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Version 1.0, August 31, 2001, Copyright, Hugh Jack 1993-2001

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1. TABLE OF CONTENTS

• TABLE OF CONTENTS 2
• OVERVIEW 8
• PROCESS CONTROL 9
• INTRODUCTION 9
• CONTROL SYSTEM CHARACTERISTICS 10
• CONTROLLER TYPES 11
• PROCESS DIAGRAMS AND SYMBOLS 11
• PRACTICE QUESTIONS 11
• DISCRETE CONTROLLER DESIGN 12
• POSITIONING CONTROLLERS 12
• TRACKING 22
• DISTURBANCE RESISTANT 25
• MULTI-CONTROLLER SYSTEMS 28
• SAMPLE TIME 34
• SUMMARY 35
• PRACTICE PROBLEMS 36
• DISCRETE SYSTEMS 38
• DISCRETE SYSTEM MODELLING WITH EQUATIONS 38
• DISCRETE CONTROLLERS 48
• BLOCK DIAGRAMS AND TRANSFER FUNCTIONS 56
• SAMPLING FUNCTIONS 68
• SYSTEM RESPONSE 72
• STEADY STATE ERROR 76
• PRACTICE PROBLEMS 78
• PETRI NETS 81
• INTRODUCTION 81
• IMPLEMENTATION FOR A PLC 87
• PRACTICE PROBLEMS 91
• CONTINUOUS CONTROL SYSTEMS 92
• CONTROL SYSTEMS 92
• ROOT-LOCUS PLOTS 113
• DESIGN OF CONTINUOUS CONTROLLERS 121
• PRACTICE PROBLEMS 121
• FUZZY LOGIC 126
• COMMERCIAL CONTROLLERS 130
• REFERENCES 130
• PRACTICE PROBLEMS 131
• MECHATRONICS CIRCUITS 132
• POWER SWITCHING 132
• USER INPUT/OUTPUT 132
• HARDWARE BASED CONTROLLERS 134
• CIRCUITS 134
• FLUIDICS 134
• PNEUMATICS 134
• PRACTICE PROBLEMS 134
• EMBEDDED CONTROLLERS 135
• TYPES 135
• CONTROLLER DESIGN EXAMPLE 135
• PRACTICE PROBLEMS 135
• DISCRETE SENSORS 136
• INTRODUCTION 136
• SENSOR WIRING 136
• CONTACT DETECTION 143
• PROXIMITY DETECTION 143
• PRACTICE PROBLEMS 156
• CONTINUOUS SENSORS 159
• INPUT ISSUES 159
• SENSOR TYPES 163
• ANGULAR POSITION 166
• LINEAR POSITION 170
• VELOCITY 173
• ACCELERATION 174
• FORCE/MOMENT 176
• FLOW RATE 181
• TEMPERATURE 182
• SOUND 185
• LIGHT INTENSITY 186
• PRESSURE 187
• PRACTICE PROBLEMS 187
• REFERENCES 188
• ACTUATORS 189
• ACTUATOR TYPES 189
• DISCRETE ACTUATORS 189
• INTRODUCTION 189
• TYPES 190
• PRACTICE PROBLEMS 195
• CONTINUOUS ACTUATORS 196
• ACTUATOR CONTROL 196
• PRACTICE PROBLEMS 202
• PROGRAMMABLE LOGIC CONTROLLERS 203
• BASIC PLCs 203
• A SIMPLE EXAMPLE 212
• PRACTICE PROBLEMS 212
• PLC CONNECTION 215
• SWITCHED INPUTS AND OUTPUTS 215
• PRACTICE PROBLEMS 226
• PLC OPERATION 232
• PLC ORGANIZATION 232
• PLC STATUS 233
• MEMORY TYPES 234
• SOFTWARE BASED PLCS 234
• PROGRAMMING STANDARDS 234
• PRACTICE PROBLEMS 236
• SWITCHING LOGIC 238
• BOOLEAN ALGEBRA 238
• DISCRETE LOGIC 240
• SIMPLIFYING BOOLEAN EQUATIONS 247
• ADDITIONAL TOPICS 250
• DESIGN CASES 253
• PRACTICE PROBLEMS 254
• NUMBERING 271
• INTRODUCTION 271
• DATA VALUES 272
• DATA CHARACTERIZATION 281
• PRACTICE PROBLEMS 283
• EVENT BASED LOGIC 286
• INTRODUCTION 286
• TIMERS, COUNTERS, FLIP-FLOPS, LATCHES 286
• PROGRAM DESIGN METHODS 303
• DESIGN CASES 306
• PRACTICE PROBLEMS 314
• SEQUENTIAL LOGIC DESIGN 321
• SCRIPTS 321
• FLOW CHARTS 325
• STATE BASED MODELLING 335
• PARALLEL PROCESS FLOWCHARTS 360
• SEQUENTIAL LOGIC CIRCUITS 370
• PRACTICE PROBLEMS 372
• ADVANCED LADDER LOGIC FUNCTIONS 406
• ADDRESSING 406
• INSTRUCTION TYPES 412
• DESIGN TECHNIQUES 440
• DESIGN CASES 442
• FUNCTION REFERENCE 445
• PRACTICE PROBLEMS 471
• PLC PROGRAMMING 478
• PROGRAMMING STANDARDS 478
• PRACTICE PROBLEMS 480
• STRUCTURED TEXT PROGRAMMING 481
• INTRODUCTION 481
• THE LANGUAGE 481
• PRACTICE PROBLEMS 494
• INSTRUCTION LIST PROGRAMMING 495
• INTRODUCTION 495
• PRACTICE PROBLEMS 498
• FUNCTION BLOCK PROGRAMMING 500
• INTRODUCTION 500
• PRACTICE PROBLEMS 501
• ANALOG INPUTS AND OUTPUTS 503
• ANALOG INPUTS 503
• ANALOG OUTPUTS 511
• DESIGN CASES 514
• PRACTICE PROBLEMS 515
• CONTINUOUS CONTROL 521
• CONTROLLING CONTINUOUS SYSTEMS 522
• CONTROLLING DISCRETE SYSTEMS 523
• CONTROL SYSTEMS 523
• DESIGN CASES 527
• PRACTICE PROBLEMS 527
• PLC DATA COMMUNICATION 528
• COMPUTER COMMUNICATIONS CATEGORIES 528
• THE HISTORY 529
• WITH PLCs 529
• SERIAL COMMUNICATIONS 530
• PARALLEL 541
• NETWORKS 541
• BUS TYPES 554
• DESIGN CASES 562
• PRACTICE PROBLEMS 563
• HUMAN MACHINE INTERFACES (HMI) 566
• INTRODUCTION 566
• HMI/MMI DESIGN 567
• DESIGN CASES 567
• PRACTICE PROBLEMS 568
• DESIGNING LARGE SYSTEMS 569
• PROGRAMMING 569
• DOCUMENTATION 570
• PLC PROGRAM DESIGN FORMS 571
• PRACTICE PROBLEMS 578
• IMPLEMENTATION 579
• ELECTRICAL 579
• SAFETY 591
• PROCESS MODELLING 594
• REFERENCES 597
• PRACTICE PROBLEMS 597
• SELECTING A PLC 599
• SPECIAL I/O MODULES 603
• PLC PROGRAMMING LANGUAGES 607
• ISSUES 607
• PRACTICE PROBLEMS 607
• PLC REFERENCES 609
• SUPPLIERS 609
• PROFESSIONAL INTEREST GROUPS 610
• PLC/DISCRETE CONTROL REFERENCES 610
• USING THE OMRON DEMO PACKAGE 614
• OVERVIEW 614
• REFERENCE GUIDE FOR OMRON PLC DEMO SOFTWARE 618
• INDUSTRIAL ROBOTICS 619
• INTRODUCTION 619
• ROBOT TYPES 632
• ROBOT APPLICATIONS 663
• END OF ARM TOOLING (EOAT) 666
• ADVANCED TOPICS 675
• PRACTICE PROBLEMS 676
• ROBOTIC PATH PLANNING METHODS 690
• INTRODUCTION: 690
• GENERAL REQUIREMENTS 696
• SETUP EVALUATION CRITERIA 704
• METHOD EVALUATION CRITERIA 709
• IMPLEMENTATION EVALUATION CRITERIA 716
• OTHER AREAS OF INTEREST 719
• COMPARISONS 720
• CONCLUSIONS 722
• APPENDIX A - OPTIMIZATION TECHNIQUES 722
• APPENDIX B - SPATIAL PLANNING 725
• APPENDIX C - TRANSFORMED SPACE 731
• APPENDIX D - FIELD METHODS 738
• APPENDIX E - NEW AND ADVANCED TOPICS 740
• REFERENCES: 741
• ROBOTIC MECHANISMS 746
• KINEMATICS 746
• MECHANISMS 749
• ACTUATORS 750
• PATH PLANNING 752
• PRACTICE PROBLEMS 758
• MOTION PLANNING AND TRAJECTORY CONTROL 763
• TRAJECTORY CONTROL 763
• PATH PLANNING 767
• MOTION CONTROLLERS 771
• SPECIAL ISSUES 774
• PRACTICE PROBLEMS 776
• MICROBOT OVERVIEW 778
• CRS PLUS ROBOT OVERVIEW 778
• BASIC DEMONSTRATION STEPS 779
• CNC MACHINES 781
• MACHINE AXES 781
• NUMERICAL CONTROL (NC) 781
• EXAMPLES OF EQUIPMENT 785
• PRACTICE PROBLEMS 788
• CNC PROGRAMMING 789
• G-CODES 790
• APT 798
• PROPRIETARY NC CODES 801
• GRAPHICAL PART PROGRAMMING 802
• NC CUTTER PATHS 803
• NC CONTROLLERS 805
• PRACTICE PROBLEMS 805