems of this renovation project is the key to success. Read carefully on the basis of the original program can be shown in Figure 13, data transfer relationship between the various subsystems. Figure 13 PLC communication between
As the PLC types, so using three types of communications instructions, such as shown in Table 3. Table 3, three kinds of communication instruction
In the ControlLogix system parameters between the CPU can not only MSG instruction to achieve, you can also define the producer / consumer labeling to achieve, the project uses the latter approach.
Coal and coal mining with cloth machine communication, for example, by two steps:
Step 1: In the process defined in the Coal cloth N15 [0] for the producers, the definition of N14 [0] for the consumer; in the coal mining machine procedures defined in the N16 [0] for the producers, the definition of N14 [0] for the consumer persons;
Step 2: Coal and coal mining in the fabric machine I / O configuration, and add each other s Ethernet communications module and the CPU (see Figure 14-15): Figure 14 Coal fabric I / O configuration Figure 15 coal mining machine I / O configuration
3.4 Monitoring screen
The transformation of the main screen of the monitor to transform the database, there are two ways to achieve.
(1) The first method is
Step 3 can be carried out:
Step 1: New OPC Server, replace the Direct Drive (Direct Drive)
Step 2: New Database, the original TAG to the new address within the node
Step 3: Modify the path to the screen in each TAG
(2) The second method is
Be divided into two steps:
Step 1: New OPC Server, replace the Direct Drive (Direct Drive)
Step 2: Modify the name of the database node, and converted the original program addresses the procedures to address.
Figure 16,17,18 monitor screen for indoor coal field:
Figure 16 indoor coal yard control system main screen
Figure 17 Coal monitor screen cloth Figure 18 coal mining machine monitoring screen
4 Conclusion
RSLogix5000 transformation tool that comes with most program transformation work complete, safe and reliable, not only greatly reduces the labor intensity of engineers, but also to enable them to expend more energy, peace of mind to deal with the function can not automatically convert.
The successful completion of the reconstruction project, once again proved Rockwell Automation Integrated Architecture has strong vitality.
References
[1] Rockwell Automation: Converting PLC-5 or SLC500 Logic to Logix-Based Logic
[2] Rockwell Automation: PLC-5 DeviceNet Scanner Module 1771-SDN User Manual