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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.Thisflexibilityincludesthequantitiesandvarietiesofparttypeswhichitcanproduce,theorderinwhichoperationsmaybeperformed,anditsabilitytoreroutepartsbackintoflowpaths.Intheend,thecontrolplatformshouldhavethecapabilitytoautomatetheflowofinformation.

Typically,therearethreetypesofcontrolplatformsusedinFMSs:

minicomputers,microcomputers,andPLCs（Maleki,1991）.Theminicomputersarebestsuitedforcomplexlarge-scale,continuous,regulatorycontrolapplications.ThePLCsareusedforrapidandrepetitiouslogiccontrol.Personalcomputers（PCs）aresuitedforoperatorinterfacefunctions.Primarily,PLCsaredesignedtoreplacehardwiringrelays,tooperateinanindustrialenvironment,tobeeasilymodifiedbyplantengineersandmaintenancepersonnel,andtobemaintainedbyplantelectricians.Currently,withtheconvergenceofunderlyingmicroprocessortechnologyand

softwareprogramming,manyusersfindthatPLCsprovideacost-effectivesolutiontoreal-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,wit