1. Manufacturing Control Processes – Lab
Introduction
Xiangzhen Sun
Teaching Assistant
xs14@my.fsu.edu
COE A213

2. Intro to Programmable Logic Controller
(PLC)
Processor
A/D Module
I/O Devices
Simulator
Instructions
Instructions
Instructions
Memory
Allocated

3. Variable Application of PLC Programming
1. Manufacturing / Machining
2. Food / Beverage
3. Metals
4. Power
5. Mining
6. Petrochemical / Chemical

4. Major Components of a Common PLC
Configuration Diagram
PROCESSOR
POWER
SUPPLY
I M
N O
P D
U U
T L
E
O M
U O
T D
P U
U L
T E
PROGRAMMING
DEVICE
From
SENSORS
Pushbuttons,
contacts,
limit switches,
etc.
To
OUTPUT
Solenoids,
contactors,
alarms
etc.

5. S7-1200: User Friendly Simulation Tool
System Architecture
Unified hardware, human machine interface (HMI), networking and development software
– eliminating barriers of interoperability between common automation devices
85.32
Input value
Progress
Input
Searching point of inflexion …
Status
%
85.32
Output value
Output
manual
%
Optimization
75.00
Setpoint value %
Start tuning
Use last settings
Abort tuning
Start measurement Stop measurement
34.05
Input1
100.00
Output1% % Setpoint1
62.00
% Time1
3780
ms
3500 4500 5500 6500
ms
40
50
60
Measure cycle
Upload
%
58.05
Input2
37.00
Output2% % Setpoint2
62.00
% Time2
6990
ms
1000 ms
40
50
60
%
40
50
60
%
Startup tuning Tuning in run
85.32
Input value
Progress
Input
Searching point of inflexion …
Status
%
85.32
Output value
Output
manual
%
Optimization
75.00
Setpoint value %
Start tuningStart tuning
Use last settingsUse last settings
Abort tuningAbort tuning
Start measurementStart measurement Stop measurementStop measurement
34.05
Input1
100.00
Output1% % Setpoint1
62.00
% Time1
3780
ms
3500 4500 5500 6500
ms
40
50
60
Measure cycle
Upload
%
58.05
Input2
37.00
Output2% % Setpoint2
62.00
% Time2
6990
ms
1000 ms
40
50
60
%
40
50
60
%
Startup tuning Tuning in run
One Software
- Common editor Engineering Station
- Instant On connections
Built-In Specialty Functions
- Loop Tune, Motion, Etc.

6. S7-1200: User Friendly Simulation Tool
Hardware Connection
Integrated Ethernet, Analog I/O, Motion Control I/O, with Scalable Expansion
– eliminating the need for additional hardware; reducing space and cost
Built-in
Ethernet
Removable
Double-Stack
Terminals
Up to 3 Specialty Modules Up to 8 Signal Module
1 Signal Board
Front panel
Signal Board
SD Memory
Card

7. S7-1200: User Friendly Simulation Tool
One Software – One User Program: Controller, HMI, Networking
Online functions
GeneralControl panel
Commissioning
Commissioning
Enabled
Referenced
Axis error
Axis status
99.0 mm/s
Drive status
Ready
Drive error
Speed:
Setpoints
100.0
Positive hardware limit switch activeLast error:
Position:
Actual values
250.0 123.68 mm
Enable
Take manual control
Acknowledge
Jog forwardsJog backwards
Start positioning Start referencing STOP
20.0 mm
1240.0 mmUpper position limit:
Lower position limit:
of Axis: Axis_1
Online functions
GeneralControl panel
Commissioning
Commissioning
Enabled
Referenced
Axis error
Axis status
99.0 mm/s99.0 mm/s
Drive status
Ready
Drive error
Speed:
Setpoints
100.0
Positive hardware limit switch activeLast error: Positive hardware limit switch activeLast error:
Position:
Actual values
250.0 123.68 mm123.68 mm
Enable
Take manual controlTake manual control
Acknowledge
Jog forwardsJog backwards
Start positioning Start referencing STOP
20.0 mm20.0 mm
1240.0 mm1240.0 mmUpper position limit:
Lower position limit:
of Axis: Axis_1
85.32
Input value
Progress
Input
Searching point of inflexion …
Status
%
85.32
Output value
Output
manual
%
Optimization
75.00
Setpoint value %
Start tuning
Use last settings
Abort tuning
Start measurement Stop measurement
34.05
Input1
100.00
Output1% % Setpoint1
62.00
% Time1
3780
ms
3500 4500 5500 6500
ms
40
50
60
Measure cycle
Upload
%
58.05
Input2
37.00
Output2% % Setpoint2
62.00
% Time2
6990
ms
1000 ms
40
50
60
%
40
50
60
%
Startup tuning Tuning in run
85.32
Input value
Progress
Input
Searching point of inflexion …
Status
%
85.32
Output value
Output
manual
%
Optimization
75.00
Setpoint value %
Start tuningStart tuning
Use last settingsUse last settings
Abort tuningAbort tuning
Start measurementStart measurement Stop measurementStop measurement
34.05
Input1
100.00
Output1% % Setpoint1
62.00
% Time1
3780
ms
3500 4500 5500 6500
ms
40
50
60
Measure cycle
Upload
%
58.05
Input2
37.00
Output2% % Setpoint2
62.00
% Time2
6990
ms
1000 ms
40
50
60
%
40
50
60
%
Startup tuning Tuning in run
I/O Config
Logic
HMI Config
Motion
PID Tuning
Networking
Central Navigation Portal

8. Programming Standards
1. LAD (ladder logic) is a graphical programming language. The representation is based on
circuit diagrams

9. Programming Standards
2. FBD (Function Block Diagram) is a programming language that is based on the graphical
logic symbols used in Boolean algebra

10. Programming Standards
3. SCL (structured control language) is a PASCAL-based (text-based), high-level programming
language. SCL program blocks can include and is compatible with LAD and FBD sub-blocks.
Variable declaration
Function defination

11. Hardware Communications
Programming device connected to the CPU
(upload your program to execute)
HMI connected to the CPU
(change program via graphical interface)
CPU connected to another CPU
(resembles 2-core processor, each processor addressable with preloaded
programs)
Simulator Demonstration
1
2
3

12. Siemens S7 vs. NI LabVIEW
PLC networking Application
LabVIEW HMI programming in
Robotics