Programmable Logic Controllers: Industrial Control offers readers an introduction to PLC programming with a focus on real industrial process automation applications. The Siemens S7-1200 PLC hardware configuration and the Totally Integrated Automation (TIA) Portal are used throughout the book. A small and inexpensive training setup with a Siemens power supply, processor, processor integrated discrete inputs-outputs, processor-integrated two-point analog inputs, processor one-output analog signal board, eight ON/OFF switch plug-in simulator, human-machine interface (HMI), four-port Ethernet switch module, and programming laptop is described and used to illustrate all programming concepts and the implementation of parts of automation projects completed by the authors in the past 15 years. The authors greatly appreciate the generous support of Siemens during the production of this book, including an expert technical review of the book conducted by the company. At the end of each chapter is a set of homework questions and small laboratory design, programming, debugging, or maintenance projects. A comprehensive capstone design project is detailed in Chap. 9, the final chapter. All programs and system configurations used in this book are fully implemented and tested. The book’s website, www.mhprofessional.com/ProgrammableLogicControllers, contains a Microsoft PowerPoint multimedia presentation with several interactive simulators. Readers are encouraged to go through the presentation and practice with the simulators to fully understand the PLC programming fundamentals covered.
An introduction to the concepts of process control and automation is provided in Chap. 1. Chapter 2 details the fundamentals of relay logic programming. It also covers the architecture and operation of PLCs. Configuration, operation, and the programming of timers and counters are the focus of Chap. 3. The book’s website contains very useful simulators for the different types of PLC timers: ON-DELAY, OFF-DELAY, and retentive timers. The website also contains additional simulators illustrating concepts covered in the book’s first three chapters, including motor start/stop and forward/reverse control. Chapter 4 is dedicated to the coverage of mathematical, logic, and commonly used command operations, with emphasis on their use in real-time industrial applications. Ladder programming for both PLC ladder logic and HMIs is discussed in detail in Chap. 5. Modular structured programming design is presented with emphasis on industrial standards and safety. Coverage is specific for the Siemens S7-1200 processor, the SIMATIC basic-panel HMI, and the PROFINET Ethernet protocol, but the concepts are applicable to other systems.
System checkouts and troubleshooting are typically the most challenging and time-consuming tasks in industrial automation process-control applications. Chapter 6 contains common design and troubleshooting techniques. It also addresses critical issues of validation, hazards, safety standards, and protection against hardware/ software failures or malfunctions. Analog programming and associated instrumentation are covered in Chap. 7. Configuration, interface, scaling, calibration, and associated user interfaces are briefly covered. Chapter 8 presents a comprehensive introduction to open- and closed-loop digital process control. Topics covered include sensors, actuators, ON/OFF control, feedback control, PID tuning, and measures of good control. This chapter is intended to provide users with an understanding of the “big picture” of a control system in terms of system tasks, requirements, and overall expectations. It can best serve advanced engineering/technology, computer science, or information technology students as a prerequisite for the fundamentals and hands-on activities covered in the first seven chapters of the book. It also can serve other readers as a cap for the skills learned in previous chapters. The book concludes with a comprehensive case study in Chap. 9. The case details the specifications of an irrigation-canal downstream water-level control. Coverage proceeds from the specification level to the final system design/implementation with associated documentation. The project is a small part of a much larger project implemented by the authors in an African country more than 10 years ago. All implementations are redone using the Siemens S7-1200 PLC system. Recent advances in industrial process control have produced more intelligent and compact PLC hardware than the one we adopted in this book, the Siemens S7-1200 system. These advances also have made available extremely friendlier development software for structured ladder programming, communication, configuration, modular design, documentation, and overall system troubleshooting, and have created many opportunities for challenging and rewarding careers in the areas of PLC technology and process automation. This book is intended for a two quarter sequence or one four-credit semester course in an academic setting with the expectation of weekly hands-on laboratory work activities. It also can be used for a two-week industrial training sequence in a small-group setting with adequate training setup for users. Successful career opportunities in the demanding field of PLC control and automation require acquisition of the skills in this book along with adequate hands-on experience.
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