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PAC——新一代工業(yè)控制系統(tǒng), 可編程自動化控制發(fā)展的未來
Has produced along with many merchants can unify the PC function and the PLC reliable programmable automation controller (PAC), at present the control system gradually started to use PAC. This white paper introduced PAC the origin as well as it with PLC and the PC difference, and had pointed out will use PAC the industry to control the future development direction.
隨著許多廠商已生產出能結合PC功能和PLC可靠性的可編程自動化控制器(PAC),目前控制系統(tǒng)已逐漸開始采用PAC。本白皮書介紹PAC的起源以及它與PLC和PC的區(qū)別,并指出了使用PAC的工業(yè)控制未來發(fā)展方向。
Table of contents
目錄
PAC will become the future the industry control mode
"80-20" principle
Constructs a better controller
Two kind of different softwares solution
PAC vision and survey application
PAC has avoided to the special hardware need
LabVIEW uses in the automated control
· PAC將成為未來的工業(yè)控制方式
· “80-20” 法則
· 構建更好的控制器
· 兩種不同的軟件解決方案
· PAC的視覺和測量應用
· PAC免除了對專門硬件的需要
· LabVIEW用于自動化控制
NI PAC system
NI PAC系統(tǒng)
PAC will become the future the industry control mode with compares based on the PC control system, related PLC (programmable logical controller) the superiority and the inferiority intense argument has already continued for ten years. Because PC and PLC are more and more small in the technical difference, and has used the commercialization along with PLC (COTS) the hardware as well as PC can use the real-time operating system, thus appeared one kind of new form controller - PAC. The PAC concept is (ARC) proposes by the automation development facility, it expressed the programmable automated controller, used in describing unified PLC and the PC function new generation of industry controller. The traditional PLC merchant uses PAC the concept to describe their high end system, but PC control merchant then uses for to describe their industrialization to control the platform.
PAC將成為未來的工業(yè)控制方式和基于PC控制系統(tǒng)相比,有關PLC(可編程邏輯控制器)優(yōu)勢和劣勢的激烈爭論已經持續(xù)了十年。由于PC和PLC在技術上的差別越來越小,并且隨著PLC采用了商業(yè)化(COTS)硬件以及PC能采用實時操作系統(tǒng),從而出現了一種新類型的控制器——PAC。PAC的概念是由自動化研究機構 (ARC) 提出的,它表示可編程自動化控制器,用于描述結合了PLC和PC功能的新一代工業(yè)控制器。傳統(tǒng)的PLC廠商使用PAC的概念來描述他們的高端系統(tǒng),而PC控制廠商則用來描述他們的工業(yè)化控制平臺。
"80-20" principle
“80-20” 法則
In PLC in 30 years which developed, it passes through develops unceasingly, already could unify simulates I/O, the network corresponds as well as uses new programming standard like IEC 61131-3. However, engineers only must use digital I/O and few simulations I/O number as well as simple programming skill on potential 80% industrial application. Comes from ARC, the unit exploitation company (VDC) as well as on the net PLC training resources PLC. The net expert estimated that,
77% PLC uses in the small application (being lower than 128 I/O)
72% PLC I/O is a numeral
80% PLC application may use 20 trapezoidal logical sets of instructions to solve
在PLC被開發(fā)出來的三十年里,它經過不斷地發(fā)展,已經能結合模擬I/O,網絡通信以及采用新的編程標準如IEC 61131-3。然而,工程師們只需利用數字I/O和少量的模擬I/O數以及簡單的編程技巧就可開發(fā)出80%的工業(yè)應用 。來自ARC、聯(lián)合開發(fā)公司(VDC)以及網上PLC培訓資源PLC.net的專家估計:
· 77%的PLC被用于小型應用(低于128 I/O)
· 72%的PLC I/O是數字的
· 80%的PLC應用可利用20條的梯形邏輯指令集來解決
Because uses traditional the tool to be possible to solve 80% industrial application, like this intensely needs to have low cost simple PLC; Thus promoted the low cost miniature PLC growth, it has the useful trapezoidal logical programming digital I/O. However, this has also created the discontinuity in the control technology, on the one hand 80% application need to use the simple low cost controller, but on the other hand other 20% application then have surpassed the function which the tradition control system can provide. Engineer is developing these 20% application to need to have the higher circulation speed, the senior control algorithm, the more simulations function as well as can well and the enterprise network integration.
由于采用傳統(tǒng)的工具可以解決80%的工業(yè)應用,這樣就強烈地需要有低成本簡單的PLC;從而促進了低成本微型PLC的增長,它帶有用梯形邏輯編程的數字I/O。然而,這也在控制技術上造成了不連續(xù)性,一方面80%的應用需要使用簡單的低成本控制器,而另一方面其它的20%應用則超出了傳統(tǒng)控制系統(tǒng)所能提供的功能。工程師在開發(fā)這些20%的應用需要有更高的循環(huán)速率,高級控制算法,更多模擬功能以及能更好地和企業(yè)網絡集成。
In 80 and the 90's, these must develop "20% application" engineers had considered uses PC in the industry control. PC provides the software function may carry out the senior task, provides the rich programming and the user environment, and the PC COTS part enables control engineer the technology which develops unceasingly to use in other applications. These technologies including floating point processor; High speed I/O main line, like PCI and ethernet; Fixed data memory; software development kit. Moreover PC also can provide the incomparable flexibility, highly effective software as well as senior low cost hardware.
在八十和九十年代,那些要開發(fā)“20%應用”的工程師們已考慮在工業(yè)控制中使用PC。PC所提供的軟件功能可以執(zhí)行高級任務,提供豐富的圖形化編程和用戶環(huán)境,并且PC的COTS部件使控制工程師能把不斷發(fā)展的技術用于其它應用。這些技術包括浮點處理器;高速I/O總線,如PCI和以太網;固定數據存儲器;圖形化軟件開發(fā)工具。而且PC還能提供無比的靈活性,高效的軟件以及高級的低成本硬件。
However, PC is not extremely suitablly uses in controlling the application. Although many engineers in integrated senior function time uses PC, these functions including simulation control and simulation, connection database, network function of as well as with third party equipment correspondence, but PLC still was at the dominant position in the control domain. Is standard PC is not but designs based on the PC control main question for the strict industry environment.
然而,PC還不是非常適合用于控制應用。盡管許多工程師在集成高級功能時使用PC,這些功能包括模擬控制和仿真、連接數據庫、網絡功能以及和第三方設備通信,但是PLC仍然在控制領域中處于統(tǒng)治地位。基于PC控制的主要問題是標準PC并不是為嚴格的工業(yè)環(huán)境而設計的。
PC mainly faces three major problems:
PC主要面臨三大問題:
Stability: The usual PC general operating system cannot provide uses in controlling the enough stability. The installment can force the processing system collapse based on the PC control equipment and not expect to again opens.
Reliability: Because PC has the magnetic hard disk and the non- reliable part which revolves, like the power source, this makes it to be easier to appear the breakdown.
Not familiar programming environment: The factory operator needs to have when maintains and fixes the breakdown restores the system the ability. The use trapezoidal logic, they may manual force the coil to restore to the perfect condition, and can fast patch the code which affects by is fast restored the system. However, the PC system needs the operator to study the new higher paraffin the tool.
· 穩(wěn)定性:通常PC的通用操作系統(tǒng)不能提供用于控制足夠的穩(wěn)定性。安裝基于PC控制的設備會迫使處理系統(tǒng)崩潰和未預料到的重啟。
· 可靠性:由于PC帶有旋轉的磁性硬盤和非工業(yè)性牢固的部件,如電源,這使得它更容易出現故障。
不熟悉的編程環(huán)境:工廠操作人員需要具備在維護和排除故障時恢復系統(tǒng)的能力。使用梯形邏輯,他們可以手動迫使線圈恢復到理想狀態(tài),并能快速修補受影響的代碼以快速恢復系統(tǒng)。然而,PC系統(tǒng)需要操作人員學習新的更高級的工具。
Although certain engineers use have the firm hardware and the specially operating system special-purpose industry computer, but because Engineer PC reliable aspect question overwhelming majority avoids in the control using PC. In addition, uses in each kind of automated duty equipment in PC, like I/O, correspondence, or movement possible need different development environment.
盡管某些工程師采用具有堅固硬件和專門操作系統(tǒng)的專用工業(yè)計算機,但是由于PC可靠性方面的問題絕大多數工程師還是避免在控制中使用PC。此外,在PC中的用于各種自動化任務的設備,如I/O、通信、或運動可能需要不同的開發(fā)環(huán)境。
Therefore these must develop "20% application" engineers either use PLC to be unable with ease to realize the function which the system needs, either uses both contains PLC and to contain PC the mix system, they use PLC to carry out the code control section, realizes the higher paraffin function with PC. Thus the present many factories workshops use the system which PLC and PC unifies, in use system PC carries on the data record, the connection bar code scanner, inserts the information in the database as well as issues the data to the net on. Uses this way establishment system the main question is this system with difficulty constructs frequently, fixes the breakdown and the maintenance. System engineer must unify frequently comes from many merchants software and hardware work to puzzle, this is because these equipment are not but design for can the joint operation.
因此那些要開發(fā)“20%應用”的工程師們要么使用一個PLC無法輕松實現系統(tǒng)所需的功能,要么采用既包含PLC又包含PC的混合系統(tǒng),他們利用PLC來執(zhí)行代碼的控制部分,用PC來實現更高級的功能。因而現在許多工廠車間使用PLC和PC相結合的系統(tǒng),利用系統(tǒng)中的PC進行數據記錄,連接條碼掃描儀,在數據庫中插入信息以及把數據發(fā)布到網上。采用這種方式建立系統(tǒng)的主要問題是該系統(tǒng)常常難以構建,排除故障和維護。系統(tǒng)工程師常常被要結合來自多個廠商軟硬件的工作所困擾,這是因為這些設備并不是為了能協(xié)同工作而設計的。
Constructs a better controller
構建更好的控制器
Because does not have suitable PC or the PLC solution, these need development complex application engineer on develops the new product with the control merchant close cooperation. They need the new product to be able to unify PC the senior software function and the PLC reliability. These important users were PLC and have provided the product development instruction based on the PC control company.
由于沒有適合的PC或PLC解決方案,那些需要開發(fā)復雜應用的工程師就和控制廠商密切合作開發(fā)新的產品。他們需要新產品能結合PC的高級軟件功能和PLC的可靠性。這些重要用戶為PLC和基于PC控制的公司提供了產品開發(fā)指導。
Realizes the software function not only to need to have the senior the software, moreover the controller hardware function also needs to have the enhancement. Because in the world scope is dropping to the PC part demand, therefore many semiconductors merchants start for the industrial application redesign their product. At present controls the domain the merchant to start in the industry control product to use the industrialization floating point processor, DRAM, solid state memory like Compact Flash as well as the fast Ethernet chip. This enables the merchant to use based on the PC control system flexibility and the usability develops a more formidable software, moreover this PC control system also may move the real-time operating system by to guarantee the reliability.
實現軟件的功能不僅需要有高級的軟件,而且控制器的硬件功能也需要有所提高。由于世界范圍內對PC部件的需求在下降,所以許多半導體廠商開始為工業(yè)應用重新設計他們的產品。目前控制領域的廠商已開始在工業(yè)控制產品中使用工業(yè)化浮點處理器、DRAM、固態(tài)存儲器如CompactFlash以及快速Ethernet芯片。這使得廠商能利用基于PC控制系統(tǒng)的靈活性和可用性來開發(fā)更為強大的軟件,而且該PC控制系統(tǒng)還可運行實時操作系統(tǒng)以保證可靠性。
This kind of new controller is the solution "20%" the application question but designs, it unified PLC and the PC two merits. The ARC industry analyst is called this kind of equipment the programmable automated controller, namely PAC. "The programmable logical controller world looks at in generally" the research in ARC, they have produced the PAC five principal characteristics. These controller characteristics are through define the software the ability to realize its function.
這種新的控制器是為解決“20%”的應用問題而設計的,它結合了PLC和PC兩者的優(yōu)點。ARC的工業(yè)分析家把這種設備稱為可編程自動化控制器,即PAC。在ARC的“可編程邏輯控制器世界概覽”研究中,他們給出了PAC的五個主要特性。這些控制器特性是通過定義軟件的能力來實現其功能的。
"Multi-purpose, has in the logic, the movement, the PID control, the actuation and processing in a platform at least two kind of above functions." Except that in order to realize special agreement like SERCOS to have to I/O makes some improvements; Moreover the software also can provide logical, the movement, processing and the PID function. For example, the movement control took the software control circulation, it can reading the digital input from the orthogonal encoder, the execution simulation control circulates and outputs the control device the simulated signal.
“多功能性,在一個平臺上有邏輯、運動、PID控制、驅動和處理中的至少兩種以上功能?!背藶榱藢崿F特殊的協(xié)議如SERCOS要對I/O做一些改進;而且軟件還能提供邏輯、運動、處理和PID的功能。例如,運動控制作為軟件控制循環(huán),它能從正交編碼器上讀取數字輸入,執(zhí)行模擬控制循環(huán)并輸出控制設備的模擬信號。
"The sole multi- regulations develop the platform use general label and the sole database visit all parameters and the function." Because PAC is like multi-purpose but designs for more the senior application, they need the senior software. In order to can highly effective design the system, the software must be the sole integrated software package, but is not the many kinds of separations software tool, these software tools in the project cannot the seamless joint operation.
“單一的多規(guī)程開發(fā)平臺使用通用標簽和單一的數據庫來訪問所有的參數和功能?!庇捎赑AC是為更為高級的應用如多功能而設計的,他們需要更為高級的軟件。為了能高效地設計系統(tǒng),軟件必須是單一的集成化軟件包,而不是多種分離的軟件工具,這些軟件工具在工程上不能無縫地協(xié)同工作。
"Through unifies IEC61131-3, the user guide and the data management, the software tool can design is surmounting many machines and the processing unit processing flow." The simplification system design on the other hand is has the senior the development kit, uses this tool to be possible to cause engineer very with ease to transform the processing concept for can actual control the machine the code.
“通過結合IEC61131-3,用戶向導和數據管理,軟件工具能設計出在跨越多個機器和處理單元的處理流程?!焙喕到y(tǒng)設計的另一方面是具有高級的圖形化開發(fā)工具,利用該工具可以使工程師很輕松地把處理的概念轉變?yōu)槟軐嶋H控制機器的代碼。
"The opening modular skeleton can solve the industrial application may distribute from the control in the factory machine to processes workshop the operation unit." Because all industrial application all needs to have highly has custom-made the characteristic, therefore the hardware must be the modulation in order to engineers may choose the appropriate part. Moreover, the software also must be able to let engineer increase and the demolition module by the system which designs needs.
“開放的模塊化構架能解決的工業(yè)應用可從控制分布于工廠機器到加工車間的操作單元?!庇捎谒械墓I(yè)應用都需要有高度的定制特性,所以硬件必須是模塊化的以便工程師們可以選擇合適的部件。而且,軟件也必須能讓工程師增加和拆除模塊以設計出所需的系統(tǒng)。
"Uses already the network interface standard which has, the language and so on, like TCPIP, OPC&XML and SQL inquiry language." Can with enterprise's network correspondence regarding the modernization control system be extremely essential. Although PAC contains has the ethernet connection, but in order to must does not have the equipment and the factory other systems the question to integrate in together, corresponds the software is very important.
“采用已有的網絡接口標準,語言等,如TCPIP,OPC&XML和SQL查詢語言?!蹦芎推髽I(yè)的網絡通信對于現代化控制系統(tǒng)是非常關鍵的。盡管PAC包含有以太網接口,但是為了要把設備和工廠其它系統(tǒng)無問題地集成在一起,通信軟件是至關重要的。
Two kind of different softwares solution
兩種不同的軟件解決方案
On the one hand the software is PAC and the PLC main difference, but on the other hand the merchant in provides the senior software in the way also to differ from. Usually they the control software which has have taken the beginning by at present, increases the function, the reliability and the usability unceasingly which the PAC programming needs. In general, some two kinds provide the PAC software the way: Based on PLC control software and based on PC control software
一方面軟件是PAC和PLC主要的區(qū)別,而另一方面廠商在提供高級軟件的方式上也有所不同。通常他們以目前已有的控制軟件作為起點,不斷增加PAC編程所需的功能、可靠性和易用性。一般說來,有兩種提供PAC軟件的方式:基于PLC控制的軟件和基于PC控制的軟件
Based on PLC concept software plan
基于PLC概念的軟件方案
The traditional PLC software merchant take is reliable also Yi Yong scanning type overhead construction software as a beginning, and increases the new function gradually. The PLC software basis general model but establishes: The input scanning, the control code movement, the input renews, as well as conventional function execution. As a result of the input circulation, the output circulation and the conventional circulation all is the hideaway, therefore control engineer only must pay attention to the control code the design. Because the merchant has completed the majority of work, this kind of strict control overhead construction causes the establishment control system to be easier and to be fast. These systems strict also can let control engineer when the development reliable procedure does not need thoroughly to understand PLC the first floor operation. However, also causes its flexible as the PLC main superiority this kind of strict scanning type skeleton being short of. The overwhelming majority PLC merchant through in the scanning type overhead construction which has increased the new function to establish the PAC software, these new functions including ethernet correspondence, movement control and senior algorithm. However, usually they can retain the PLC familiar programming way as well as it in logical and the control aspect inherent characteristic. Therefore this kind of PAC software usually is for suit the special type application but to design, like logic, movement and PID, but regarding the application which has custom-made then lacks the flexibility, like the correspondence, the data record or have custom-made control algorithm.
傳統(tǒng)的PLC軟件廠商以可靠且易用的掃描式架構軟件為起點,并逐漸增加新的功能。PLC軟件根據通用模型而建立:輸入掃描,控制代碼運行,輸入更新,以及常規(guī)功能執(zhí)行。由于輸入循環(huán),輸出循環(huán)和常規(guī)循環(huán)都是隱藏的,所以控制工程師只需關注控制代碼的設計。由于廠商已完成了大部分工作,這種嚴格的控制架構使得建立控制系統(tǒng)更為容易和快速。這些系統(tǒng)的嚴格性也能讓控制工程師在開發(fā)可靠的程序時無需深入了解PLC的底層操作。然而,作為PLC主要優(yōu)勢的這種嚴格的掃描式構架也導致其靈活性的欠缺。絕大多數PLC廠商通過在已有的掃描式架構中增加新的功能來建立PAC軟件,這些新功能包括以太網通信,運動控制和高級算法。然而,通常他們會保留PLC熟悉的編程方式以及其在邏輯和控制方面固有的特點。因此這種PAC軟件通常是為了適合特殊類型應用而設計的,如邏輯,運動和PID,但是對于定制的應用則缺乏靈活性,如通信、數據記錄或定制的控制算法。
Based on PC concept software plan
基于PC概念的軟件方案
The traditional PC software merchant take the extremely nimble general programming language as a beginning, can provide to the hardware deep level visit. This kind of software also has the control overhead construction which the reliability, determinism as well as supposes in advance. Although engineer can be the PLC programmers establishes the scanning type skeleton, but it is not based on the PC software inherent. These cause the PC software to be extremely nimble, suits these need senior extremely the overhead construction, the programming skill or the control complex application, but causes originally to be supposed actually the simple application complication.
傳統(tǒng)PC軟件廠商以非常靈活的通用編程語言為起點,能提供對硬件的深層次訪問。該種軟件也具有可靠性、確定性以及預設的控制架構。盡管工程師能為PLC編程人員建立起掃描式構架,但是它并不是基于PC的軟件所固有的。這些使得PC軟件極為靈活,非常適合那些需要高級的架構、編程技巧或者系統(tǒng)級控制的復雜應用,但卻使本應簡單的應用復雜化。
These merchants first must be able to provide the reliability and determinism which general operating system like Windows does not have. They may through use the real-time operating system (RTOS) Tathagata realize from Ardence Phar Lap or Wind River VxWorks. These RTOS can control system each stratification plane, from I/O read-write speed to controller on each regulation priority. Then in order to enable engineer easily to develop the reliable control procedure, the merchant increased the abstract level and I/O read-write overhead construction. Thus this kind of nimble software suits extremely in the customized control, data record and correspondence, but discards the PLC programming overhead construction the price is causes the procedure the development difficulty increase.
這些廠商首先要能提供通用操作系統(tǒng)如Windows所不具備的可靠性和確定性。它們可以通過采用實時操作系統(tǒng)(RTOS)如來自Ardence的Phar Lap或Wind River的VxWorks來實現。這些RTOS能控制系統(tǒng)的各個層面,從I/O讀寫速率到控制器上各個線程的優(yōu)先級。然后為了使工程師能更為容易地開發(fā)出可靠的控制程序,廠商增加了抽象層和I/O讀寫架構。因而這種靈活軟件非常適合于定制控制,數據記錄和通信,但舍棄PLC編程架構的代價是使程序的開發(fā)難度增加。
NI has developed can move LabVIEW procedure a series of PAC to deliver the platform. LabVIEW has become tests and surveys the software the fact standard. It has direct-viewing being similar in the flow chart programming way, and through is easy the contact surface which uses to provide all functions which the senior programming language has. Using LabVIEW RT and LabVIEW FPGA, we can unify LabVIEW and the real-time operating system and download directly to FPGA (scene programmable gate array) the platform provide the reliability and determinism.
NI已開發(fā)出能運行LabVIEW程序的一系列PAC運載平臺。LabVIEW已成為測試和測量軟件的事實標準。它具有直觀的類似于流程圖的圖形化編程方式,并通過易用的界面來提供高級編程語言所具備的所有功能。利用LabVIEW RT和LabVIEW FPGA,我們能結合LabVIEW和實時操作系統(tǒng)并直接下載到FPGA(現場可編程門陣列)平臺來提供可靠性和確定性。
Based on PAC vision and survey application
基于PAC的視覺和測量應用
NI has the survey the profession background, it caused PAC through the introduction high speed survey and the machine vision to surmount simple I/O. Needs high speed to gather the measurement result in many industrial applications by to use in vibrating or the power quality analysis. Gathers to the data uses for to monitor revolves the machinery condition, determined the maintenance timetable, distinguishes the electrical machinery the attrition degree as well as the adjustment control algorithm. Engineers the usual use special data acquisition system or the independent instrument gather these data and the use correspondence main line the data feeds to the control system. But NI PAC may carry on the high accuracy directly by each second million speed the survey, and transmits directly the data to the control system processes immediately.
NI具有測量的行業(yè)背景,它通過引入高速測量和機器視覺使PAC超越了簡單的I/O。在許多工業(yè)應用中需要高速采集測量結果以用于振動或功率品質分析。采集到的數據用來監(jiān)測旋轉機械的狀態(tài),確定維護時間表,識別電機的磨損程度以及調整控制算法。工程師們通常使用專門的數據采集系統(tǒng)或獨立儀器來采集這些數據并利用通信總線把數據輸入到控制系統(tǒng)。而NI的PAC正可以以每秒百萬個采樣點的速率直接進行高精度的測量,并把數據直接傳送到控制系統(tǒng)來立即處理。
Engineers also may use the visual function in theirs control system. In the pas