TILI Automation

 As per IEC 62443, Industrial Automation and Control Systems (IACS) refers to the collection of personnel, hardware, and software that can affect or influence the safe, secure, and reliable operation of an industrial process. Most IACS can be remotely operated or monitored, but the risk and challenges in enabling remote actions can vary according to the type of system and its function. The following types of IACS are considered in this recommended practice. Basic Process Control System (BPCS) Basic Process Control System (as per the definition in IEC 61511-1: a system which responds to input signals from the process, its associated equipment, other programmable systems and/or operators and generates output signals causing the process and its associated equipment to operate in the desired manner but which does not perform any SIF.). Basic Process Control System (BPCS) is a system which handles process control and monitoring for the facility. It will take inputs from sensor and proce...

 Develop the PLC program to execute the operational sequence of the packaging process. The purpose of this process is to pack 50 pieces of the product in each container. As the product passes through the light beam, it is deflected by the photoelectric proximity switch and counted by PLC counter When the counter reaching 50, the solenoid operator deflector plate energizes to channel the product from chute A to chute B. When the second count of 50 reached, the solenoid-operated deflector plate de-energizes to channel the product back to chute A and the sequence continues. Stop PB is pressed anytime to stop the process. Manual reset is pressed to resetting the accumulator value of the counter to any time. PLC Packaging Process PLC IO Details PLC Programming PLC Program Description  The following description explains the logic rung wise. RUNG 0000 Latching rung to operate the system through Master Start (I:0/0) and Stop PB (I:0/1). RUNG 0001 Start memory latch (B3:0/0) and proxim...

 Complete and accurate documentation is critical to the commissioning and ongoing maintenance and operation of a PLC or DCS system and should be a high priority of design contract administration. PLC or DCS system documentation provided by the system designer and/or system integrator should include the following: One-line diagrams Piping and instrumentation diagrams (P&IDs) Sequences of operation Instrument data sheets Points list Loop diagrams or I/O wiring diagrams Binary logic diagrams Control schematics PLC / DCS program listing HMI description (screenprints and database) Software configuration management documentation Facility physical and information security policies All PLC or DCS documentation should be furnished in both hard copy and appropriate electronic format. The electronic format should be capable of revision; i.e. scanned documents or portable document format (pdf) files are not acceptable, although pdfs may be submitted as archive copies in addition to revisab...

 Let’s study the working of positive and negative edge detection instruction in Siemens PLC programming with example ladder logic. Edge Detection in PLC Block Description Positive RLO edge detection: It detects the rising edge signal change in the address from 0 to 1 and displays it as RLO as 1 after the instruction. The RLO prior to the instruction is stored in the memory address. Negative RLO edge detection: It detects the falling edge signal change in the address from 1 to 0 and displays it as RLO as 1 after the instruction. The RLO prior to the instruction is stored in the memory address Address Positive edge Detection: POS compares the signal state of address 1 with the signal state from the previous scan, which stored in address 2. If the current RLO state is “1” and the previous state was “0” (detection of rising edge), the RLO bit will be “1” after this instruction. Address Negative Edge Detection: NEG compares the signal state of address 1 with a signal state from the prev...

Let’s study the working of SAVE and BR instructions in Siemens PLC programming. SAVE and BR Instructions in PLC Block Description SAVE: Save coil-like symbol in Siemens PLC is to saving Result of Logical Operation (RLO) into BR Memory. BR: BR contact like symbol in Siemens PLC is to retrieve the output to trigger any other output or block. This bit enables your program to interpret the result of a word logic operation as a binary result and to integrate this result in a binary logic string. Let’s try to understand SAVE and BR instruction in ladder logic and FBD, Example 1: Turn ON Q0.0 using I0.0-When I0.0 is turning ON, it will make Q0.0 to go ON. Function Block Diagram (FBD): Save instruction is used to store RLO of I0.0 into BR memory bit of the status word. By using BR contact, Q0.0 is turned ON. Example 2: Turn ON Q0.0 using I0.0 and Q0.1 using I0.1- When input I0.0 is turning ON it will make output Q0.0 to go ON and input I0.1 is turning ON it will make output Q0.1 to go ON. Ladd...

Let’s study the working of pulse timer instruction in Siemens PLC programming. Pulse Timer in PLC  Block Description Pulse Timer: When Timer receives positive pulse at the set input (S), it enables the Q output as long as the preset value set for the timer. The signal change is necessary in order to enable the timer. Timer will run as long as the input sign (S)  at “1” or accumulator value reaches preset value. The signal state at the output (Q) is at “1” as long as the timer is running. If input (S) changed from “1 to 0” before the time interval has elapsed, timer stopped along with disabling output (Q). The timer reset input enables to reset the timer while it’s running. Accumulator value backs to zero. Accumulator value can be read at the BI and BCD output of the timer. Pulse Extended Timer: When Timer receives positive pulse at the set input (S), it enables the Q output as long as the preset value set for the timer. The signal change is necessary in order to enable the tim...

 Let’s study the working of converter instruction in Siemens PLC programming using different ladder logics and programs. Converter Instruction in PLC Block Description Round to double integer: It reads the input floating point value and converts it to double integer and round to nearest integer. The result is output by the parameter OUT. Truncate double integer part: It reads the input floating point value and converts it to double integer and round to zero mode. The result is output by the parameter OUT. Ceiling: It reads the input floating point value and converts it to double integer. The result is the lowest integer which is greater than the floating point number i.e  Round to + infinity mode. The result is output by the parameter OUT. Floor: It reads the input floating point value and converts it to double integer. The result is the greatest integer component which is greater than the floating point number i.e Round to -infinity mode. The result is output by the parameter...