英文原文AstudyonPLCbymeansofthedirectconversionoftheladderdiagramtocircuitdesignlanguage1.PLCoverviewProgrammablecontrolleristhefirstinthelate1960sintheUnitedStates,thencalledPlcprogrammablelogiccontroller(ProgrammableLogicController)isusedtoreplacerelays.Fortheimplementationofthelogicaljudgment,timing,sequencenumber,andothercontrolfunctions.TheconceptispresentedPlcGeneralMotorsCorporation.Plcandthebasicdesignisthecomputerfunctionalimprovements,flexible,genericandotheradvantagesandrelaycontrolsystemsimpleandeasytooperate,suchastheadvantagesofcheappricescombinedcontrollerhardwareisstandardandoverall.Accordingtothepracticalapplicationoftargetsoftwareinordertocontrolthecontentoftheuserproceduresmemorycontroller,thecontrollerandconnectingtheaccusedconvenienttarget.Inthemid-1970s,thePlchasbeenwidelyusedasacentralprocessingunitmicroprocessor,importexportmoduleandtheexternalcircuitsareused,large-scaleintegratedcircuitsevenwhenthePlcisnolongertheonlylogical(IC)judgmentfunctionsalsohavedataprocessing,PIDconditioninganddatacommunicationsfunctions.InternationalElectrotechnicalCommission(IEC)standardspromulgatedprogrammablecontrollerforprogrammablecontrollerdraftmadethefollowingdefinition:programmablecontrollerisadigitalelectroniccomputersoperatingsystem,specificallyforapplicationsintheindustrialdesignenvironment.Itusedprogrammablememory,usedtoimplementlogicintheirinternalstorageoperations,sequencecontrol,timing,countingandarithmeticoperations,suchasoperatinginstructions,andthroughdigitalandanaloginputandoutput,thecontrolofvarioustypesofmachineryorproductionprocesses.Programmablecontrollerandrelatedperipherals,andindustrialcontrolsystemseasilylinkedtoformawhole,toexpanditsfunctionaldesign.Programmablecontrollerfortheuser,isanon-contactequipment,theprocedurescanbechangedtochangeproductionprocesses.Theprogrammablecontrollerhasbecomeapowerfultoolforfactoryautomation,widelypopularreplication.Programmablecontrollerisuser-orientedindustriesdedicatedcontrolcomputer,withmanydistinctivefeatures.First,highreliability,anti-interferencecapability；Second，programmingvisual,simple；Third,adaptabilitygood；Fourthfunctionalimprovements,strongfunctionalinterface.2.HistoryofPLCProgrammableLogicControllers(PLC),acomputingdeviceinventedbyRichardE.Morleyin1968,havebeenwidelyusedinindustryincludingmanufacturingsystems,transportationsystems,chemicalprocessfacilities,andmanyothers.Atthattime,thePLCreplacedthehardwiredlogicwithsoft-wiredlogicorso-calledrelayladderlogic(RLL),aprogramminglanguagevisuallyresemblingthehardwiredlogic,andreducedtherebytheconfigurationtimefrom6monthsdownto6daysMoodyandMorley,1999.AlthoughPCbasedcontrolhasstartedtocomeintoplace,PLCbasedcontrolwillremainthetechniquetowhichthemajorityofindustrialapplicationswilladhereduetoitshigherperformance,lowerprice,andsuperiorreliabilityinharshenvironments.Moreover,accordingtoastudyonthePLCmarketofFrostandSullivan1995,anincreaseoftheannualsalesvolumeto15millionPLCsperyearwiththehardwarevalueofmorethan8billionUSdollarshasbeenpredicted,thoughthepricesofcomputinghardwareissteadilydropping.TheinventorofthePLC,RichardEMorley,fairlyconsidersthePLCmarketasa5-billionindustryatthepresenttime.ThoughPLCsarewidelyusedinindustrialpractice,theprogrammingofPLCbasedcontrolsystemsisstillverymuchrelyingontrial-and-error.Alikesoftwareengineering,PLCsoftwaredesignisfacingthesoftwaredilemmaorcrisisinasimilarway.MorleyhimselfemphasizedthisaspectmostforcefullybyindicatingIfhouseswerebuiltlikesoftwareprojects,asinglewoodpeckercoulddestroycivilization.”Particularly,practicalproblemsinPLCprogrammingaretoeliminatesoftwarebugsandtoreducethemaintenancecostsofoldladderlogicprograms.ThoughthehardwarecostsofPLCsaredroppingcontinuously,reducingthescantimeoftheladderlogicisstillanissueinindustrysothatlow-costPLCscanbeused.Ingeneral,theproductivityingeneratingPLCisfarbehindcomparedtootherdomains,forinstance,VLSIdesign,whereefficientcomputeraideddesigntoolsareinpractice.ExistentsoftwareengineeringmethodologiesarenotnecessarilyapplicabletothePLCbasedsoftwaredesignbecausePLC-programmingrequiresasimultaneousconsiderationofhardwareandsoftware.Thesoftwaredesignbecomes,thereby,moreandmorethemajorcostdriver.Inmanyindustrialdesignprojects,morethanofthemanpowerallocatedforthecontrolsystemdesignandinstallationisscheduledfortestinganddebuggingPLCprograms.Inaddition,currentPLCbasedcontrolsystemsarenotproperlydesignedtosupportthegrowingdemandforflexibilityandreconfigurabilityofmanufacturingsystems.Afurtherproblem,impellingtheneedforasystematicdesignmethodology,istheincreasingsoftwarecomplexityinlarge-scaleprojects.TheobjectiveofthisthesisistodevelopasystematicsoftwaredesignmethodologyforPLCoperatedautomationsystems.Thedesignmethodologyinvolveshigh-leveldescriptionbasedonstatetransitionmodelsthattreatautomationcontrolsystemsasdiscreteeventsystems,astepwisedesignprocess,andsetofdesignrulesprovidingguidanceandmeasurementstoachieveasuccessfuldesign.Thetangibleoutcomeofthisresearchistofindawaytoreducetheuncertaintyinmanagingthecontrolsoftwaredevelopmentprocess,thatis,reducingprogramminganddebuggingtimeandtheirvariation,increasingflexibilityoftheautomationsystems,andenablingsoftwarereusabilitythroughmodularity.Thegoalistoovercomeshortcomingsofcurrentprogrammingstrategiesthatarebasedontheexperienceoftheindividualsoftwaredeveloper.3.NowofPLCFromthestructureisdividedintofixedPLCandModulePLC,thetwokindsofPLCincludingCPUboard,I/Oboard,displaypanel,memoryblock,power,theseelementsintoadonotremoveoverall.ModuletypePLCincludingCPUmodule,I/Omodules,memory,thepowermodules,bottomoraframe,thesemodulescanbeaccordingtocertainrulescombinationconfiguration.Intheuserview,adetailedanalysisoftheCPUsinternalunnecessary,butworkingmechanismofeverypartofthecircuit.TheCPUcontrolworks,byitreadsCPUinstruction,interpretstheinstructionandexecutesinstructions.Butthepaceofworkbyshocksignalcontrol.Unitworkunderthecontrollercommandusedinadigitalorlogicoperations.Incomputingandstorageregisterofcomputationresult,itisalsoamongthecontrollercommandandwork.CPUspeedandmemorycapacityistheimportantparametersfotPLC.itsdeterminesthePLCspeedofwork,IOPLCnumberandsoftwarecapacity,solimitstocontrolsize.CentralProcessingUnit(CPU)isthebrainofaPLCcontroller.CPUitselfisusuallyoneofthemicrocontrollers.Aforetimethesewere8-bitmicrocontrollerssuchas8051,andnowtheseare16-and32-bitmicrocontrollers.UnspokenruleisthatyoullfindmostlyHitachiandFujicumicrocontrollersinPLCcontrollersbyJapanesemakers,SiemensinEuropeancontrollers,andMotorolamicrocontrollersinAmericanones.CPUalsotakescareofcommunication,interconnectednessamongotherpartsofPLCcontrollers,programexecution,memoryoperation,overseeinginputandsettingupofanoutput.Systemmemory(todaymostlyimplementedinFLASHtechnology)isusedbyaPLCforaprocesscontrolsystem.Asideform.thisoperatingsystemitalsocontainsauserprogramtranslatedformaladderdiagramtoabinaryform.FLASHmemorycontentscanbechangedonlyincasewhereuserprogramisbeingchanged.PLCcontrollerswereusedearlierinsteadofPLASHmemoryandhavehadEPROMmemoryinsteadofFLASHmemorywhichhadtobeerasedwithUVlampandprogrammedonprogrammers.WiththeuseofFLASHtechnologythisprocesswasgreatlyshortened.Reprogrammingaprogrammemoryisdonethroughaserialcableinaprogramforapplicationdevelopment.Usermemoryisdividedintoblockshavingspecialfunctions.Somepartsofamemoryareusedforstoringinputandoutputstatus.Therealstatusofaninputisstoredeitheras“1”oras“0”inaspecificmemorybit/eachinputoroutputhasonecorrespondingbitinmemory.Otherpartsofmemoryareusedtostorevariablecontentsforvariablesusedinusedprogram.Forexample,timevalue,orcountervaluewouldbestoredinthispartofthememory.PLCcontrollercanbereprogrammedthroughacomputer(usualway),butalsothroughmanualprogrammers(consoles).ThispracticallymeansthateachPLCcontrollercanprogrammedthroughacomputerifyouhavethesoftwareneededforprogramming.TodaystransmissioncomputersareidealforreprogrammingaPLCcontrollerinfactoryitself.Thisisofgreatimportancetoindustry.Oncethesystemiscorrected,itisalsoimportanttoreadtherightprogramintoaPLCagain.ItisalsogoodtocheckfromtimetotimewhetherprograminaPLChasnotchanged.Thishelpstoavoidhazardoussituationsinfactoryrooms(someautomakershaveestablishedcommunicationnetworkswhichregularlycheckprogramsinPLCcontrollerstoensureexecutiononlyofgoodprograms).AlmosteveryprogramforprogrammingaPLCcontrollerpossessesvarioususefuloptionssuchas:forcedswitchingonandoffofthesysteminput/outputs(I/Olines),programfollowupinrealtimeaswellasdocumentingadiagram.Thisdocumentingisnecessarytounderstandanddefinefailuresandmalfunctions.Programmercanaddremarks,namesofinputoroutputdevices,andcommentsthatcanbeusefulwhenfindingerrors,orwithsystemmaintenance.Addingcommentsandremarksenablesanytechnician(andnotjustapersonwhodevelopedthesystem)tounderstandaladderdiagramrightaway.Commentsandremarkscanevenquotepreciselypartnumbersifreplacementswouldbeneeded.Thiswouldspeeduparepairofanyproblemsthatcomeupduetobadparts.Theoldwaywassuchthatapersonwhodevelopedasystemhadprotectionontheprogram,sonobodyasidefromthispersoncouldunderstandhowitwasdone.Correctlydocumentedladderdiagramallowsanytechniciantounderstandthoroughlyhowsystemfunctions.Electricalsupplyisusedinbringingelectricalenergytocentralprocessingunit.MostPLCcontrollersworkeitherat24VDCor220VAC.OnsomePLCcontrollersyoullfindelectricalsupplyasaseparatemodule.ThoseareusuallybiggerPLCcontrollers,whilesmallandmediumseriesalreadycontainthesupplymodule.UserhastodeterminehowmuchcurrenttotakefromI/Omoduletoensurethatelectricalsupplyprovidesappropriateamountofcurrent.Differenttypesofmodulesusedifferentamountsofelectricalcurrent.Thiselectricalsupplyisusuallynotusedtostartexternalinputoroutput.UserhastoprovideseparatesuppliesinstartingPLCcontrollerinputsbecausethenyoucanensuresocalled“pure”supplyforthePLCcontroller.Withpuresupplywemeansupplywhereindustrialenvironmentcannotaffectitdamagingly.SomeofthesmallerPLCcontrollerssupplytheirinputswithvoltagefromasmallsupplysourcealreadyincorporatedintoaPLC.4.PLCdesigncriteriaAsystematicapproachtodesigningPLCsoftwarecanovercomedeficienciesinthetraditionalwayofprogrammingmanufacturingcontrolsystems,andcanhavewideramificationsinseveralindustrialapplications.Automationcontrolsystemsaremod