Jon Stenerson
FUNDAMENTALS OF PROGRAMMABLE LOGIC CONTROLLERS, SENSORS,
AND COMMUNICATIONS, 3/e
Hardcover, pp. 654, plus XVII
Pearson Prentice Hall, Upper Saddle River, New Jersey, 2004
ISBN 0-13-061890-X
In general about the book
All industrial processes need some form of control if they are to run safely and economically. Automation of these processes, such as controlling machines or factory assembly lines, is done through the use of small computers called programmable logic controllers (PLCs). The PLC implements control of machines and manufacturing processes through a set of specific functions such as logic, sequencing, timing, counting, and arithmetic. A modern PLC is usually programmed in one of several languages, ranging from ladder logic to C. Perhaps the biggest benefit of PLCs is their small size, which allows computational power to be placed immediately to the machinery to be controlled, as well as their durability, which allows them to operate in harsh environments. The proximity of PLCs to the equipment that they control allows them to affect: a) the sensing of the process; b) the control of the machinery through a reduced number of wires; and c) quality improvement of sensor data as a consequence of reducing noise induced in the signal lines.
This book is an introduction material to PLCs. It describes the architecture of PLC, identifies the characteristics of commonly used input-output modules and wiring, and describes communication links, including industrial buses.
Chapter content
The book is divided into 23 chapters, two appendices, a Glossary, and an Index. It comes with CD-ROM in which LogixPro programming and simulation software is included. The details of each chapter are as follows:
Chapter 1 (Safety and Lockout/Tagout, pp. 1- 16) involves the reader with the meaning of terms accident, lockout and tagout. In addition, it points to the requirements for lockout/tagout devices and testing of machines, equipment or components.
Chapter 2 (Overview of Programmable Logic Controllers, pp. 17- 38) describes the global structure of the PLC, identifies its building blocks, and points to some typical PLC applications.
Chapter 3 (Overview of Number Systems, pp. 39- 50) explains data representations of decimal, binary, BCD, octal and hexadecimal number systems.
Chapter 4 (Fundamentals of Programming, pp.51- 67) deals with the basics of ladder logic programming, including terminology and common symbols. After defining terms such as contact, coil, rung, scan, normally open and normally closed contacts, writing ladder diagrams for simple applications are given.
Chapter 5 (Rockwell Automation Addressing and Instructions, pp. 69- 87) concentrates on Rockwell Automation memory organization and addressing, explains usage of various instructions, and writing simple programs.
Chapter 6 (Input/Output Modules and Wiring, pp. 89- 112) explains the main characteristics of analog and digital input-output (I/O) modules and their wiring to the external world. At the end some details concerning the use of remote I/O modules and operator terminals are given.
Chapter 7 (Timers and Counters, pp. 113- 149) describes the use and programming of timers and counters in ladder logic. In the rest the possibilities and specifics of timers and counters from several leader companies in PLCs production (GE Fanuc, Gould Modicom, Omron, AutomationDirect, and Rockwell Automation) are presented.
Chapter 8 (Math Instructions, pp. 151- 186) presents typical usage of arithmetic instructions mainly intended to simplify the programmerXs task. It covers implementation of the most common arithmetic instructions such as compare, add, subtract, multiply and division for various PLCs.
Chapter 9 (Advanced Instructions, pp. 187- 213) focuses on explanation of special instructions such as copy, move, masked move, file fill, message transfer, block transfer, ramp, file bit comparison and diagnostic detect, proportional-, integral-, and derivate-instruction, and sequencer instruction. In general these instructions make the process of programming complex systems easier.
Chapter 10 (Advanced Programming, pp. 215- 236) concentrates on techniques and principles used in advanced programming. The main topics considered here are with stage programming, step programming, fuzzy logic, and state logic.
Chapter 11 (Industrial Sensors, pp. 237- 283) describes principles of operation and usage of various analog and digital industrial sensors. The wiring of these sensors with PLC is covered, too.
Chapter 12 (IEC 61131-3 Programming, pp. 285- 311) deals with the International Standard IEC 61131 as a common collection of standards devoted to programming controllers and their associated peripherals. Details about structured text programming, ladder diagramming, instruction list programming, and sequential function chart programming are given.
Chapter 13 (Supervisory Control and Data Acquisition, pp. 313- 348) explains the possibilities of SCADA software. In the rest, development of a simple industrial application based on SCADA is presented in more details.
Chapter 14 (Overview of Plant Floor Communication, pp. 349- 381) presents the basic concepts of industrial networks and explains how communication between computers and PLCs is realized. The discussion includes details about LANs, token passing access method, industrial networks, device level networks, process buses, devices buses, control level-, and enterprise level-communication.
Chapter 15 (Communications, ControlLogix and DeviceNet, pp. 383- 423) looks at industrial networks. The three main types of industrial networks information-, control-, and devices-networks are considered. The purpose and capabilities of Rockwell Automation ControlLogix technology (used for control, communication, and integrating various types of networks), and DeviceNet (communications link that connect industrial devices to a network) are considered.
Chapter 16 (PC-Based Control, pp. 425- 446) is devoted to the usage of PC-based systems for industrial control. The discussion starts with an overview of PC-based control, after that flowchart programming is involved, next the details related to application programming are given, and at the end the structure of an open controller system is presented.
Chapter 17 (Fundamentals of Process Control, pp. 447- 482) concentrates on principles of process control. Open- and closed-loop systems are studied. The concepts of proportional, integral, and differential (PID) control are analyzed.
Chapter 18 (Instrumentation, pp. 483- 517) describes various types of process control systems and points to principles of operation of the appropriate instrumentation used for measurement of process parameters.
Chapter 19 (Batch and Continuous Processes, pp. 519- 535) describes various types of process control systems and instrumentation. The operation of batch and continuous processes are illustrated with two practical examples of systems: beer brewing and whiskey distilling.
Chapter 20 (Embedded Controllers, pp.539- 558) concentrates on more pronounced usage of embedded controllers. Several typical applications and programming of embedded controllers are described.
Chapter 21 (Introduction to Robotics, pp. 559- 589) explains why robots are used in industry, today. The programming and interfacing of robots with other devices is considered.
Chapter 22 (Industrial Automation Controllers, pp. 591- 608) describes industrial automation controllers as systems mainly intended for special application controls such as motion and process control. The discussion includes an overview of industrial automation controllers and a global view of their hardware structure.
Chapter 23 (Installation and Troubleshooting, pp. 609- 630) points to the fact that installation, troubleshooting, and maintenance of an automated system presents very important phase of any project. Useful practical suggestions related to choice of cabinets, and realization of wiring, grounding, and noise protection are given. In addition, details about how to provide the groundwork for proper installation and troubleshooting of integrated systems are presented.
The book contains two appendices. Appendix A shows some common input-output device symbols. Appendix B deals with Control-Logix addressing and project organization.
Useful for undergraduate in Electrical Engineering and Automation Control
This book identifies the main design characteristics and internal architecture of PLCs, explains the processing of inputs and outputs of PLCs, describes communication links involved with control systems, suggests how to write efficient programs using LogixPro programming and simulation software, and gives an overview of global tendencies in development and realization of modern automation control systems.
The organization of the book is good. It is well written. The presentation of the material is clear.
In my opinion, the book is tailored toward upper-level undergraduate students in Electrical Engineering and Automation Control, and practicing engineers interested in designing industrial automation systems.
All in all, I highly recommend this book.
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