IEC (International Electrotechnical Commission) is the authority that publishes different standards in the  fields  of  electrical  and  electronics  engineering,  to  be  used  internationally.  In  the  area  of manufacturing, it has demanded a new standard to fulfil better solutions of dynamic requirements. The  IEC  61499  redacted  by  IEC  offers  interoperability,  portability,  configurability  and  distributed control applications for manufacturing processes. However, this standard is not a replacement of IEC 61131-3,  one  of  the  most  used  standards  in  industry;  instead,  it  is  a  complement  of  it.  The  basic software units of IEC 61499 are named Function Blocks (FBs), which can be described as blocks that encapsulate functionality. By combining FBs together, it is possible to solve complex problems.   The  objective  of  this  project  (in  close  cooperation  with  another  project)  is  to  develop  a  software environment in Java language. It follows the requirements of IEC 61499, and implement a Function Block  designer  and  a  runtime  execution  environment,  as  a  part  of  an  existing  Wise-ShopFloor framework. The scope of this project covers:     FB  algorithm  editor:  Each  FB  has  one  or  more  algorithms,  which  can  be  defined  in  the algorithm editor using IEC 61131-3 or Java.     FB serialization: Opening and saving the configuration of FBs in Java Class file is one of the tasks  of  this  project.  As  soon  as  the  configuration  is  saved,  the  Java  code  of  FB  can  be generated. Java code is generated because compiled Java allows execution of FB. Saving in Java  Class  file  permits  portability,  i.e.  the  saved  configuration  can  be  opened  in  any  JVM system, and vice versa.      Case study: A simulation of an assembly station using an ABB IRB 140 robot is studied and implemented using the runtime simulator of the Java platform, in which some basic FBs have been also created in a library. This project also includes: (1) implementation of user interface and (2) FB serialization in XML. It  is  anticipated  that  the  developed  environment  will  be  able  to  save  and  open  FBs  configurations either in XML or in Java Class, following the specification of IEC 61499. It will allow portability and reusability.  Because  of  the  portability,  the  so-designed  FBs  can  be  validated  using  another  FB environment such as FBDK (Function Block Development Kit).

O presente trabalho tem como objetivo o desenvolvimento de uma estratégia de programação para um robô de cinco graus de liberdade com acionamento pneumático. A proposta para tal estratégia de programação utiliza como base a linguagem SFC (Sequential Function Chart) normatizada pela IEC 61131-3. A principal característica deste tipo de linguagem é a simplicidade na integração com diversos elementos presentes em ambiente fabril, juntamente a garantia do sequenciamento das ações e a facilidade de programação. O estudo foi realizado em três etapas: a primeira, destina-se à criação de sub-rotinas em linguagem SFC para movimentação ponto a ponto, pick and place, e paletização. Desta forma, através da definição de alguns dados de entrada, é possível reprogramar o robô de forma gráfica e intuitiva; a segunda etapa do estudo constituiu na criação de um Programa Tradutor em linguagem baseada em scripts de Matlab que, através de um servidor OPC (Ole for Process Control), faz a interpretação do programa em linguagem SFC e o traduz para a linguagem do sistema de controle do robô; já, a última etapa destina-se à realização de testes utilizando um CLP Compact Logix da AllenBradley em conjunto com o software de programação RSLogix 5000, o software Matlab e o sistema de controle do robô pneumático. A partir dos resultados, Conclui-se que a aplicação e utilização este tipo de programação para tarefas de movimentação de robôs é plenamente viável, o que pode vir a simplificar as etapas de programação, e ampliando a integração entre os diversos sistemas fabris, na medida em que os seus elementos poderão trocar facilmente informações necessárias à automação. / The present study has as main goal to present a differentiated form of programming for a prototype of a robot of five degrees of freedom with pneumatic drive. This program is based on the language SFC (Sequential Function Chart) standardized by IEC 61131-3. The main feature of this type of language is simplicity in integration with various elements present in the manufacturing environment, ensuring the sequencing of actions and ease of programming. The system used as a test bench consists of a pneumatic robot which currently control actions are carried out through specific programming routines combined with dedicated control boards, working with Matlab software. The study was conducted in three stages: the first, for creating subroutines in SFC language to linear movement, pick and place movement and palletizing movement, thus, by setting some input data it is possible to reprogram the robot for tasks in a graphical and intuitive way; the second stage of the study consisted in creating a translator program in Matlab language based on scripts that, through an OPC server (Ole for Process Control), interpreters the program in SFC language and translates it into the language of the control system robot; the last step was intended for testing this programming approach by using a PLC Compact Logix from Allen-Bradley in conjunction with RSLogix 5000 programming software, Matlab and the control system of the pneumatic robot. It was concluded that the implementation and use of this type of programming for robot handling tasks are both feasible. It simplifies the programming steps and enhances the integration between the various manufacturing systems, since the elements could directly exchange information, because they are in the same language.

O presente trabalho tem como objetivo o desenvolvimento de uma estratégia de programação para um robô de cinco graus de liberdade com acionamento pneumático. A proposta para tal estratégia de programação utiliza como base a linguagem SFC (Sequential Function Chart) normatizada pela IEC 61131-3. A principal característica deste tipo de linguagem é a simplicidade na integração com diversos elementos presentes em ambiente fabril, juntamente a garantia do sequenciamento das ações e a facilidade de programação. O estudo foi realizado em três etapas: a primeira, destina-se à criação de sub-rotinas em linguagem SFC para movimentação ponto a ponto, pick and place, e paletização. Desta forma, através da definição de alguns dados de entrada, é possível reprogramar o robô de forma gráfica e intuitiva; a segunda etapa do estudo constituiu na criação de um Programa Tradutor em linguagem baseada em scripts de Matlab que, através de um servidor OPC (Ole for Process Control), faz a interpretação do programa em linguagem SFC e o traduz para a linguagem do sistema de controle do robô; já, a última etapa destina-se à realização de testes utilizando um CLP Compact Logix da AllenBradley em conjunto com o software de programação RSLogix 5000, o software Matlab e o sistema de controle do robô pneumático. A partir dos resultados, Conclui-se que a aplicação e utilização este tipo de programação para tarefas de movimentação de robôs é plenamente viável, o que pode vir a simplificar as etapas de programação, e ampliando a integração entre os diversos sistemas fabris, na medida em que os seus elementos poderão trocar facilmente informações necessárias à automação. / The present study has as main goal to present a differentiated form of programming for a prototype of a robot of five degrees of freedom with pneumatic drive. This program is based on the language SFC (Sequential Function Chart) standardized by IEC 61131-3. The main feature of this type of language is simplicity in integration with various elements present in the manufacturing environment, ensuring the sequencing of actions and ease of programming. The system used as a test bench consists of a pneumatic robot which currently control actions are carried out through specific programming routines combined with dedicated control boards, working with Matlab software. The study was conducted in three stages: the first, for creating subroutines in SFC language to linear movement, pick and place movement and palletizing movement, thus, by setting some input data it is possible to reprogram the robot for tasks in a graphical and intuitive way; the second stage of the study consisted in creating a translator program in Matlab language based on scripts that, through an OPC server (Ole for Process Control), interpreters the program in SFC language and translates it into the language of the control system robot; the last step was intended for testing this programming approach by using a PLC Compact Logix from Allen-Bradley in conjunction with RSLogix 5000 programming software, Matlab and the control system of the pneumatic robot. It was concluded that the implementation and use of this type of programming for robot handling tasks are both feasible. It simplifies the programming steps and enhances the integration between the various manufacturing systems, since the elements could directly exchange information, because they are in the same language.

O presente trabalho tem como objetivo o desenvolvimento de uma estratégia de programação para um robô de cinco graus de liberdade com acionamento pneumático. A proposta para tal estratégia de programação utiliza como base a linguagem SFC (Sequential Function Chart) normatizada pela IEC 61131-3. A principal característica deste tipo de linguagem é a simplicidade na integração com diversos elementos presentes em ambiente fabril, juntamente a garantia do sequenciamento das ações e a facilidade de programação. O estudo foi realizado em três etapas: a primeira, destina-se à criação de sub-rotinas em linguagem SFC para movimentação ponto a ponto, pick and place, e paletização. Desta forma, através da definição de alguns dados de entrada, é possível reprogramar o robô de forma gráfica e intuitiva; a segunda etapa do estudo constituiu na criação de um Programa Tradutor em linguagem baseada em scripts de Matlab que, através de um servidor OPC (Ole for Process Control), faz a interpretação do programa em linguagem SFC e o traduz para a linguagem do sistema de controle do robô; já, a última etapa destina-se à realização de testes utilizando um CLP Compact Logix da AllenBradley em conjunto com o software de programação RSLogix 5000, o software Matlab e o sistema de controle do robô pneumático. A partir dos resultados, Conclui-se que a aplicação e utilização este tipo de programação para tarefas de movimentação de robôs é plenamente viável, o que pode vir a simplificar as etapas de programação, e ampliando a integração entre os diversos sistemas fabris, na medida em que os seus elementos poderão trocar facilmente informações necessárias à automação. / The present study has as main goal to present a differentiated form of programming for a prototype of a robot of five degrees of freedom with pneumatic drive. This program is based on the language SFC (Sequential Function Chart) standardized by IEC 61131-3. The main feature of this type of language is simplicity in integration with various elements present in the manufacturing environment, ensuring the sequencing of actions and ease of programming. The system used as a test bench consists of a pneumatic robot which currently control actions are carried out through specific programming routines combined with dedicated control boards, working with Matlab software. The study was conducted in three stages: the first, for creating subroutines in SFC language to linear movement, pick and place movement and palletizing movement, thus, by setting some input data it is possible to reprogram the robot for tasks in a graphical and intuitive way; the second stage of the study consisted in creating a translator program in Matlab language based on scripts that, through an OPC server (Ole for Process Control), interpreters the program in SFC language and translates it into the language of the control system robot; the last step was intended for testing this programming approach by using a PLC Compact Logix from Allen-Bradley in conjunction with RSLogix 5000 programming software, Matlab and the control system of the pneumatic robot. It was concluded that the implementation and use of this type of programming for robot handling tasks are both feasible. It simplifies the programming steps and enhances the integration between the various manufacturing systems, since the elements could directly exchange information, because they are in the same language.

Many industrial control systems use programmable logic controllers (PLCs) since they provide a highly reliable, off-the-shelf hardware platform. On the programming side, function blocks (FBs) are reusable PLC components that can be composed to implement the required system behaviour. A higher quality system may be realized if the FBs are pre-certified to be compliant with an international standard such as IEC 61131-3. Unfortunately, the set of programming notations defined in IEC 61131-3 lack well-defined formal semantics. As a result, tool vendors and users of PLCs may have inconsistent interpretations of the expected system behaviour. To address this issue, we propose an engineering method for formally verifying the conformance of candidate implementations of FBs (and their compositions) to their high-level, input-output requirements. The proposed method is sufficiently general to handle FBs supplied by IEC 61131-3, and industrial FB applications involving real-time requirements. Our method involves several steps. First, we use tabular expressions to ensure the completeness and disjointness of the requirements for the FB. Second, we formalize the candidate implementation(s) of the FB in question. Third, we state and prove theorems regarding the consistency and correctness of the FB. All three steps are performed using the Prototype Verification Systems (PVS) proof assistant. As a first case study, we apply our approach to the IEC 61131-3 standard to examine the entire library of FBs and their supplied implementations described in structured text (ST) and function block diagrams (FBDs). As a second case study, we apply our approach to two realistic sub-systems taken from the nuclear domain. Applying the proposed method, we identified three kinds of issues: ambiguous behavioural descriptions, missing assumptions, and erroneous implementations. Furthermore, we suggest solutions to these issues. / Thesis / Doctor of Philosophy (PhD) / A formal verification approach for the function block based control systems

Detta arbete har syftat till att ställa två av de större automationstillverkarna Siemens och Rockwell Automation mot varandra kring utvalda faktorer som: prestanda, kommunikation och tillgängliga mjukvaruverktyg. Studien har utformat tester på olika PLC-enheter från respektive tillverkare, redogjort för skillnader i de erbjudna kommunikationslösningarna samt analyserat mjukvaruverktygen utifrån utvalda egenskaper men också internationellt erkända standarder. Undersökningen har visat på bättre prestanda på processorer från Rockwell Automation än motsvarande från Siemens för ett givet tillämpningsområde. Vad befattar kommunikationslösningar med ethernet-teknologi har Siemens visat på bättre prestanda, stabilare kommunikation och ett mer komplett ekosystem som svarar på flera av de behov som kan uppstå i industriverksamhet. Mjukvaruverktygen från Siemens erbjuder mer objekt-orienterad funktionalitet och har visat sig betydligt mer kompatibel med den väletablerade standarden IEC 61131-3 som utformar programmeringsmetodiker för PLC-enheter och är tänkt att svara mot framtidens behov av interoperabilitet och effektivisering. Av resultaten som fåtts har en bedömning gjorts att Siemens erbjuder ett mer fördelaktigt utbud av produkter och tjänster som svarar väl mot framtidens krav. / This paper treats two competing suppliers of automation technology, Siemens and Rockwell Automation and directly compares them for a given set of factors in the following categories: performance, communication and software tools. The study consists of performance tests made on different PLC’s from these suppliers, considerations in the differences of communication technology and analysis of the programming tools according to chosen criteria’s but also by the degree of compliance with internationally established standards. The tests have shown the PLC from Rockwell Automation as having better performance for the chosen criteria (PLC’s for small to medium sized machines). Siemens offers more performance and more stable industrial ethernet communication over ProfiNET than does Rockwell Automation with EtherNet/IP. Accordingly, Siemens offers more flexibility in meeting future industrial needs. The software tools provided by Siemens offer a more object-oriented approach for programming PLC’s than equivalent tools from Rockwell Automation. TIA Portal offered by Siemens is more than twice as compliant with the internationally accepted standard IEC 61131-3 as Studio 5000 from Rockwell and in being more compliant benefits from increased interoperability and effective programming. The results show that Siemens’ products and services for automation benefits the customer in long term viability.

Made available in DSpace on 2014-12-17T15:48:03Z (GMT). No. of bitstreams: 1 HanielMB_DISSERT.pdf: 4925062 bytes, checksum: b4c15cc32318b96fa9ccd3be61b6e7e6 (MD5) Previous issue date: 2012-11-01 / PLCs (acronym for Programmable Logic Controllers) perform control operations, receiving information from the environment, processing it and modifying this same environment according to the results produced. They are commonly used in industry in several applications, from mass transport to petroleum industry. As the complexity of these applications increase, and as various are safety critical, a necessity for ensuring that they are reliable arouses. Testing and simulation are the de-facto methods used in the industry to do so, but they can leave flaws undiscovered. Formal methods can provide more confidence in an application s safety, once they permit their mathematical verification. We make use of the B Method, which has been successfully applied in the formal verification of industrial systems, is supported by several tools and can handle decomposition, refinement, and verification of correctness according to the specification. The method we developed and present in this work automatically generates B models from PLC programs and verify them in terms of safety constraints, manually derived from the system requirements. The scope of our method is the PLC programming languages presented in the IEC 61131-3 standard, although we are also able to verify programs not fully compliant with the standard. Our approach aims to ease the integration of formal methods in the industry through the abbreviation of the effort to perform formal verification in PLCs / Controladores L?gico Program?veis (PLCs Programmable Logic Controllers, em ingl?s) desempenham fun??es de controle, recebendo informa??es do ambiente, processando-as e modificando este ambiente de acordo com os resultados obtidos. S?o comumente utilizados na ind?stria nas mais diversas aplica??es, do transporte de massa ? ind?stria do petr?leo, g?s e energias renov?veis. Com o crescente aumento da complexidade dessas aplica??es e do seu uso em sistemas cr?ticos, faz-se necess?ria uma forma de verifica??o que propicie mais confian?a do que testes e simula??o, padr?es mais utilizados na ind?stria, mas que podem deixar falhas n?o tratadas. M?todos formais podem prover maior seguran?a a este tipo de sistema, uma vez que permitem a sua verifica??o matem?tica. Neste trabalho fazemos uso do M?todo B, que ? usado com sucesso na ind?stria para a verifica??o de sistemas cr?ticos, possui amplo apoio ferramental e suporte ? decomposi??o, refinamento e verifica??o de corretude em rela??o ? especifica??o atrav?s de obriga??es de prova. O m?todo desenvolvido e apresentado aqui consiste em gerar automaticamente modelos B a partir de programas para PLCs e verific?-los formalmente em rela??o a propriedades de seguran?a, estas derivadas manualmente a partir dos requisitos do sistema. O escopo do trabalho s?o as linguagens de programa??o para PLCs do padr?o IEC 61131-3, mas sistemas com linguagens que apresentem modifica??es em rela??o ao padr?o tamb?m s?o suportados. Esta abordagem visa facilitar a integra??o de m?todos formais na ind?stria atrav?s da diminui??o do esfor?o para realizar a verifica??o formal de PLCs

Tese de mestrado integrado. Engenharia Electrotécnia e Computadores. Faculdade de Engenharia. Universidade do Porto. 2013

The industrial manufacturing of today is achieved through the use of programmable logic controllers (PLC). The way PLCs are programmed remains largely unchanged since their conception 40 years ago, but complexity and software size have increased, and requirements have becomemore elaborate. Model-driven engineering (MDE) practices, formal verification and automated testing could help manage these challenges. This study seeks to improve development practices in the context of a company that delivers automation projects. Through design science methodology the state of the field is investigated and an artefact is developed. The artefact shows potential benefits resulting from the introduction of model-driven code generation, which is evaluated through an experiment with engineers. Our results indicate the engineers may benefit from incorporating generated code in their work.

An industrial control valve has been designed by Eaton (AxisPro® valve). The servo performance valve has onboard electronics that features external and internal sensor interfaces, advanced control modes and network capability. Advanced control modes are implement in the valves firmware. With the help of the white space it is possilbe to execute custom code directly on the valve that interact with these controls. Small OEM applications, like rubber moulding machines, benefit from the comination of build in controls and custom code, to provide adaptations for their special machines.