Programmable controllers were originally introduced to
replace large panels of relays used for running automobile
assembly lines. Controller flexibility allowed reprogramming
for year-to-year model changes. Early controllers were
restricted to discrete (ON/OFF) control. Programs were represented
by the use of ladder diagrams (Section 5.2), the same
way that relay logic is represented.
Programmable controller capability has been extended to
include mathematical functions, file manipulations, analog
signal manipulations, and techniques for dealing with highspeed
signals. Programmable controllers are now routinely
linked together in networks, connected to general-purpose
computer systems, and connected to specialized intelligent
devices, as was shown in Section 5.4. These devices include
displays, high-speed control cards, and interfaces to specialized
sensors such as bar code readers and RF identifiers.
Many programmable controller suppliers support computer
software for program development, program annotation, and
program storage/retrieval.
These added capabilities have allowed the application of
programmable controllers in many areas outside of the traditional
automobile assembly-type service. They are used for
continuous process control high-speed packaging, energy distribution,
and automated warehousing. Many of these applications
strain the capability of ladder logic for program
design and implementation.
The software available in many programmable controllers
has extended ladder logic to serve these diverse applications.
To engineer a software system correctly, the application’s
requirements must be well understood. A graphic representation
of these requirements is described below. Among the
ladder logic advances are indirect addressing, program flow
modification, incorporation of mathematical or scientific
instructions, communication with intelligent devices, and
methods for working with high-speed signals. Ladder logic
segments can be organized using sequential flow chart languages
to produce a sequentially oriented program.
Productivity enhancements developed for computer programmers
are appearing in PLC programming software.
Many program editors emulate MS Visual Studio formats
with multiple windows and tool bars, pull-down menus, and
visible “tree” structure for the project. Wizards have appeared
in programming editors to automate tasks. If fact, Siemens
provides one wizard in its S7 (200) programming software
that automatically programs a Master-Slave polling task.
PLC logic simulation, a powerful tool for programming
and debugging even before the hardware is on hand, is
becoming more widely available.
Most major PLC manufacturers
now offer PC-based PLC simulation software. Even
the hardware configuration is easier. PLCs used to be configured
with switches and jumpers. Now PLCs can be programmed
and configured remotely over the network.
GRAPHIC DESCRIPTION OF CONTROL REQUIREMENTS
There have been many studies of time and money investments
in building computer systems.
2,3
One key conclusion of these
studies is that spending more time on the planning, design,
and study of systems can have several benefits. One benefit
is that the risk of project failure is reduced. Another benefit
is that the resulting system is more likely to meet real needs
and to provide continuing returns.
