Preface |
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xiii | |
Authors |
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xv | |
1 Industrial Automation |
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1 | (18) |
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1.1 The Industrial Control System |
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1 | (5) |
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1.2 Automation and Process Control |
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6 | (3) |
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1.3 Purpose of Industrial Automation |
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9 | (1) |
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1.4 Industrial Automation Circuits |
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10 | (3) |
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1.5 Computer-Based Industrial Control and Automation |
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13 | (5) |
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18 | (1) |
2 Hardware Components for Automation and Process Control |
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19 | (60) |
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19 | (18) |
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20 | (4) |
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2.1.2 Pneumatic Actuators |
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24 | (1) |
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2.1.3 Micro-Electro-Mechanical Systems |
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24 | (1) |
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25 | (1) |
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2.1.4.1 Relays' Operation Principle |
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25 | (2) |
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27 | (2) |
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2.1.6 General Purpose Relays |
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29 | (1) |
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30 | (1) |
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2.1.8 Pulse Bistable Relays |
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31 | (1) |
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32 | (1) |
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2.1.10 Electric Contact Classification |
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33 | (2) |
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2.1.11 Solenoid Linear Actuators |
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35 | (2) |
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37 | (1) |
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2.2.1 Thermal Overload Relay |
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38 | (26) |
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40 | (7) |
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2.2.3 Photoelectric Switches |
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47 | (3) |
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50 | (2) |
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52 | (5) |
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57 | (2) |
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2.2.7 Temperature and Pressure Switches |
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59 | (5) |
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2.3 Timers, Drum Switches, and Special Components |
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64 | (11) |
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64 | (3) |
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67 | (2) |
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2.3.3 Three-Phase Monitoring Relays |
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69 | (1) |
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70 | (1) |
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2.3.5 Specific Solenoid Actuators |
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71 | (1) |
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2.3.6 Counters and Hour Meters |
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72 | (1) |
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73 | (2) |
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75 | (4) |
3 Industrial Automation Synthesis |
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79 | (38) |
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3.1 Introductory Principles in Designing Automation Circuits |
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79 | (3) |
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3.1.1 The Latch Principle |
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79 | (2) |
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3.1.2 The Principle of "Command" |
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81 | (1) |
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3.2 Step-by-Step Basic Automation Examples Synthesis |
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82 | (9) |
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3.2.1 Motor Operation with Thermal Overload Protection |
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82 | (1) |
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3.2.2 Operation and Fault Indication |
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83 | (1) |
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3.2.3 Machine Operation with Starting Delay |
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84 | (3) |
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3.2.4 Machine Operation with Stopping Delay |
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87 | (1) |
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3.2.5 Periodic Operation of Machine with Two Time Constants |
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88 | (1) |
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3.2.6 Machine Operation with Automatic or Manual Control |
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88 | (1) |
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3.2.7 Operation of Two Machines with a Common Manual Command or Separate Automatic Commands |
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89 | (1) |
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3.2.8 Operation of Two Machines with a Common Automatic Command or Separate Manual Commands |
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90 | (1) |
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3.2.9 Operation of a Machine from Two or More Points |
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90 | (1) |
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3.2.10 Control Panel for Operating n Machines |
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91 | (1) |
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3.3 The Meaning of the Electrical and Mechanical Latch |
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91 | (4) |
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3.3.1 Sequential Start-Latch of Machines (Chain Latch) |
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93 | (1) |
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3.3.2 Motor Operation with Power Supply from Two Different Networks |
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94 | (1) |
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3.4 Automation Circuits for Motors |
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95 | (3) |
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3.4.1 Motor with Inversion in Rotation |
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95 | (1) |
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3.4.2 Motor with a Star-Delta (Y-Delta) Start |
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96 | (1) |
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3.4.3 Automation of Various Motor Types |
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97 | (1) |
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3.5 Automation Circuits with Sensors |
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98 | (4) |
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3.5.1 Starting a Machine with Cancelling Ability |
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98 | (2) |
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3.5.2 Pump Operation Based on Level Control |
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100 | (1) |
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3.5.3 Operation of Two Pumps According to Demand |
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100 | (1) |
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3.5.4 Automation of a Garage Door |
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101 | (1) |
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3.6 Automation Circuit Design Regulations |
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102 | (3) |
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3.7 Implementation of Automation Circuits |
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105 | (2) |
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107 | (6) |
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3.8.1 Machine Operation Control from Multiple Positions |
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107 | (1) |
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3.8.2 Operation Control of a Power Transformer |
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108 | (1) |
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3.8.3 Operation of Two Pumps with a Cyclic Alteration, Based on a Low-High Demand |
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109 | (3) |
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3.8.4 Operation of Three Air Compressors with Predefined Combinations |
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112 | (1) |
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113 | (4) |
4 Logical Design of Automation Circuits |
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117 | (42) |
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4.1 Introduction to Logical Design of Automation Circuits |
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117 | (1) |
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4.2 Boolean Logic Components |
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118 | (3) |
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4.2.1 Postulates and Theorems of Boolean Algebra |
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120 | (1) |
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121 | (24) |
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4.3.1 Classical State Diagrams |
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121 | (3) |
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4.3.2 State Diagrams with Sensors |
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124 | (4) |
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4.3.3 Step-by-Step Transition due to a Discrete Successive Signal |
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128 | (5) |
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4.3.4 State Diagrams with Time Relays |
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133 | (2) |
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4.3.5 Components' State Diagram Method |
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135 | (2) |
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4.3.6 State Diagrams and Minimum Realizations |
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137 | (5) |
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4.3.7 Sequential Automation Systems |
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142 | (3) |
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145 | (10) |
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4.4.1 Bidirectional Lead Screw Movable Worktable with Two Speeds |
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146 | (2) |
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4.4.2 Palindromic Movement of a Worktable with Memory |
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148 | (3) |
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4.4.3 Operation of N Machines with Pause under Specific Conditions |
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151 | (4) |
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155 | (4) |
5 Elements of Electro-Pneumatic Components |
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159 | (34) |
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5.1 Introduction to Electro-Pneumatic Components |
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159 | (1) |
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159 | (1) |
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5.3 Production of Pressurized Air |
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160 | (1) |
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5.4 Distribution of Pressurized Air |
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161 | (2) |
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163 | (3) |
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5.5.1 Single-Acting Cylinders |
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163 | (1) |
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5.5.2 Double-Acting Cylinders |
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164 | (2) |
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5.6 Calculations in the Case of Pneumatic Cylinders |
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166 | (1) |
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5.6.1 Length of Piston Stroke |
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167 | (1) |
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5.6.2 Speed of Piston's Translation |
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167 | (1) |
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5.7 Pressurized Air Flow Control Valves |
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167 | (8) |
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167 | (1) |
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5.7.2 Manual Actuation of a Valve |
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168 | (2) |
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5.7.3 Mechanical Actuation of a Valve |
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170 | (1) |
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5.7.4 Electrical Actuation of a Valve |
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170 | (4) |
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5.7.5 Pneumatic Actuation of a Valve |
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174 | (1) |
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5.8 Circuits for Electro-Pneumatic Automation |
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175 | (3) |
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5.9 Electro-Pneumatic Applications |
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178 | (5) |
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5.9.1 Industrial Automation of an Arrangement for Separating Similar Balls |
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178 | (1) |
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5.9.2 Industrial Automation of an Object Stamping Machine |
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179 | (2) |
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5.9.3 Industrial Automation of a Conveyor Arrangement for Objects Shorting |
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181 | (2) |
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183 | (10) |
6 Basic Operating Principles of PLCs |
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193 | (78) |
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193 | (7) |
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6.2 Modular Construction of a PLC |
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200 | (2) |
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202 | (2) |
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6.4 Digital Input Modules |
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204 | (5) |
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6.5 Digital Output Modules |
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209 | (7) |
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6.5.1 Technical Specifications for Digital Input/Output Modules |
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212 | (4) |
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6.6 Analog Input/Output Modules |
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216 | (6) |
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6.6.1 Analog Input Modules |
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216 | (3) |
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6.6.2 Accuracy in the Conversion of Analog Signals |
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219 | (1) |
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6.6.3 Analog Output Modules |
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220 | (2) |
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6.7 Special Purpose Input/Output Modules |
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222 | (3) |
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6.7.1 Fast Input Response Modules |
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223 | (1) |
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6.7.2 Stepper Motor Control Modules |
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223 | (1) |
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6.7.3 Three Terms (PID) Control Modules |
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224 | (1) |
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6.7.4 Communication Modules |
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225 | (1) |
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6.8 Central Processing Unit |
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225 | (8) |
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6.8.1 Memory Organization |
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227 | (4) |
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231 | (1) |
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6.8.2.1 Read Only Memory (ROM) |
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231 | (1) |
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6.8.2.2 Random Access Memory (RAM) |
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231 | (1) |
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6.8.2.3 Erasable Programmable Read Only Memory (EPROM) |
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231 | (1) |
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6.8.2.4 Electrically Erasable Programmable Read Only Memory (EEPROM) |
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232 | (1) |
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6.8.3 Addressing I/Os and Other Internal Elements |
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232 | (1) |
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6.9 PLC Expansion and I/O Configuration |
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233 | (10) |
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6.9.1 Local and Peripheral I/O System |
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234 | (2) |
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236 | (7) |
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6.10 On the Installation of PLCs |
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243 | (21) |
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6.10.1 Electrical Enclosure for the PLC Installation |
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243 | (2) |
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6.10.2 Electromagnetic Interference |
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245 | (4) |
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249 | (2) |
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6.10.4 Electromagnetic Shielding of Cables |
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251 | (1) |
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6.10.5 Lightning Protection |
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252 | (1) |
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6.10.6 Input Devices with Leakage Current-Impedance Adjustment of I/Os |
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253 | (3) |
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6.10.7 Input Impedance Adjustment |
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256 | (1) |
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6.10.8 Output Impedance Adjustment |
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257 | (2) |
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6.10.9 Parallelizing Digital Outputs of PLCs-Transitional Protection of I/Os |
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259 | (2) |
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6.10.10 Starting the Operation of a PLC and Fault Detection |
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261 | (3) |
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Review Questions and Problems |
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264 | (7) |
7 Basic Programming Principles of PLCs |
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271 | (84) |
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7.1 Introduction to Programming of PLCs |
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271 | (2) |
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7.2 The IEC 61131 Standard |
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273 | (5) |
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7.3 Structural Programming |
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278 | (3) |
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7.4 Basic Programming Instructions |
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281 | (11) |
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7.4.1 The Result of an Instruction Execution |
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284 | (3) |
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7.4.2 Boolean Logic Instructions |
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287 | (1) |
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7.4.3 Activation Instructions |
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288 | (2) |
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7.4.4 Complementary Instructions |
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290 | (2) |
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7.5 Programming According to the IEC 61131-3 Standard |
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292 | (55) |
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7.5.1 General Highlights and Restrictions in PLC Programming |
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292 | (8) |
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7.5.2 Programming with Boolean Logic and Activation Instructions |
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300 | (15) |
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7.5.3 Programming with Timers and Counters |
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315 | (8) |
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7.5.4 Using Structural Programming |
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323 | (4) |
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7.5.5 Programming Mathematical Operations |
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327 | (2) |
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7.5.6 Applications of PLC Programming |
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329 | (18) |
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347 | (8) |
8 Industrial Networks of PLCs |
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355 | (18) |
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8.1 Topology of a Network |
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357 | (2) |
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357 | (1) |
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358 | (1) |
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359 | (1) |
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8.2 Communication Protocols |
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359 | (3) |
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8.2.1 Master/Slave Method of Access |
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360 | (1) |
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8.2.2 Carrier Sense with Collision Detection Method of Access |
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360 | (1) |
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8.2.3 Token Passing Method of Access |
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361 | (1) |
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8.3 Implementation of Industrial Networks |
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362 | (8) |
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8.3.1 Data Transmission Media |
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362 | (1) |
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363 | (1) |
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364 | (1) |
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8.3.4 The Communication Task of PLCs |
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365 | (2) |
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8.3.5 The Actuator-Sensor Interface (AS-I) Network |
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367 | (1) |
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8.3.6 The Profibus Network |
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368 | (1) |
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368 | (2) |
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370 | (3) |
9 PID Control in the Industry |
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373 | (8) |
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373 | (3) |
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376 | (5) |
10 Industrial Applications |
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381 | (28) |
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10.1 Cyclic Operation of Traffic Lights |
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381 | (1) |
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10.2 Conveyor System for an Assortment of Objects by Pairs |
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381 | (2) |
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10.3 Packaging System of Different Balls |
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383 | (1) |
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10.4 Conveyor System for Transferring Granular Material with Weight Control |
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384 | (1) |
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10.5 The Food Industry: A Machine for Production of Tzatziki Salad |
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385 | (2) |
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10.6 Retentive Reciprocating Movement of a Worktable |
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387 | (1) |
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10.7 Wooden Plate Stacking, Painting and Transferring Process |
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388 | (1) |
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10.8 An Automated Billiard Table Controlled by a PLC |
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388 | (1) |
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10.9 Automated Filling of Two Milk Tanks |
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389 | (1) |
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10.10 Modular Programming for a Set of Processing and Repairing Stations |
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390 | (1) |
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10.11 Traffic Light Control of a Complex Intersection |
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391 | (1) |
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10.12 Combined Operation of Two Conveyor Belts |
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392 | (1) |
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10.13 A Machine with Three Operational States and an Acknowledgement Signal |
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392 | (1) |
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10.14 Chemical Cleaning Process of Metallic Objects |
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392 | (1) |
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10.15 Driving a Step Motor Through a PLC |
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393 | (1) |
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10.16 Stacking Machine of Light Objects |
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394 | (1) |
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10.17 A Simple Robotic Arm for Pickup and Placement of Light Objects |
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395 | (1) |
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10.18 Heat Treatment Process in a Chamber Furnace |
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396 | (1) |
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10.19 Working Time Monitoring of a Machine under a Three-Shift Schedule |
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397 | (1) |
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10.20 Feeding an Assembly Machine with Components in Bulk |
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398 | (1) |
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10.21 A Roller Conveyor System for Wrapping Plastic Membrane |
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399 | (1) |
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10.22 Color-Based Separation of Plastic Balls |
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399 | (2) |
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10.23 The Shearing Machine of an Unfolded Aluminum Sheet |
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401 | (1) |
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10.24 Inlet and Outlet Rate Monitoring of Transferred Objects In and Out of a Process Machine |
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402 | (1) |
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10.25 A Metal Plate Rolling Mill Machine and Control of Their Thickness |
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402 | (1) |
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10.26 An Object Painting and Transporting System |
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403 | (1) |
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10.27 A Multiple Bottle Packing Station |
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404 | (1) |
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10.28 A Barrel-Filling System for Dry Bulk Material |
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405 | (1) |
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10.29 An Electro-Pneumatic System for Pickup and Lay Down of Plastic Containers |
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406 | (3) |
Appendix A: Arithmetic Systems |
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409 | (10) |
Appendix B: Analog I/O Values Scaling |
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419 | (2) |
Further Reading |
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421 | (4) |
Index |
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425 | |