Power Programming Program StructuresPower Programming V2 0 - Program

1、Confidential - For Internal Use Only. Copyright 2005 Rockwell Automation, Inc. All rights reserved.,1,Power ProgrammingProgram Structure,Ulrich Arlt / Achim Thomsen / Dan Seger / Tom Soistmann Robert Guenther,2,Confidential - For Internal Use Only. Copyright 2005 Rockwell Automation, Inc. All rights

2、 reserved.,Recap of S88 Execution and Equipment Layer,3,Confidential - For Internal Use Only. Copyright 2005 Rockwell Automation, Inc. All rights reserved.,V2.1 Machine Layer DefinitionReflection on S88,A Machine (Packaging) resembles a Unit A Machine has a local OPERATION which contains the Interfa

3、ce to an own HMI / Pushbuttons / Safety and Load Circuit Alternatively or additionally it will also provide a Remote OPERATION in a tight Line Integration Operations will use Machine Level COMMANDs to interface to multiple PROCEDUREs (such as Automatic / Manual / Single-Step Examples). Apart from Au

4、tomatic there is no common standard for PROCEDUREs to be implemented PROCEDUREs will be interlocked against each other (Only one PROCEDURE can be active at any one point in time) A PROCEDURE Change requires the Originating PROCEDRE to be in a certain condition / its PHASE to be in a certain state. E

5、ach PROCEDURE will typically be complimented by an individual State Machine (ideally covered by a PHASE, but also potentially a self-defined Sequence. To communicate its status to the OPERATION the State Machines will provide a feedback (success / no success, Error) To communicate to Machine Modules

6、, an abstraction layer is defined that resembles the functional interface. This Interface is one set of “Common Services” that each module has to comply to (but not each Service will cause an activity in the associated module). We call it a Command-Condition Interface The mechanism defined to Exchan

7、ge Commands and Conditions is defined in Power Programming, while the actual Commands and Conditions used in a machine are up to the Users requirements.,4,Confidential - For Internal Use Only. Copyright 2005 Rockwell Automation, Inc. All rights reserved.,Implementation of a Machine in RSLOGIX5000,In

8、 RSLOGIX5000 a Machine is implemented as a program with associated Phases. OPERATIONThe Operation is mapped to one routine, providing the interlocks between the Modes and the Commands to the Phases. PROCEDUREsEach Mode is mapped to an individual Routine. COMMANDThe Command-to-Module Interface is imp

9、lemented within the State Routines of the Phase. In each State the Signals are generated that cause the associated activity within all associated Modules. CONDITIONThe Condition Interface is an individual Routine that collects all the Signals from the associated Modules and provides combined signals

10、 for the completion of a command. STATE MACHINES / PHASESThe State Machines for each Mode are either mapped to separate Phases or are directly implemented as Routines in the Machine Module. MES_DATA_InterfaceThe MES Data for the machine is collected in an individual routine (Example).,5,Confidential

11、 - For Internal Use Only. Copyright 2005 Rockwell Automation, Inc. All rights reserved.,Static Illustration of a Machine / Packaging Unit in RSLOGIX,Unit Container (=Program),Unit Operation (one / multiple),Unit PROCEDURE (multiple),Interface Module Conditions,Unit-Phase (multiple),StatesInterface M

12、odule Commands,6,Confidential - For Internal Use Only. Copyright 2005 Rockwell Automation, Inc. All rights reserved.,Module (Section) DefinitionReflection on S88,A Machine Module / Machine Section is an EQUIPMENT MODULE An EQUIPMENT MODULE will typically use a concerted set of DEVICES to fulfill a d

13、efined part of a process. EQUIPMENT MODULEs can contain EQUIPMENT MODULES, which allows division of functionality into sub-functions. E.g. Feeding Paper may contain MODULES UNWIND and DANCER(see reflections at the end of the document) It receives MODEs, STATEs and COMMANDs from its associated Machin

14、e / UNIT Depending on its own Logic it makes decisions to execute a particular part of its instructions resembling the current MODE / STATE and COMMAND. A set of Instructions that fulfills a standard functionality (typically an algorithm or standard service), which can be duplicated resembles a CONT

15、ROL MODULE.,7,Confidential - For Internal Use Only. Copyright 2005 Rockwell Automation, Inc. All rights reserved.,Implementation of an EQUIPMENT MODULE in RSLOGIX5000,In RSLOGIX5000 a MODULE is implemented as a program. Internal Logic (when to call what)The dividing logic is mapped on the Main Routi

16、ne of the Program.It will evaluate active COMMANDs from the Machine Layer, make decisions, which part needs to be executed and provide feedback (in form of MODULE CONDITIONs and STATUS) Dedicated Functionality / Services The individual Functions are placed in Sub-Routines that are executed depending

17、 on active Commands from the UNIT / MACHINE Layer.,8,Confidential - For Internal Use Only. Copyright 2005 Rockwell Automation, Inc. All rights reserved.,Static Illustration of a MODULE / Packaging EQUIPMENT MODULE in RSLOGIX,Equipment Module Container,Internal Logic / Decisions,Services / Functional

18、ity(Examples),Status / Fault Handing(Examples),9,Confidential - For Internal Use Only. Copyright 2005 Rockwell Automation, Inc. All rights reserved.,CONTROL MODULE DefinitionReflection on S88,A Functionality / Execution Module is a CONTROL MODULE A CONTROL MODULE is algorithm centric / while UNIT an

19、d EQUIPMENT MODULES are more organization centric. CONTROL MODULES will be the algorithms in an EQUIPMENT MODULE that reflect the activities associated to a COMMAND from a UNIT. The decision of mapping which COMMAND to which CONTROL MODULE(s) is made in the EQUIPMENT MODULE. (The question of when a

20、service has to be carried out) Ideally CONTROL MODULES will provide the signal flow required to immediately map COMMANDs and CONDITIONs. The sum of all signals handed to a CONTROL MODULE is considered the CONTROL MODULE Interface. CONTROL MODULEs as a sum form a Technology Library. They are generate

21、d independent of UNIT / MACHINE and EQUIPMENT MODULE definitions.,10,Confidential - For Internal Use Only. Copyright 2005 Rockwell Automation, Inc. All rights reserved.,Implementation of a CONTROL MODULE in RSLOGIX5000,In RSLOGIX5000 a CONTROL MODULE is implemented as a routine or an AOI (V16) Commo

22、n Interface:All CONTROL MODULES in a library should contain a common Interface content that allows them to immediately interface to COMMANDs and CONDITIONs in an Equipment Module.This set of common signals (Inputs / Outputs) should contain Information such as Restart, Fault, Completion in order to b

23、e able to substitute one particular service in the system (e.g. a Motor On_OFF) with another (e.g. a Frequency Converter Start Stop). Individual Interface:A CONTROL MODULE in a library should provide its parameters in a way that it can be projected with very little code modifications. In case of a r

24、outine this will mean passing of parameters and minimizing local Tags. In an AOI use of Optional (not required) parameters can allow a flexible operation.,11,Confidential - For Internal Use Only. Copyright 2005 Rockwell Automation, Inc. All rights reserved.,Static Illustration of a Service / Functio

25、nalityPackaging CONTROL MODULE in RSLOGIX,Control Module Invocation,Algorithms as required,Control Module Container,12,Confidential - For Internal Use Only. Copyright 2005 Rockwell Automation, Inc. All rights reserved.,Dynamic Model Power Programming,S88 does not provide a dynamic Model It defines t

26、he layers of execution code In the dynamic Model we will show How Signal Transfer happens on the entire System Unit Equipment Module Control Module How the mapping of Activities within an Equipment Module to Command to Condition can be a help of documenting the Machine Code and internal Sequence. We

27、 will use a an animated practical example From a simple push button to the required activity (s) what signals will be generated, what feedback will be provided. Example Code Description Show the mapping of Commands and Conditions to routines within the equipment modules Provides the Basis for good M

28、achine Process and Engineering Flow Documentation,13,Confidential - For Internal Use Only. Copyright 2005 Rockwell Automation, Inc. All rights reserved.,Power Programming Extensions,PackML Scope,Operation(Remote),Process Cell (Beer),Machine Control Filler,Operation(Remote),Machine Control Packer,Mod

29、ule Control Infeed,Axis Control Smart Belt,Module Control Wrapping,Axis Control Rotating Knife,Command-Condition,Templates for Line Control Interface to Machine Control PackTags View Templates OEE Templates,Operation Procedures Phases MES Data,Interface to Templates for Motion / Process Control depe

30、ndent functions Status & Diagnostics to Machine Control,Advanced Homing Fault Handling Diagnostics No Product/No Bag Flying Shear Cam Calculationon the Fly Cam Recovery Multi-Axis Coordination Coordinate Transformation Linear / CircularInterpolation Simple PLS Complex PLS Rotating Knife Simple Motion Smart Belt ,Routines for Execution,Execution,Execution,Control Modules,Overview over the Signal Flow throughout an Application,OperationLocal,OperationLocal,14,Confidential - For Internal Use Only. Copyright 2005 Rockwell Automation, Inc. All rights rese