可编程序控制器(Programmable Controller)原本应简称PC,为了与个人计算机专称PC相区别,所以可编程序控制器简称定为PLC(Programmable Logic Controller),但并非说PLC只能控制逻辑信号。PLC是专门针对工业环境应用设计的,自带直观、简单并易于掌握编程语言环境的工业现场控制装置。
PLC的基本组成
PLC基本组成包括中央处理器(CPU)、存储器、输入/输出接口(缩写为I/O,包括输入接口、输出接口、外部设备接口、扩展接口等)、外部设备编程器及电源模块组成,见图1。PLC内部各组成单元之间通过电源总线、控制总线、地址总线和数据总线连接,外部则根据实际控制对象配置相应设备与控制装置构成PLC控制系统。
图1 PLC的基本组成
1. 中央处理器
中央处理器(CPU)由控制器、运算器和寄存器组成并集成在一个芯片内。CPU通过数据总线总线、地址总线、控制总线和电源总线与存储器、输入输出接口、编程器和电源相连接。
小型PLC的CPU采用8位或16位微处理器或单片机,如8031、M68000等,这类芯片价格很低;中型PLC的CPU采用16位或32位微处理器或单片机,如8086、96系列单片机等,这类芯片主要特点是集成度高、运算速度快且可靠性高;而大型PLC则需采用高速位片式微处理器。
CPU按照PLC内系统程序赋予的功能指挥PLC控制系统完成各项工作任务。
2. 存储器
PLC内的存储器主要用于存放系统程序、用户程序和数据等。
1)系统程序存储器
PLC系统程序决定了PLC的基本功能,该部分程序由PLC制造厂家编写并固化在系统程序存储器中,主要有系统管理程序、用户指令解释程序和功能程序与系统程序调用等部分。
系统管理程序主要控制PLC的运行,使PLC按正确的次序工作;用户指令解释程序将PLC的用户指令转换为机器语言指令,传输到CPU内执行;功能程序与系统程序调用则负责调用不同的功能子程序及其管理程序。
系统程序属于需长期保存的重要数据,所以其存储器采用ROM或EPROM。ROM是只读存储器,该存储器只能读出内容,不能写入内容,ROM具有非易失性,即电源断开后仍能保存已存储的内容。
EPEROM为可电擦除只读存储器,须用紫外线照射芯片上的透镜窗口才能擦除已写入内容,可电擦除可编程只读存储器还有E2PROM、FLASH等。
2)用户程序存储器
用户程序存储器用于存放用户载入的PLC应用程序,载入初期的用户程序因需修改与调试,所以称为用户调试程序,存放在可以随机读写操作的随机存取存储器RAM内以方便用户修改与调试。
通过修改与调试后的程序称为用户执行程序,由于不需要再作修改与调试,所以用户执行程序就被固化到EPROM内长期使用。
3)数据存储器
PLC运行过程中需生成或调用中间结果数据(如输入/输出元件的状态数据、定时器、计数器的预置值和当前值等)和组态数据(如输入输出组态、设置输入滤波、脉冲捕捉、输出表配置、定义存储区保持范围、模拟电位器设置、高速计数器配置、高速脉冲输出配置、通信组态等),这类数据存放在工作数据存储器中,由于工作数据与组态数据不断变化,且不需要长期保存,所以采用随机存取存储器RAM。
RAM是一种高密度、低功耗的半导体存储器,可用锂电池作为备用电源,一旦断电就可通过锂电池供电,保持RAM中的内容。
3. 接口
输入输出接口是PLC与工业现场控制或检测元件和执行元件连接的接口电路。PLC的输入接口有直流输入、交流输入、交直流输入等类型;输出接口有晶体管输出、晶闸管输出和继电器输出等类型。晶体管和晶闸管输出为无触点输出型电路,晶体管输出型用于高频小功率负载、晶闸管输出型用于高频大功率负载;继电器输出为有触点输出型电路,用于低频负载。
现场控制或检测元件输入给PLC各种控制信号,如限位开关、操作按钮、选择开关以及其他一些传感器输出的开关量或模拟量等,通过输入接口电路将这些信号转换成CPU能够接收和处理的信号。输出接口电路将CPU送出的弱电控制信号转换成现场需要的强电信号输出,以驱动电磁阀、接触器等被控设备的执行元件。
1)输入接口
输入接口用于接收和采集两种类型的输入信号,一类是由按钮、转换开关、行程开关、继电器触头等开关量输入信号;另一类是由电位器、测速发电机和各种变换器提供的连续变化的模拟量输入信号。
以图2所示的直流输入接口电路为例,R1是限流与分压电阻,R2与C构成滤波电路,滤波后的输入信号经光耦合器T与内部电路耦合。当输入端的按钮SB接通时,光耦合器T导通,直流输入信号被转换成PLC能处理的5V标准信号电平(简称TTL),同时LED输入指示灯亮,表示信号接通。微电脑输入接口电路一般由寄存器、选通电路和中断请求逻辑电路组成,这些电路集成在一个芯片上。交流输入与交直流输入接口电路与直流输入接口电路类似。
图2 直流输入接口电路
滤波电路用以消除输入触头的抖动,光电耦合电路可防止现场的强电干扰进入PLC。由于输入电信号与PLC内部电路之间采用光信号耦合,所以两者在电气上完全隔离,使输入接口具有抗干扰能力。现场的输入信号通过光电耦合后转换为5V的TTL送入输入数据寄存器,再经数据总线传送给CPU。
2)输出接口
输出接口电路向被控对象的各种执行元件输出控制信号。常用执行元件有接触器、电磁阀、调节阀(模拟量)、调速装置(模拟量)、指示灯、数字显示装置和报警装置等。输出接口电路一般由微电脑输出接口电路和功率放大电路组成,与输入接口电路类似,内部电路与输出接口电路之间采用光电耦合器进行抗干扰电隔离。
微电脑输出接口电路一般由输出数据寄存器、选通电路和中断请求逻辑电路集成在芯片上,CPU通过数据总线将输出信号送到输出数据寄存器中,功率放大电路是为了适应工业控制要求,将微电脑的输出信号放大。
3)其它接口
若主机单元的I/O数量不够用,可通过I/O扩展接口电缆与I/O扩展单元(不带CPU)相接进行扩充。 PLC还常配置连接各种外围设备的接口,可通过电缆实现串行通信、EPROM写入等功能。
4. 编程器
编程器作用是将用户编写的程序下载至PLC的用户程序存储器,并利用编程器检查、修改和调试用户程序,监视用户程序的执行过程,显示PLC状态、内部器件及系统的参数等。
编程器有简易编程器和图形编程器两种。简易编程器体积小,携带方便,但只能用语句形式进行联机编程,适合小型PLC的编程及现场调试。图形编程器既可用语句形式编程,又可用梯形图编程,同时还能进行脱机编程。
目前PLC制造厂家大都开发了计算机辅助PLC编程支持软件,当个人计算机安装了PLC编程支持软件后,可用作图形编程器,进行用户程序的编辑、修改,并通过个人计算机和PLC之间的通信接口实现用户程序的双向传送、监控PLC运行状态等。
5. 电源
PLC的电源将外部供给的交流电转换成供CPU、存储器等所需的直流电,是整个PLC的能源供给中心。PLC大都采用高质量的工作稳定性好、抗干扰能力强的开关稳压电源,许多PLC电源还可向外部提供直流24V稳压电源,用于向输入接口上的接入电气元件供电,从而简化外围配置。
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TrippLite NetCommander KVM over Ethernet Interface Module B078-101-PS2 CB7350
Troncom Tsnap 520 15SW T-SNAP DS1 Digital interface module
TTC Acterna T-Berd 209 T-Carrier Analyzer T1 Test 30554 Interface Module Option
TTC FIREBERD 41440 T1/FT1 INTERFACE ADAPTER MODULE FOR ANALYZERS
TTC ISU 6000 Interface Switching Unit For 4 Modules in a Fireberd 6000
TTC V.35/306 DTE/DCE Interface Adapter Module Model 40202
TURCK INTERFACE MODULE IM1-121Ex-R/24V DC/SWITCHING AMPLIFIER
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Unico 100-732.1 Interface Module
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Unico 306-563 306563 I/O Parallel Interface Module
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UNICO INC. 309-482 CPU SERIAL INTERFACE MODULE 309482
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UPB Computer Interface Module PIM UMC-DB9-W SAUMCDB9W
UPB Simply Automated UMCDB9W Serial Interface Module
US Tec TP-KSU8 8-Port KSU Interface Module
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V/R 847490-206 MECH DISP INTERFACE MODULE
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V2DIP1-48 VNC2-48 USB host development module FTDI Flash drive interface
VAA-4E-G2-ZE Pepperl Fuchs AS- Interface Sensor Module
Vanner Power Group Interface Module Model IFM1
VAOVA FMT-104U IN-CAR FM MODULATOR WITH USB INTERFACE 12 MONTHS WARRANTY
VARIAN COMPUTER INTERFACE MODULE.
VARIAN E1147480 ANALOG/DIGITAL I/O INTERFACE MODULE
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Varian Process Module Interface 04-722283-010 REV
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VEEDER ROOT INTERSTITIAL SENSOR INTERFACE MODULE PN 329358-001
Veeder Root PLLD Interface Module Board 330886-002 for TLS-350
Veeder Root Vapor Sensor Interface Module
Veeder-Root TLS-350 330313-001 PLLD Interface Module
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vidicom model IM-1 interface module
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Volvo Parking Distance Control Interface Module Restoring Parking Sensor Tone
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WAGO 289-447 INTERFACE MODULE WITH SUB MINI D-MALE CONN. 25 POLE 289447
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WELLS FARGO SIEMENS SXE-2LW ADDRESSABLE POINT INTERFACE MODULE EXACTPOINT SM APT
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Western Servo Design ICSB-S3 Interface Module
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Works on 2000 different vehicles No key required
Works on over 2400 different vehicles No key required
World’s Largest Reseller of Foundry/Brocade
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XPRESSKIT DBALL DATA ALL INTERFACE /W FIRMWARE MULTI MODULE DEI BYPASS MODULE
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XpressKIT Interface and Bypass Modules from Directed Electronics DBALL
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XpressKIT Interface and Bypass Modules from Directed Electronics XK01
XpressKIT Interface and Bypass Modules from Directed Electronics XK02
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XpressKIT Interface and Bypass Modules from Directed Electronics XK06
XpressKIT Interface and Bypass Modules from Directed Electronics XK07
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YOSHIMURA FOR POLARIS RZR 800/S 08-10
YOSHIMURA FOR POLARIS RZR 800/S 08-10
YOSHIMURA FOR POLARIS XP900RZR 2011
YOSHIMURA FOR POLARIS XP900RZR 2011
YOSHIMURA FOR POLARIS XP900RZR 2012
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YOSHIMURA FOR SUZUKI KINGQUAD 750 08-1
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YOSHIMURA FOR YAMAHA RAPTOR 700 06-10
YOSHIMURA FOR YAMAHA RAPTOR 700 06-10
YOSHIMURA FOR YAMAHA RHINO 700 08-11
YOSHIMURA FOR YAMAHA RHINO 700 08-11
YOSHIMURA FOR YAMAHA YFZ450R 09-12
YOSHIMURA FOR YAMAHA YFZ450R 09-12
YOSHIMURA FOR YAMAHA YFZ450X 2010
YOSHIMURA FOR YAMAHA YFZ450X 2010
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YOSHIMURA PIM2 PERIPHERAL INTERFACE MODULE HONDA CRF450R 2009
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YOSHIMURA PIM2 PERIPHERAL INTERFACE MODULE KAWASAKI KX250F 2011
YOSHIMURA PIM2 PERIPHERAL INTERFACE MODULE KAWASAKI KX250F 2012
YOSHIMURA PIM2 PERIPHERAL INTERFACE MODULE KAWASAKI KX450F 2009-2011
YOSHIMURA PIM2 PERIPHERAL INTERFACE MODULE KAWASAKI KX450F 2012
YOSHIMURA PIM2 PERIPHERAL INTERFACE MODULE KTM 350SXF 2011
YOSHIMURA PIM2 PERIPHERAL INTERFACE MODULE SUZUKI RMX450Z 2010
YOSHIMURA PIM2 PERIPHERAL INTERFACE MODULE SUZUKI RMZ250 2010-2011
YOSHIMURA PIM2 PERIPHERAL INTERFACE MODULE SUZUKI RMZ450 2008-2009
YOSHIMURA PIM2 PERIPHERAL INTERFACE MODULE YAMAHA YZ250X YZ250R 2008-2011
YOSHIMURA PIM2 PERIPHERAL INTERFACE MODULE YAMAHA YZ450F 2010-2011
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