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@#@TheoreticalComputerScience253(2001)61{93@#@DevelopingaHybridProgrammableLogicControllerPlatformforaFlexibleManufacturingSystem@#@HenningDierks1@#@UniversityofOldenburg,FachbereichInformatik,Postfach2503,2900Oldenburg,Germany@#@Abstract:
@#@Inthisarticle,wepresentthedesignandimplementationofaflexiblemanufacturingsystem(FMS)controlplatformbasedonaprogrammablelogiccontroller(PLC)andapersonalcomputer(PC)-basedvisualman-machineinterface(MMI)anddataacquisition(DAS)unit.ThekeyaspectofanFMSisitsflexibilitytoadapttochangesinademandingprocessoperation.ThePLCprovidesfeasiblesolutionstoFMSapplications,usingPC-basedMMI/DAS,wherebyPLCsareoptimizedforexecutingrapidsequentialcontrolstrategies.PCsrunningMMI/DASfront-endsmakeintuitiveoperationinterfaces,fullofpowerfulgraphicsandreportingtools.InformationfromthePCcanbedistributedthroughacompany’slocalareanetworkorwebusingclient-servertechnologies.Currently,withtheconvergenceofunderlyingmicroprocessortechnologyandsoftwareprogram-mingtechniques,manyusersfindthatPLCsprovideacost-effectivesolutiontoreal-timecontrolinsmall-tomedium-sizedprocessplants,especiallywhencombinedwithsupervisoryPCsusinghybridsystems.ThemajorworkofthisarticledemonstratesthatPLCsareresponsivetorapidandrepetitiouscontroltasks,usingPCsthatpresenttheflowofinformationautomationandacceptoperatorinstructions,therebyprovidingtheuseratooltomodifyandmonitortheprocessastherequirementschange.@#@KeyWords:
@#@PLC、FMS、PC.@#@1.Introduction@#@Inavarietyofproductmanufacturingindustries,themostautomatedformofproductionisaFlexiblemanufacturingsystem(FMS),firstintroducedin1970s.SincetheFMSscanprovideahighpotentialforproductivityimprovementinbatchmanufacturing,thenumberofFMSsisgrowingsubstantially(GrooverandZimmers,1984).Theaccelerationthroughouttheworldisduetoincreasedglobalcompetition,reducedmanufacturingcycletimes,andcutsinproductioncosts.@#@Generally,anFMSconsistsofagroupofmachinesorotherautomatedworkstations,whichformintomodularsubsystems,suchasCNCmachines,robots,visionsystems,andaprocessstation.Theseareinterconnectedbyamaterialshandlingsystemandusuallydrivenbyacomputer(Maleki,1991).Eachmodularsystemrequiresanindividualmodularcontrolsystem,withdifferentcomponentsbeingcontrolledbyindividualcontrollerunits.Allofthemodularsubsystemsarecontrolledbycomputersasusual.Thesecontrollersperformtheirintendedtasksundersupervisionofahigherlevelcontroller.Tothesystem,boththecontroldevicesaswellastheflowofinformationneedtobeautomated.ThekeyaspectofanFMSisitsabilitytoadapttochangesinthecontroltasks.This flexibilityincludesthequantitiesand varietiesofparttypeswhichitcanproduce,theorderinwhichoperationsmaybeperformed,anditsabilitytoreroutepartsbackintoflowpaths.Intheend,thecontrolplatformshouldhavethecapabilitytoautomatetheflowofinformation.@#@Typically,there are three typesof controlplatforms used inFMSs:
@#@minicomputers,microcomputers,andPLCs(Maleki,1991).Theminicomputersarebestsuitedforcomplexlarge-scale,continuous,regulatorycontrolapplications.ThePLCsareusedforrapidandrepetitiouslogiccontrol.Personalcomputers(PCs)aresuitedforoperatorinterfacefunctions.Primarily,PLCsaredesignedtoreplacehardwiringrelays,tooperateinanindustrialenvironment,tobeeasily modifiedbyplantengineersandmaintenancepersonnel,andtobemaintainedbyplantelectricians.Currently,withtheconvergenceofunderlyingmicroprocessortechnologyandsoftwareprogramming,manyusersfindthatPLCsprovideacost-effectivesolutionto@#@real-timecontrolinsmall-tomedium-sizedprocessplants,especiallywhencombinedwithsupervisoryPCsusinghybridsystems.@#@Thepurposeofthisarticleistoaddressthestate-of-the-arttechnologyofFMSs.ThedesignandconstructionofanFMSusingPLC-controlledandPC-basedvisualman-machineinterface(MMI)anddataacquisitionsystem(DAS) arepresented.Itisorganizedasfollows.Section2beginswiththedescriptionoftheFMSonthefactoryflooroftheCenterforManufacturingSystemsattheNewJerseyInstituteofTechnology(NJIT).Section3showstheoperationaldescriptionoftheFMS.Sections4and5presenttheapplicationsofPLC-controlledandPC-basedMMI/DASfortheFMSatNJIT.Section6containsasummaryoftheadvantagesofthisPLC-controlledandPC-basedMMI/DASforFMSapplication.@#@2.DescriptionoftheFMS@#@SIhandlingconveyorsystem@#@Thisconsistsoffourcarts,A,B,C,andD,withfixturesmountedoneach,twotransfertables,TT1andTT2,anddualconveyorswhichtran