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English translationThe E- Behind EverythingElectricity and magnetism run nearly everything we plug in or turn on. Although its something we take for granted, it has taken hundreds of years of experimentation and research to reach the point where we flick a switch and the lights go on.People knew about electricity for a long time. Ancient Greeks noticed that if they rubbed a piece of amber, feathers would stick to it. Youve experienced a similar thing if youve ever had your hair stick up straight after you combed it, or had your socks stick together when you removed them from the drier. This is called static electricity, but back then nobody knew how to explain it or what to do with it. Experiments using friction to generate static electricity led to machines that could produce large amounts of static electricity on demand. In 1660 German Otto von made the first electrostatic generator with a ball of sulfur and some cloth. The ball symbolized the earth, and he believed that this little replica of the earth would shed part of its electric “soul” when rubbed. It worked, and now scientists could study electric shocks and sparks whenever they wanted.As scientists continued to study electricity, they began thinking of it as an invisible fluid and tried to capture and store it. One of the first to do this was Pieter van, Holland. In 1746 he wrapped a water-filled jar with metal foil and discovered that this simple device could store the energy produced by an electrostatic generator. This device became known as the jar. were very important in other peoples experiments, such as Benjamin Franklins famous kite experiment. Many people suspected that lightning and static electricity were the same thing, since both crackled and produced bright sparks. In 1752 Franklin attached a key to a kite and flew it in a storm-threatened sky. (NOTE that Franklin did not fly a kite in an actual storm. NEVER do that!) When a thundercloud moved by, the key sparked. This spark charged the jars and proved that lightning was really electricity. Like many experimenters and scientists Franklin used one discovery to make another. Franklin was not the only scientist inspired to conduct experiments with electricity. In the 1780s, the Italian scientist Luigi made a dead frogs leg move by means of an electric current. called this “animal electricity.” He thought that the wet animal tissue generated electricity when it came in contact with metal probes. He even suggested that the soul was actually Italian Alessandro Volta was skeptical of conclusions. In 1799 he discovered that it wasnt animal tissue alone producing the electric current at all. Volta believed that the current was actually caused by the interaction of water and chemicals in the animal tissue with the metal probes. Volta stacked metal disks separated by layers of cardboard soaked in salt water. This so-called voltaic pile produced an electric current without needing to be charged like a jar. This invention is still around today, but we call it the battery. Voltas pile was a lot different from the batteries you put in your Discman. It was big, ugly, and messy, but it worked, making Volta the first person to generate electricity with a chemical reaction. His work was so important that the term voltthe unit of electrical tension or pris named in his honor. As for Galvani, although he was proven wrong, his work stimulated research on electricity and the body. That research eventually proved that nerves do carry electrical impulses, an important medical discovery. Like electricity, magnetism was baffling to the earliest researchers. Today manufactured magnets are common, but in earlier times the only available magnets were rare and mysterious rocks with an unexplainable attraction for bits of iron. Explanations of the way they work sound strange today. For example, in the 1600, English doctor William Gilbert published a book on magnetism. He thought that these strange substances, called “lodestones,” had a soul that accounted for the attraction of a lodestone to iron and steel. The only real use for lodestones was to make compasses, and many thought the compass needles movement was in response to its attraction to the earths “soul.” By 1800, after many years of study, scientists began wondering if these two mysterious forceselectricity and magnetismwere related. In 1820 Danish physicist Hans Oersted showed that whenever an electric current flows through a wire, it produces a magnetic field around the wire. French mathematician Andr-Marie used algebra to come up with a mathematical formula to describe this relationship between electricity and magnetism. He was one of the first to develop measuring techniques for electricity. The unit for current, the ampere, abbreviated as amp or as A, is named in his honor. Groundbreaking experiments in electromagnetism were conducted by British scientist Michael Faraday. He showed that when you move a loop of a wire in a magnetic field, a little bit of current flows through the loop for just a moment. This is called induction. Faraday constructed a different version of it called the induction ring. In later years, engineers would use the principle of the induction ring to build electrical transformers, which are used today in thousands of electrical and electronic devices. Faraday also invented a machine that kept a loop of wire rotating near a magnet continuously. By touching two wires to the rotating loop, he could detect the small flow electric current. This machine used induction to produce a flow of current as long as it was in motion, and so it was an electromagnetic generator. However, the amount of electricity it produced was very tiny. There was still another use for induction. Faraday also created a tiny electric motortoo small to do the work of a steam engine but still quite promising. For thousands of years electricity and magnetism were subjects of interest only to experimenters and scientists. Nobody thought of a practical way of using electricity before the 1800s and it was of little interest to most people. But by Faradays time inventors and engineers were gearing up to transform scientific concepts into practical machines.Telegraphs and TelephonesOne of the most important ways that electricity and magnetism have been put to use is making communication faster and easier. In this day of instant messaging, cell phones, and pagers, its hard to imagine a time when messages had to be written and might spend weeks or even months reaching their destination. They had to be carried great distances by ships, wagon, or even by horsebackyou couldnt just call somebody up to say hello. That all changed when inventors began using electricity and magnetism to find better ways for people to talk to each other. The telegraph was first conceived of in the 1700s, but few people pursued it. By the 1830s, however, advancements in the field of electromagnetism, such as those made by Alessandro Volta and Joseph Henry, created new interest in electromagnetic communication. In 1837, English scientist Charles Wheatstone opened the first com telegraph line between London and Camden Town, a distance of 1.5 miles. Building on, Samuel Morse, an American artist and inventor, designed a line to connect Washington, DC and Baltimore, Maryland in 1844. Morses telegraph was a simple device that used a battery, a switch, and a small electromagnet, but it allowed people miles apart to communicate instantly. Although Morse is often credited with inventing the telegraph, his greatest contribution was actually Morse, a special language designed for the telegraph. Morses commercialization of the telegraph spread the technology quickly. In 1861 California was connected to the rest of the United States with the first transcontinental telegraph line. Five years later, engineers found a way of spanning the Atlantic Ocean with telegraph lines, thus connecting the United States and Europe. This was an enormous and challenging job. To do it engineers had to use a huge ship called The Great Eastern to lay the cable across the ocean. It was the only ship with enough room to store all that cable. The world was connected by wire before the nation was connected by railthe transcontinental railroad wasnt completed until 1869! The telegraph was the key to fast, efficient railroad service. The railroads and the telegraph expanded side-by-side, crisscrossing every continent, except Anta, in the late 1800s. In the late 19th and early 20th centuries, telegraphy became a very lucrative business for companies such as Western Union. It also provided women with new career options. As convenient as the telegraph was, people dreamt of hearing the voices of loved ones who lived far away. Pretty soon, another instrument to communicate across distances was invented. Alexander Graham Bell, a teacher and inventor, worked with the deaf and became fascinated with studying sound. In 1875, Bell discovered a way to convert sound waves to an undulating current that could be carried along wires. This helped him invent the telephone. The first phone conversation was an inadvertent one between Bell and Watson, his assistant in the next room. After spilling some acid, Bell said “Mr. Watson, come here. I want you.” He patented his device the same year. Early phone service wasnt as portable and convenient as todays. At first, telephones we connected in pairs. You could call only one person, and they could only call you. The telephone exchange changed all that. The first exchange was in New Haven, Connecticut in 1878. It allowed people who subscribed to it to call one another. Operators had to connect the calls, but in 1891 an automatic exchange was invented. Some problems had to be solved, though, before long-distance telephoning could work. The main one was that the signal weakened with distance, disappearing if the telephone lines were too long. A solution was found in 1912 with a way to amplify electrical signals, and transcontinental phone calls were possible. A test took place in 1914, and the next year, Bell, who was in New York, called Watson, who was in San Francisco. He said the same thing he had said during the first phone conversation. Watsons answer? “It will take me five days to get there now!”Plc development1.1 Motivation Programmable Logic Controllers (PLC), a computing device invented by Richard E. Morley in 1968, have been widely used in industry including manufacturing systems, transportation systems, chemical process facilities, and many others. At that time, the PLC replaced the hardwired logic with soft-wired logic or so-called relay ladder logic (RLL), a programming language visually resembling the hardwired logic, and reduced thereby the configuration time from 6 months down to 6 days Moody and Morley, 1999. Although PC based control has started to come into place, PLC based control will remain the technique to which the majority of industrial applications will adhere due to its higher performance, lower price, and superior reliability in harsh environments. Moreover, according to a study on the PLC market of Frost and Sullivan 1995, an increase of the annual sales volume to 15 million PLCs per year with the hardware value of more than 8 billion US dollars has been predicted, though the prices of computing hardware is steadily dropping. The inventor of the PLC, Richard E Morley, fairly considers the PLC market as a 5-billion industry at the present time. Though PLCs are widely used in industrial practice, the programming of PLC based control systems is still very much relying on trial-and-error. Alike software engineering, PLC software design is facing the software dilemma or crisis in a similar way. Morley himself emphasized this aspect most forcefully by indicating Moody and Morley, 1999, p. 110: If houses were built like software projects, a single woodpecker could destroy civilization.” Particularly, practical problems in PLC programming are to eliminate software bugs and to reduce the maintenance costs of old ladder logic programs. Though the hardware costs of PLCs are dropping continuously, reducing the scan time of the ladder logic is still an issue in industry so that low-cost PLCs can be used. In general, the productivity in generating PLC is far behind compared to other domains, for instance, VLSI design, where efficient computer aided design tools are in practice. Existent software engineering methodologies are not necessarily applicable to the PLC based software design because PLC-programming requires a simultaneous consideration of hardware and software. The software design becomes, thereby, more and more the major cost driver. In many industrial design projects, more than SO0/a of the manpower allocated for the control system design and installation is scheduled for testing and debugging PLC programs Rockwell, 1999. In addition, current PLC based control systems are not properly designed to support the growing demand for flexibility and reconfigurability of manufacturing systems. A further problem, impelling the need for a systematic design methodology, is the increasing software complexity in large-scale projects. 1.2 Objective and Significance of the Thesis The objective of this thesis is to develop a systematic software design methodology for PLC operated automation systems. The design methodology involves high-level description based on state transition models that treat automation control systems as discrete event systems, a stepwise design process, and set of design rules providing guidance and measurements to achieve a successful design. The tangible outcome of this research is to find a way to reduce the uncertainty in managing the control software development process, that is, reducing programming and debugging time and their variation, increasing flexibility of the automation systems, and enabling software reusability through modularity. The goal is to overcome shortcomings of current programming strategies that are based on the experience of the individual software developer. A systematic approach to designing PLC software can overcome deficiencies in the traditional way of programming manufacturing control systems, and can have wide ramifications in several industrial applications. Automation control systems are modeled by formal languages or, equivalently, by state machines. Formal representations provide a high-level description of the behavior of the system to be controlled. State machines can be analytically evaluated as to whether or not they meet the desired goals. Secondly, a state machine description provides a structured representation to convey the logical requirements and constraints such as detailed safety rules. Thirdly, well-defined control systems design outcomes are conducive to automatic code generation- An ability to produce control software executable on commercial distinct logic controllers can reduce programming lead-time and labor cost. In particular, the thesis is relevant with respect to the following aspects. Customer-Driven Manufacturing In modern manufacturing, systems are characterized by product and process innovation, become customer-driven and thus have to respond quickly to changing system requirements. A major challenge is therefore to provide enabling technologies that can economically reconfigure automation control systems in response to changing needs and new opportunities. Design and operational knowledge can be reused in real-time, therefore, giving a significant competitive edge in industrial practice. Higher Degree of Design Automation and Software Quality Studies have shown that programming methodologies in automation systems have not been able to match rapid increase in use of computing resources. For instance, the programming of PLCs still relies on a conventional programming style with ladder logic diagrams. As a result, the delays and resources in programming are a major stumbling stone for the progress of manufacturing industry. Testing and debugging may consume over 50% of the manpower allocated for the PLC program design. Standards IEC 60848, 1999; IEC-61131-3, 1993; IEC 61499, 1998; ISO 15745-1, 1999 have been formed to fix and disseminate state-of-the-art design methods, but they normally cannot participate in advancing the knowledge of efficient program and system design. A systematic approach will increase the level of design automation through reusing existing software components, and will provide methods to make large-scale system design manageable. Likewise, it will improve software quality and reliability and will be relevant to systems high security standards, especially those having hazardous impact on the environment such as airport control, and public railroads. System Complexity The software industry is regarded as a performance destructor and complexity generator. Steadily shrinking hardware prices spoils the need for software performance in terms of code optimization and efficiency. The result is that massive and less efficient software code on one hand outpaces the gains in hardware performance on the other hand. Secondly, software proliferates into complexity of unmanageable dimensions; software redesign and maintenance-essential in modern automation systems-becomes nearly impossible. Particularly, PLC programs have evolved from a couple lines of code 25 years ago to thousands of lines of code with a similar number of 1/O points. Increased safety, for instance new policies on fire protection, and the flexibility of modern automation systems add complexity to the program design process. Consequently, the life-cycle cost of software is a permanently growing fraction of the total cost. 80-90% of these costs are going into software maintenance, debugging, adaptation and expansion to meet changing needs Simmons et al., 1998.Design Theory Development Today,

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