History of Industrial Control

PC or PLC ?PC or PLC ?

1990 -

PLCsPLCs

1970 - 1995

Relays & ContactsRelays & Contacts

1950 - 1975

- Hard-wired Electrical Circuits

- Microprocessor Based- Proprietary Hardware- Electrical Circuit Programs

- Open Hardware Platforms- Integrated Software- Graphical Programming

Less Expensive, Easier to Use, Higher Productivity

Why MX Computer Control?

Best in class PC based control software.

Mitsubishi and Steeplechase, two leaders in their fields.

A proven real-time operating system.

Best in class intelligent distributed input / output devices.

An objective supplier.

Price

Performance

Micro PLCs

Rack PLCs

Why MX Computer Control?

PCS/DCS

Why MX Computer Control?

Faster design cycles.

MX Computer Control.

Features specifically for discrete automation.

Reduce machine downtime.

Future-proofing your factory .

Complete, integrated solution.

50% reduction in downtime and installation time.

Operator level diagnostics.

Hard real-time control.

Go from this...

PLCOperator Station

I/O Modules

Programming PC

Computer RoomCell Control PLC

testing widgets

32 passed

0 failed

…to this!

I/O Modules

Computer Room

testing widgetstesting widgets

32 passed32 passed

0 failed0 failed

Five rules of PC-based control..

Provide deterministic real-time performance(Hard real-time control)Same or better determinism than a PLC.

Control must always have the highest priority.

Windows tasks must not interrupt control tasks.

Five rules of PC-based control..

Survive failure of NT.

PC must not lose control if Windows or NT fails.

Control must be informed of OS failure (NT), allowing:∗ Continued execution of control program, or∗ Orderly I/O shutdown.

Five rules of PC-based control..

Provide protection from Windows applications and drivers.

Bad OS drivers (kernel mode drivers) can write data anywhere, including the I/O table.

Five rules of PC-based control..

Survive a hard disk failure.

Hard disk has the lowest MTBF.

The control engine loaded and protected in memory.

Five rules of PC-based control..

Use robust, reliable real-time kernel.

Installed base.

History in ‘mission critical’ applications.

InIn ConCon troltrol OO

Disk ServicingDisk Servicing

utut

MouseMouse

Real-TimeTasks

NT DPC

User Tasks User Tasks

Windows NT Priority

Non-Deterministic Scan Times

Soft Logic processing

Hard real-time processing

InIn ControlControl OutOut

DiskDisk User TasksUser Tasks

InIn ControlControl

Deterministic, Repeatable Scan Times (1 to 500 ms)

Real-Time OS Priority

All windows processing

Logic control

MxCCControl

Designer

MxCCControl

DesignerMxCCHMI

MxCCHMI

Excel,SPC,

Data Logging

Excel,SPC,

Data Logging

OtherWindows

Applications

OtherWindows

Applications

WindowsWindows

Real-time OS approach

Real Time PLC Control EngineReal Time PLC Control Engine Watch DogTimer

I/O Drivers ...I/O Drivers ...

Hard Real Time OSFirewall

Windows

RTOS

Not all vendors meet THE 5

vital rules of PC-based controlMake sure the solution meets your needs.

Deterministic real-time performance.

Protection against other applications and drivers.

Control must survive Windows crash.

Control must survive hard-disk crash.

Robustness - history and installed base.

MXCC flowchart programmingIntuitive and self documenting.

Cuts design cycles 50-70%.

Powerful diagnostic capability.

Flow chart programming

Basic Constructs:

• Actions

• Decisions

• Comments

• Flows

• Connectors

• Start/Stop

sub_prog.flo

I/O

Advanced Constructs:

• Sub-Programs

• I/O Specific Calls

• Parallel Branch & Merge

• PID Support PID

Ladder logic editor

IEC-1131 based relay ladder logic editor.A transition tool to the future.

Flowchart enhanced ladder logic

a = (b + c / d) *2;

Message = “Station 1 Faulted”;

speed > setpoint *0.75

- Actions, decisions, and diagnostic messages.

Insert flowchart blocks directly in ladder logic.

Decision

Action

Combined flowchart/ladder

Both ladder and flowcharts execute together.Combine them with flowchart enhanced ladder.

Using a diagnostic wizard

Replaces standard ‘decision’ element where diagnostic logic would be added.

Loops back on itself for a given condition.

Using a diagnostic wizard

Fill in the decision criteria.Fill in the time-out fault period.Fill-in any fault logic conditions.Diagnostic wizard does the rest.

Using a diagnostic wizard

Using a diagnostic wizard

Automatically generates diagnostic codes.

ABF special functions

Over time, a history of the flowchart’s execution will be visible.

Execution tails

The tags referenced in the selected element are shown in the Instant Watch.

This is the element contents.List of tags in the element

Here are the tag values

If no element is selected, all tags referenced in the flowchart are shown.

Instant watch

Double click on a tag name to bring up a Local Force Window

The Local Force Window allows you to change internals or force I/O’s

Toggle and force

Reduce down time

With legacy PLC systems:

Most machine faults are mechanical.

Ladder logic makes it difficult to incorporate diagnostics.Operators don’t understand PLC ladder logic.

With MXCC:

Most maintenance calls are electrical because :

Empower the operator with on-line diagnostics.Graphically visually describe the fault and recovery.

User Interface

Graphical Operator InterfaceWindows based MMI.Draw your operator screens.Direct access to MXCC data.

MXCC MMI FeaturesDirect access to MXCC run-time data.

MXCC tag browser.

Pre-built panel instruments.

Graphic animation.- Colour, fill, size, position, rotate, visibility.

Real-time trending.- Trend charts, bar charts, X-Y plots.

Powerful command language.- Sounds, execute applications, files, HMI screen displays.

Import .PCX and .ADE files.

More benefits

Factory floor connectivity

I/O

MxCC

I/O

Office ClientPC

TCP/IP - Ethernet

MxCC

PC data from factory floor to office.

Production statistics.

Current machine status.

Downtime analysis.

Remote programming

MxCC #1 MxCC #2 MxCC #3

MxCC on a remote PC

Ethernet

Designer runs here

These stations have MxCC Runtime. They also run WinNT applications

MXCC - Single tag database

ControlDesignerControl

Designer MxCC MMIMxCC MMI DDEServerDDE

ServerReal-TimeSimulation

Real-TimeSimulation

Client-Server

Network

Client-Server

Network

Common Tag Database& I/O Configuration

Common Tag Database& I/O Configuration

Real-Time Control EngineReal-Time Control Engine

MX ComputerControl

A70BDE-ABFI/O Scanner Interface Card

A Series Expansion Rack

Uses standard and Special I/O Modules

Rack based I/O

Distributed I/O

CC Link, Profibus, Net10

Drivers:Mitsubishi A-Series AB Remote I/O Data Highway +

Datalogic Devicenet Fast DDE

GE-Fanuc Genius Generic I/O Honeywell SDS

Interbus-S (Full Slot) Interbus-S (Half Slot) MEI DSP

Modicon S908 Optomux Profibus

PID Loop - Floating RS-232/422 - Serial Port PAMUX

Industrial I/O support

Real-time simulationUse flowcharts to simulate response.

Verify your design.

Re-use your designRe-useable program modules - subprograms.

Re-useable HMI components - dynamos.

More benefitsDDE server.

Data express DLL toolkit.

PID control options.

Motion control options.

Database import/export.

HMI flexibility.

Station Faulted?

Display"Station 1 Faulted"

Station 1 FaultedStation 1 Faulted

On-line diagnosticsDiagnose faults directly in the flow chart.

Display fault and corrective action to operator.

Query operator for responses.

Operational diagnostics

It’s your choice, PLC or PC?

Price

Performance

Micro PLCs

Rack PLCs

PCS/DCS

ALL FROM MITSUBISHI!

Questions?