PLC

What is “T I A“

Totally Integrated Automation stands for a new concept to realize industrial automation tasks.  Existing automation solutions are together composed from a mix of different system technology and manufacturers.   

Programmable logic controllers are employed in the field level whereas the cell level uses a mixture of PC and PLCs and the process control level only uses PCs.

So far it is customary that each of these systems uses a whole different type of software and user interface.  Additional differences result as soon as different manufacturers provide the components or include enhancements.

By the variety of these different solutions, frequent communication problems occur.  Data must be read or written multiple times so that no consistent concept for the preparation of large data quantities exists.

The fundamental idea is a consistent technology base for individual problem solutions.  It should demand a thorough project maintenance and service philosophy. 

 

Totally Integrated Automation means the overcoming of the existing system limit.  All devices and systems are integrated into a thorough automation solution in which uniformity is reached in data storage, configuration, and in programming as well as communication.

 

The following features distinguish a T I A- System:

 

Common data storage

Data is entered only once and is factory regulated for the user (in PLC or computer memory by a visualization system or distributed I/O).  If the data is required at another point, the software collects this data for all common databases.   The costly consistency check is then not required.

Scalable systems

All inherent components and systems are configured, programmed, taken into operation, debugged and monitored for a solution with a single fully integrated and modular established software kit.  The user can use the following tools under a user interface for each solution.

Open interface

The communication is fully integrated into the systems so that a problem free data exchange can occur between the several systems and components.  For example, it is not very important to know the later communication link by the configuration of a PLC.  The network adjustment establishes only one selection criteria by the configuration and is changeable at any time.  Thus the distributed configuration of different automation solutions is no longer a problem.  The PROFIBUS is used as a system bus.  

                Complete integration

Complete integration of drive technology. Tools for configuration, diagnosis and commission are integrated in STEP 7.

Cost reducing

Cost reducing for the configuration, maintenance and employee training are the results of these integrated concepts.  The optimal use of the hardware allows the hardware costs to be reduced.

.                 Compatibility and modularity 

The generated automation solutions are not completed systems through the compatibility and modularity of the components and the software only one time but are expandable each time without problems if centralized or distributed. 

Common database

The common database is also useful for third party systems through definite interface standards.  OPC (OLE for Process Control) allows the process data representation in Windows-based service, observation and control systems.  The use of an older S5 program is possible through conversion.

3.             Presentation of the various systems

This chapter serves as a presentation to the most important systems:

 

·            SIMATIC S7-200/300/400

·            Industrial communication

·            HMI (Human Machine Interface)

·            SIMATIC Industry software

 

3.1            The SIMATIC PLC- controller

3.1.1         SIMATIC S7-200

(Image 1: SIMATIC S7-200)

 

 

The SIMATIC S7-200 is the CPU for the lower level performance range.

It is available in various grades. 

 

·            The CPU is qualified for open and closed loop control tasks in machines and system      construction.

·            It is real time capable and offers extensive communication possibilities over a PROFIBUS

or PC/PPI cable and over a free programmable interface protocol.

·            The SIMATIC S7-200 offers modular extensibility and integrated PID closed loop control functions. 

·            The program software STEP 7 Micro/Win enables a quick introduction in the programming and         configuration.

 

3.1.2         SIMATIC S7-300

 

(Image 2: SIMATIC S7-300)

 

The SIMATIC S7-300 family offers the automation solutions for the lower and middle performance range.

 

Properties of the SIMATIC S7-300

 

·            Program memory up to 85 K instructions

·            Up to 1024 digital in- and outputs

·            Multipoint capable interface for the configuration of smaller networks and for configuration with   help of a PC/PG.

·            Quick execution time in which the performance capable CPU executes 1024 binary instructions    inside of 0.1 ms.

·            Modular configuration and quick enhancements are possible through interface modules with an         integrated back plane bus. 

·            Modular extensibility through an extensive program module of digital, analog, simulation and         function modules to communications and other types of modules.

·            Integrated functions: counters, positioning, closed loop control, and frequency measuring by      the CPUs 312/314 IFM.

·            Integrated PROFIBUS interface by the 300 2-DP Series.  CPU also usable as a slave.

·            Processing of extensive mathematical formulas.

·            Preparation of cyclic HMI service integrated into the operating system of the CPU.

·            Quick and simple configuration and programming with help from STEP 7.

·            Extensive diagnostic possibilities with help from STEP 7.  Error message buffer with time stamp         and module diagnostic help the user during error searching.

 

3.1.3         SIMATIC S7-400

 (Image 3: SIMATIC S7-400)

The CPUs of the family SIMATIC S7-400 build the solutions for the middle and higher performance range (e.g. automobile and machine tool construction or instrumentation and control).

 

Properties of the SIMATIC S7-400

 

·            Program memory up to 660 K instructions.

·            Up to 131056 digital in- and outputs.

·            Multipoint capable interface for the configuration of smaller networks and for configuration with   help of the PC/PG.

·         Quick execution time that the performance capable CPU executes 1024 binary instructions  inside of 0.1 ms.

·            Modular configuration and quick enhancements are possible through interface modules with         integrated back plane bus. 

·          An extensive program module of digital, analog, simulation and function modules to     communications and other types of modules.

·            Integrated PROFIBUS interface by the S7-400 2-DP Series. The profile

PROFIBUS-DP/FMS/PA and Industrial Ethernet are useable.

·            Processing of extensive mathematical formulas.

·            Preparation of cyclic HMI service integrated into the operating system of the CPU.

·            Quick and simple configuration and programming with help from STEP 7.