BewhizPLC

Position Control Units Omron CS series

2011-08-15T06:37:00.000-07:00

Position Control units Omron CS-series are the special unit of Omron PLCs CS series to control Servo driver or Stepping motor in making position. This position control units. This position control units usually also called by the name NC units. NC units have a primary function as pulse generator that is used to drive the servo driver or servo motor controller.

The main convenience of NC units are all positioning parameters can be done with the program through the work area and data memory area (DM).

IAI Robo Cylinder

2011-08-14T01:14:00.000-07:00

IAI Robo Cylinder is as an alternative to pneumatic cylinder that have many weakness. It has been discussed a litle before, pneumatic cylinder has a limited movement. With this robot can be obtained the movement by smooth and rapid or even without a beat at all.
Robo cylinder is normally used in simple application with sinle axis. The application is usually a linear application and moving from point to point.
Robo cylinder has a structure composed by the ballscrew and driven by servo or stepper motor. Stepper motor is used to type with low speed , such as RCP2 and ERC. While the servo motors used in robots that require high speed such as type RCS. Both RCP and RCS series are available in rod, slider, and flat type configuration.

There are differences characteristics between RCP and RCS series.

RCP actuators have capabilities a higher payload in lower velocities, and when payload is increased the RCP actuator will start decreasing according to its pulse motor torque.
RCS actuators will be constant in velocity throughout it's payload rating. When payload is over, then AC servo motor controller will fault.

For each type has a different type of motor, RCP2 uses 24V Pulse motor, RCA uses 24V servo motor, and RCS2 uses servo motor with voltage 200V.
Here are the various types of robo cylinder based on its configuration:
Type of Robo Cylinder Actuator :
Controller Integrated type
ERC2

ERC2 Rod type
with double guide

ERC2 Pulse motor
straight ype

Slider type: Rod type:
RCP2,RCA,RCS2 RCP2,RCA,RCS2

RCP2 Slider type

RCS2 Rod type

Arm type: Cleanroom type:
RCA,RCS2 RCP2CR,RCACR,RCS2CR

RCA Arm type

RCP2CR Cleanroom type

Gripper/Rotary type: Dust/splash proof type:
RCP2,RCS2 RCP2W,RCAW,RCS2W

RCS2 Gripper and Rotary type

RCP2W Dust/Splash proof type

Robo Cylinder Controller

Gateway Unit, It is used for connecting Robo Cylinder controller to field network such as Device Net and CC-Link.
Device Net, Device Net model is RCM-GW-DV.
CC-Link, CC-Link model is RCM-GW-CC.
PS24 24VDC, This is DC Powe supply with momentary of 17A.
PCON, it is controller for RCP2 with the model are C/CG/CY/PL/PO/SE.
PSEL, PSEL program controller for RCP2. There is only one model of C model.
ACON, ACON controller for RCA series. With the model are C/CG/CY/PL/PO/SE.
ASEL, It is program controller for RCA series with the model is C.
SCON, It is controller for RCS2 with the model is C.
SSEL, It is program controller for RCS2 with the model is C.
RCS, It is controller for RCS. There are two models RCS incremental type controller and RCS-C absolute type controller/RCS-E for economical type.
ECON, ECON controller for RCS, is a single-axia controller for economy,flexibility, and easy for use.
X-SEL, X-SEL is for RCS, is a multi axis controller compatible with the actuator RCS series.

Robo Cylinder PC Software :

The latest version program is " RC PC Software version 7 ". This software is used for the controller with type of PCON, ACON, SCON, ERC2, ASEP, PSEP.

Connecting GP3000 with Omron PLCs C/V Series

2011-08-13T23:13:00.000-07:00

To connect the Digital Proface GP3000 with Omron PLCs C/CV series, required setting of communication parameter between them. Two kinds of software needed to perform these setting.

Omron CX Programmer, to set the PLC communication parameter.
GP-Pro EX, to set GP3000 series communication parameter.

PLC type to be used as an example is the Omron C200HG. Communication will be done via the RS232C port on the CPU unit.

Communication Cable:

There are two kinds of cable used for communication between Omron C200HG and GP3000, buy ready-made cable, or create your own.

Omron Sysmac Link cable, CA3-CBLSYS-01 by Proface.
Create your own cable:

Setting of GP3000 Communication Parameter:
By using GP-Pro EX software, do setup as shown below picture.
Maker : Omron Corporation Series: C/CV Serie Host Link Port : Com1
SIO Ttype : RS232C
Speed : 19200
Data Length : 7
Parity : Even
Stop Bit : 2
Flow Control : Er(DTR/CTS)
RI/VCC : RI

Setting of PLC Communication Parameter:
By using Omron CX Programmer, do setup of to Custom.
Baud : 19200
Format: 72E
Mode : Host Link

After setup of the GP3000 and the PLC, do testing by connecting the GP3000 and PLC.

Digital Proface GP3000 Series

2011-08-13T09:16:00.000-07:00

GP3000 Series by Proface

Graphic operator interface GP3000 is HMI or the touch screen is manufactured by Proface. GP3000 comes with the major features such as Video input interface, USB, Sound input, Various communication, video unit, ethernet interface, CF card, and serial communication.
Referring to what is required by the user, GP3000 is devided into four class. Classes are devided based on the features or facilities that exist in each class of GP3000.

Multimedia class(M) with video input. it is multimedia class with real visualization through video recording and playback.
Control class(C), with flexibility for I/O configurations based on the needs.There are three type of I/O, DIO (direct I/O, available in 8 in and 2 out), Flex network (bit variable in-out 1024 point max, integer variable in-out 256 points max), CANopen master(bit variable in-out 1024 point max, integer variable in-out 256 points max).
Handy class(H), It is handheld type which enhanced safety and easy to use. This type also equipped with emergency stop button wit three color red, yellow, and grey. also available without emergency button. There is also additional 3 position enable switch if a hazardous event occurs.
Standart Class, It comes with equipped with information network connection. This Standard class is basic of the three other class.

GP3000 Handy Class(H)

GP3000 Model selection
GP3000 is available in various sizes, starting from 3.8", 5.7", 7.5", 10.4", 12.1" and 15". The following is " model nomenclature" as guide in the selection of GP3000:

Screen Editor Software
To create screen is used " GP-Pro EX ". The latest version which can be used is GP-Pro EX version 2.7. It is the software with user friendly menu and icon, easy creation, with off-line simulation and even easy in conversion of previuos models.
Cable type used for transfers/communication between PC and GP3000:

USB Transfer cable (2 meters) " CA3-USBCB-01 ".
Ethernet Interface " 10BASE-T/100BASE-TX) ".

Conectable Devices

PLC :Control Technology, Fanuc, Fatec Automation, Fuji Electric, GE Intelegent platform, Hitachi, Hitachi Industrial equipment system, JTEKT, Keyence, Koyo Electronics, LS Industrial, MEIDENSHA, Mitsubishi Electric, Mitsubishi Heavy Industri, Omron, Panasonic Electric Works, Rockwell Automation, Saia-Burgess Controls, Schneider Electric SA, Sharp Manufacturing System, Siemans AG, Siemans Building Technologies, Toshiba, Toshiba Machine, Yaskawa Electric, Yokogawa Electric.
Temperature and Process Controllers: Chino Corporation, Fuji Electric, Omron, RKC Instruments, Shinko Technos, Yamatake, Yokogawa Electric.
Inverter, Servo and Robot : Fuji Electric, Hitachi Industrial Equipment system, Mitsubishi Electric, Sanmei Electric, Yaskawa Electric, Hyundai Heavy Industries, IAI.
FieldBus and Others: CAN in Automation, CC-Link Partner Association, ODVA, PROFIBUS International, Cognex, Digital Electronics, Modbus IDA, ODVA.

Memory Area of Omron CP1H PLCs

2011-08-13T03:35:00.000-07:00

Memory area of PLC is the allocation of internal memory PLC that is accesible to be used as an operand of an instruction. Before learning the PLC programming technique. For PLC programmer, understanding the memory area of PLC is a must.

In this chapter, Omron CP1H is used as the example. This is fairly representative, due to the other series is similar. Likewisw for the other brands are basically the same principle.
In the memory area of Omron CP1H consists CIO area, Work area(W), Holding area(H), Auxiliary area(A), DM area(DM), Timer(T), Counter(C), Task flag area(TK), Data registers(DR), Index registers(IR), Condition flag area, and Clock pulse area.

The following table is a memory allocation for Omron CP1H. For example by knowing the allocations, it will be known to the allocation of operands that can be used, or operands that stiil keep even if power of PLC is off.

I/O Memory area CP1H by Omron

From the table above can be explained as follows:

1. Common Input Output area (CIO)

Generally used as data exchanges such as I/O refresing with PLC units. Words that are not allocated to unit can be used as work words or work bits on program.

CIO Memory Area Omron CP1H

2. Work Area (W)
This area is used as programming. Words in this work area can be used for programming and can not be used for I/O exchanged with external I/O terminal.
3. Holding Area (H)
Words in this Holding area can be used for programming. They will retain the status when PLC is turned ON or the operating mode is changed (Program-Monitor-Run).
4. Auxiliary Area (A)
These words are allocated to specific functions in the system, so it can not be used for programming or read only. example is for program date.
5. Temporarry Relay Area (TR)
TR area is used to record the status of program branches.
6. Data Memory Area (D)
It is multi purpose data area that normally accessed only in words. The contains of these words retain although PLS switch ON-OFF or operation mode is changed (Program-Monitor-Run).
7. Timer/Counter Area
This timer number is T0 to T4095
8. Condition flags
This flags contan arithmatic flags, such as error flag, equal flag, always On, Always Off. etc.
9. Clock Pulses
On and Off by the internal timer of CPU.

10. Task Flag Area (TK)

This flag status for corresponding cyclic task.
11. Index Registers (IR)
Used to store memory address. It is IR0 to IR15.

12. Data Register (DR)

Used togather with IR. It is DR DR0 to DR15.

Omron Modular PLCs Series

2011-08-12T09:54:00.001-07:00

This type of Omron Modular PLCs is widely used as a machine control because It is middle PLC which is expandable both input-output and functions. It is flexible of Omron Sysmac with easy structure arranged on backplane. However, there are several PLCs are connected with backplane-free structure between CPU and modules so it is not necessary the backplane.

Unlike the model of Omron Micro PLCs, modules can be added as needed through a backplane or backplane-free structure.The modules could be positioning, analog, communication, counter, standard I/O and so on.
There are four types of Omron Modular PLCs, such as CJ2, CJ1H/CJ1G, CS1H/CS1G, and CS1D. Here will be described briefly on the specifications of these type of PLC:
1. CJ2

Data communication with EtherNet/IP data link function.
Serial communication RS232C,RS422,RS485 and USB.
Open Field bus standard.
Motion control network.
Motion control with multi axes upto 20 axes by 5 position controls.
High speed execution program.
High flexible, adapt PLC with the needs.

Omron PLC Modular CJ2

2. CJ1H/CJ1G

Compact PLC with 90 mm high, and 65 mm dept.
With flexible backlane-free structure.
Wide range of according to system requirement.
Wide range of modules selection, from standard I/O, positioning etc.
Analog I/O, process control, temperature etc
10 Communication models, such as DeviceNet, CompoNet.

Omron PLC Modular CJ1

3. CS1H/CS1G
This is the superior of Omron Modular PLCs. It is equipped with responsiveness and good data control function, also motion with greater precision.

1.6 times faster instruction execution.
3 time higher of PCMIX(everage instruction can be executed in 1 micro second.
Shorter 2.5 to 4.8 times in cycle time of 128 inputs and outputs.
LD instruction 2 times faster, Out 8 times faster, subroutine 17.6 faster.
System bus baud rete doubled.
The variation of Cycle time reduced by multiple cycle.
Data link, remote I/O communications, and protocol macro refresh performance improved.
CPU unit cpacity improved up to 5.120 I/O points, Programming 250Ksteps, Data memory 448 Kwords and 4.096 timer/counter.
Control up to 960 points I/0.
Up to 50 m, distance between two series expansion.
Nested interlock for CPU unit version 2.0 or later.
High accuracy of positioning with XY table.
Binary set value of timer/counter.
DeviceNet to read maintenance data.
Error generation while debugging.
PID autotuning.
Conversion of floating point decimal and character string.

Omron PLC Modular CS1

3. CS1D
To reduce the risk this plc system is added redundant vital component such as CPUs, power supplies, and expansion cables. It is to respond the customor's need regarding reliability that this PLC uses proven duplex technology to the CS series to provide highly reliable PLC system.
There are three systems of this PLC.

Duplex CPU, Dual I/O expansion system, and dual expansion cable. for superior redundancy and maintenability.
Duplex CPU, and single I/O expansion system. It can replace the device during operation.
Single CPU unit, It is ideal when you need to improve network redundancy, power supplay or other units.

And about the features of this PLC are:

Support of communication with ethernet, compoNet, deviceNet, controller link,
No need special programming device when maintenance or unit replacement.
Units and expansion backplane can be added online.
Units can be replaced online by duplex of expansion cable .
To replace duplex unit can be done by online.

Omron PLC Modular CS1D

Omron Micro PLCs Series

2011-08-11T20:12:00.001-07:00

In this chapter will be described on the category of Omron PLCs. Omron PLCs are classified based on the capabilities or features, as well as the capacity of input-output (I/O). This chapter will start for the first category is the Omron Micro PLCs. And regarding the other categories will be discussed in subsequent chapters.
Omron Micro PLCs is a type of Omron PLC which is the smallest category. There is limited ability or features as well as the number of input-output (I/O), when compared with others type.
However, some of this type has been equipped with facilities such as analog input-output, pulse output, and serial communication.

Just as a reminder, " an analog input-output means" that the PLC is capable recieving or sending and processing analog signal (eg, 4-20mA o-10 Volt) or in other words not only capable of processing digital input-output (I/O). Example of this application is a temperature measurement which one do as processing signal from a temperature control that generates an analog signal. Or otherwise controlling the set point value of temperature via a temperature control.

"While the pulse output is a pulse" signal which is used to drive servo motor via servo motor driver. Or this often referred to as a pulse generator.

"For serial communication ports", can be connected to HMI, touch screen, computer and other devices.

It can be said that with Omron Micro PLC is much better than the konvensional control (relay etc). The main thing is more compact space or simplify the wiring, and flexibilty in programming the machine control.
Here are the some types of Omron Micro PLCs:
1. CP1E (economical), 20
There are three models with input-output capacity(I/O) 20 to 160 points, USB as peripheral port, and serial port :

CP1E-E(basic model): Program capacity : 2Ksteps, Data memory : 2Kwords, Timer/Counter 256, Hi-speed counter 10Khz x 6 inputs.
CP1E-N :support programable terminal, inverter and position control (servo), Program capacity : 8 Ksteps, Data memory : 8 Kwords, Timer/Counter 256, Hi-speed counter 100Khz x 2 inputs and 10 Khz x 2 inputs.
CP1E-NA : built in 2 analog input, and 1 analog output. Program capacity : 8 Ksteps, Data memory : 8 Kwords, Timer/Counter 256, Hi-speed counter 100Khz x 2 inputs and 10 Khz x 2 inputs.

CP1E

2. CP1L

Support USB as peripheral port.
Motion control with two axis at maximum 100 khz. and support basic function of motion, origin, acceleration, decceleration, etc.
High speed counter four axis counter of single phase input.
Support Modbus RTU without programming, optional serial communication port.
Expanable I/O points. I/O capacity 10~180 points.
There are 3 models: CP1L (10 I/O point, program capacity 5 Ksteps), CP1L-L ( 14 and 20 I/O point with 1 expand, program capacity 5 Ksteps), CP1L-M ( 30,40 and 60 I/O point with 3 expand, program capacity 10 Ksteps),

CP1L

3. CP1H

Support USB as peripharel port and two sreial ports.
Built in pulse output four axes. full function of motion origin, acceleration, decceleration etc.
High speed input-output counter of 1 MHz.
Faster instruction process time.
ModBus-RTU easy Master.
Serial PC link.
Analog I/O with setting input connector.
Two 7 segmens display status.

CP1H

4. CPM1A
This is the old type of C series Omron PLC.

Compact PLC with built in I/O. I/O capacity 10~100.
Program capacity 2.048 words , and 1.024 words data memory.
Timer/Counter 128, basic instructions 14, special instruction 79, and analog switch adjustment 2 pcs.
Communication with Omron PTs in Host link or NT link. additional RS232 device is necassary.
CX programmer and programming consule.

CPM1A

5. CPM2C
This ultra slim PLC is the completion of CPM2A.

I/O capacity 10~362.
High speed counter/sincronized control.
Pulse output with one axis 10 KHz.
Temperature control and monitoring with PID function.
Simultaneous communication.
CX programmer and programming consule.

CPM2C

6. CPM2A

I/O capacity 80~120
Real time clock.
High speed counter/sincronized control.
Analog signal processing control.
Pulse output with one axis 10 KHz.
Temperature control and monitoring with PID function.
Program memory 4 Kwords , 2 K words for data memory.

CPM2A

7. ZEN
Simple programable controller, direct programming and data entry by front button and display panel LCD, and real time clock. I/O capacity 10~44.

ZEN

Wiring Connection of PLC

2011-08-10T01:51:00.000-07:00

CP1H PLC by Omron

This chapter will explain about how to make wiring connection on PLC circuit. And as an example, will be used Omron micro PLC CP1H series.

Before going any further about how to do wiring on the CP1H PLC, the following will be explained about the parts or structures of this PLC:

Parts of Omron CP1H

Battery covers, location of backup battery
Operation indicators, power, err/alarm, BKUP, RUN, INH, PRPHL.
Peripheral USB Port, connecting PC for CX Programmer both monitoring and programming.
7-segmen display, 2 digits of 7 segmen shows CPU status such as error and codes.
Analog Adjuster, adjusting value of A642 in range 0 to 256.
External analog setting input connector, adjusting of value A642 by external input voltage 0 to 10 Volt.
Dip switch, used for PLC setting, such as memory program protection, transfer data from memory cassete, serial communication setting, A395 status.
Analog input terminal block and base(XA cpu only).
Analog input switch(XA cpu only) to determine of voltage or current used on analog input.
Slot for memory cassette CP1W-ME05M.
Power supply, ground and input terminal block.
Option board slots, two slots for option boards such as RS232C, RS422A/485, LCD, and ethernet.
Input indicator.
Expansion I/O connector.
Output indicators.
External power supply and output terminal block.
Connector for CJ unit adapter.

Power Supply Connection

If viewed from supply of power, there are two types of CP1H CPU. AC type and DC type. CP1H-X40DR-A is example of AC type which supply of voltage 100 to 240 VAC. And the example of DC type is CP1H-X40DR-D with 24 DC 24 Volt. A and D which distinguish these type. The following figures are the example of about how for connecting the supply of power:

Omron CP1H with Power supply AC 100~240 Volt

CP1H wiring of AC power supply

Omron CP1H with Power supply DC 24 Volt

CP1H wiring of DC power supply

Input device connection
There are several models of the connection between input device and the PLC input circuit. Basically can be devided as follows:

NPN type, Simply be explained, that for NPN type is if the input device used is negative voltage (0 Volt of 24 Volt DC), and the common terminal of PLC input circuit is connected to positive (+24 Volt DC).
PNP type, This is in contrast with NPN type that the input device used is positive voltage (+24 Volt DC), and the common terminal of PLC input circuit is connected to negative voltage (0 Volt of 24 Volt DC).

Selection method connection between NPN and PNP models is depend on the input device. For example, there are two types of sensor model, NPN and PNP. In addition to these considerations, sometimes there are also concerned with style and safety considerations.The following figures are several models of connection between input device and PLC input circuit:

1. Input device is contact, example relay, switch, push button

2. Input device is 2 wire

3. Input device NPN open-collector

4. Input device NPN current output

5. Input device PNP current output

6. Input device voltage output

Output device connection
There are two models of PLC output circuit :
1. Output relay

PLC with this output has relay output to drive the load. And the load will be driven by the contact relay. Of course it can drive the load with DC and AC voltage. Similarly, variations can be made with how to connect the common terminal on output circuit. Below is the figures about the output circuit connection model:

PLC output relay connection

2. Output Transistor.

For the PLC with transistor output, there are two ways to arrange output device. This is determined by the DC voltage that connected to common. If common is connected to positive called as " Sourching transistor output", and if common is connected to negative called as "Sinking transistor output". That can be clarified with the figures below:

Sourching Transistor Output

Sinking Transistor Output

In its application, the selection of a PLC output relay or transistor really considered. Some considerations can be a type of load. It is recommended to use external relay so that the internal relay of PLC unencumbered directly. As for load that require a faster response would be better to use the transistor output.
In addition, output relay also has a weakness for relay contact having a shorter life time.

Numerical System in PLC

2011-08-08T07:33:00.000-07:00

Numerical System in PLC is numbers or system numbers used by the PLC in performing logic operation.

Numerical Sytem in PLC

This numerical system must be understood, when we will learn about programming of PLC. The following descriptions will explain the numerical system and terms are often used in PLC programming techniques:

1.Decimal Number (Dec)
This numerical system is the number we use in every day. Everyone certainly have understood. In the program PLC is usually used as " setting value" or actual value. For example on the " Timer instruction" on Omron PLC, decimal value is marked with "#". And in Mitsubishi PLC is marked with "K".

2. Binary Number (Bin)

It is base-2 numerical system which represented with value 0 and 1. This numbers can be grouped with the terms as follows:

Bit, the basic of binary numbers with the value of 0 or 1.
Nibble, composed of sequential 4 bits. example: b3 to b0 called one nibble.
Byte, composed of sequential 8 bits. example : b7 to b0 called one byte.
Word, composed of sequential 16 bits. example : b15 to b0 called one word.
Double words, composed of sequential 32bits. example: b31 to b0 called double words.

3. Binary Code Decimal (BCD)

BCD is used to express decimal digit with a nibble or 4 bits. 4 decimal digits can be expressed by sequential 16 bits.

4. Hexadecimal(Hex)

It is base-16 numerical system. For the numbers 0 to 9, either in decimal (dec) or hexadecimal (dec) is the same. While the numbers 10 to 15 in decimal would be as follows : 10=A, 11=B, 12=C, 13=D, 14=E, 15=F.
5. Octal
It is base 8 numerical system and uses digit 0 to 7. This numerical system usually used on input output or I/O PLC.

POPCOM Windows for Yamaha Robot

2011-08-07T02:16:00.000-07:00

POPCOM Windows is software for Yamaha robot. With this software we can create, editing program, point position teaching an so on.

This application software is equipped with simple function that will be easy for operation. The following types of controller that can be controlle by this application software are:
SRC, SRCA, SRCH, SRCH-3, ERC, DRC, DRCA, DRC-R, DRCH, DRCH-E, TRC(3 axes), TRCH(4 axes), ERCX/SRCX, DRCX, TRCX(2 axes), TRCX(3 axes), TRCX(4 axes), SRCP, SRCD, ERCD, SR1-X, SR1-P.
System Requirements:

Operating system: MS Windows version 3.1 or higher.
Computer type: using 80386 or higher processor.
Memory : more than 4 MB
Hard disk : more than 2MB
CD ROM : higher than four times speed
Serial port: 1 port for connecting with controller
Controller : adaptable controller ERCD/ERCX/SR1-P/SR1-X/DRCX/TRCX.

The type of serial communication cable for the POPCOM Windows is POPCOM-SSC-1-3L.

POPCOM Serial cable type by Yamaha

There are two types of based pin numbethe robot via computer.
rs and maker,

1. by IBM 9-25 pin

2. by NEC 25-25 pin

And about the length of cable is 3.5 meters and 5 meters.
About the features that exist on POPCOM Windows is as follows:

Single screen, all items are displayed in one screen that it will be to acces and monitor.
Help function, by choosing help function you can find the information you need.
Program and Point editting, easy to edit the program and point position.
Manual running, Can run manually the robot via computer like using HPB.
Creating point data, including MDI(manual data input), point teaching, manual teaching by moving the robot manually(by hand).

YamahaVIP Plus Software

2011-08-05T22:49:00.001-07:00

VIP Plus is window based application to control Yamaha robot RCX series controller. This software was used to create the program, parameters, point position, monitor and manual running via these software.

Controller type: The RCX series controllers that can be controlled by this software are RCX40, RCX142, RCX143, RCX144, RCX221, RCX222, RCX240.

System Requirements:

Operating system : Microsoft Windows 2000/XP/Vista ( no subject operation warranty for 64 bits version).
CPU and memory: higher than recomended by OS which is used.
Hard disk : more than 40 MB.
Comunication : RS 232C and ethernet.

Yamaha RCX series

The image on the side is an example of Yamaha robot controller RCX series that can be accessed via VIP Plus. Using this software, there are new functions to access this controller:

Robot operation, on-line command can do by connecting PC and controller.
Data check function, to compare to correct error before operation.
On-line editing, eneble editing data by connecting PC and controller.

Some others features are, easy to use, programming editing with the program and point can be edited alone, and help.
About type of RS232 communication cable used is VIP+SSC25L. This cable has length of 5 meters.

Omron CX-One

2011-08-05T22:48:00.000-07:00

CX-ONE is released by Omron is an integrated software tool that can be used for all Omron PLCs and components. Thus, with just one software CX ONE, can be used for setting PLC, touch screen, servo, positioning, temperature, networking and so on.

System Requirements

Operating system: Microsoft Window XP (service pack 3 or higher), Microsoft Window Vista, Microsoft Window 7.
Computer and Memory : processor recomended by Microsoft.
Hard Disk : minimum 3.4 GB for installing the complete CX-ONE.
Display : XGA (1024X768) 16 bit or better.
Communication ports: RS 232C, USB and Ethernet.
Registration: intenet connection is necessary.

Contents of CX-ONE

CX-Programmer

to create and debug PLC program Sysmac CS/CJ/CP/NSJseries, C series, CVM1/C series and also to create and monitor Sysmac CS/CJ high speed psoition control.

CX-Integration

to set up FA network, such controller link, deviceNet, CompoNet, CompoWay, and Ethernet networks. this also includes DeviceNet cnfiguration, Routing table and data link component.

CX-Protocol

to create protocols or communication sequences between CS/CJ/CP/NSJ or C200HX/HG/HE communications board and other general purpose external devices.

CX-Position

to create and monitor data Sysmac CS/CJ series positioning control unit except for high speed type.

CX-Motion NCF

to create and monitor data Sysmac CS/CJ series positioning control unit and servo driver with Mechatrolink-II communications.

CX-Motion MCH

to create data, motion program, and monitor data Sysmac CS/CJ series MCH unit.

CX-Motion

to create and monitor data Sysmac CS/CJ, C200HX/HG/HE, CVM1/CV series motion control unit.

CX-Drive

to set and control data inverter and servo motor.

CX-Process Tool

to create and debug function block for Sysmac CS/CJ series loop controllers (loop controller unit/boards, process control CPU unit, loop control control CPU units)

CX-Designer
to create screen data of NS series PT.

CX Configurator FDT
to set various units by installing its DTM module.

CX-Thermo
to set control and control parameters temperature control.

Network Configurator
to set tag data links Sysmac CJ2(built in ethernet/IP) CPU and ethernet/IP unit.

CX-Server
CX-One application to communicate with Omron components such as PLC, display, temperature control.

Switch box utility
to monitor I/O and change present value of PLC

CX-simulator
to simulate Sysmac CS/CJ/NSJ series CPU unit.

Face plate autobuilder for NS
Output screen data as project files for NS series PTs from information function block created by CX-Process tool.

NV Designer
to create screen data of NV series PT.

CX-FLnet
to set up and monitor Sysmac CS/CJ series FLnet.

PLC Tools
CX-ONE applications component which installed automatically. such as CX-Programmer and CX-Integrator, I/O tables, PLC memory, PLC setup, PLC error logs, File memory, PLC Clock, Routing and data table.

Automation With Robot

2011-08-05T06:04:00.000-07:00

Robot is intelegent mechanical device or system that can perform tasks or high precision motion based on programs that have been made.

Robot Motoman
HP3XFC by Yaskawa

Today, many robots have been created so as to perform work that could no do humans. Even some of robots have been made to resemble human beings capable of responding like a human. But in this chapter, the focus of discussion is a robot that is used in the field of industrial automation which made by some makers such Yamaha, IAI, Yaskawa, ABB and so on.

Based on its structure, robots that are widely used in the field of industrial automation can be grouped into three categories as follows:

Single Axis Robot, robot that has only one arm, and usually only uses one motor.
Cartesian(XY-X) Robot, robot that has more than one arm and motor, capable of movement according cartesian coordinates (X and Y)
SCARA Robot, SCARA stands for Selective Compliance Assembly Robot Arm. This robot has compliance only in X and Y directions and has rigidy in Z direction. This robot usually used in assembling works because it has outstanding speed and be able to save the space.

Some robots are also categorized based on the application. In industry, these applications include welding, assembling, process components (pick and place), material handling, painting, cutting and so on.

Nowdays robots are widely used in industry because of the ability to do the job faster and more efficiently than the conventional way (other actuator) or even humans. As a simple description is application of single axis robotic when compared with a air cylinder (controlled by air):

Air cylinder MY3
by SMC

Robot Flip F10
by Yamaha

Smoother motion , especially when starting and stopping. This because the robot has the function of setting " acceleration and decceleration ", while the air cylinder depents only by how much air supply.
Speed and precision, The robot can move faster with high accuracy.
Point Position, Robot can perform movements with different point position, while the air cylinder only perform a full stroke movement.

The structure of robot :
The structure of robot is devided into two parts

Robot Controller, is a part of the robot that functioned as a control, driver and power that move robot actuator. In this controller is a program that determines how a movement performed by the robot. This program was created by the user or a programmer in accordance with the desired movement.
Robot actuator, is the part of robot that performs the function of movement. The main parts of actuator consists of servo motor AC or DC type, brake, encoder or resolver, mechanical ball screw drive system. And about the brake is usually only used in vertical application.

Ball screw of T6T7 Type by Yamaha

Robot Actuator Structure by Yamaha

System Configuration
The following image is an example of basic configuration of a control system with a robot. As an application example is single axis Yamaha robot Flip-X series.
From the following image can be explained:

The controller is SR1 type with actuator Flip X series.
Programming tool, HPB programming box or POPCOM communication software. Both are used to enter parameters, programs, and point position data that determines the movement to be performed by robot.
External control, This is the input-output controller that can be used PLC and conventional circuit. Some commands are received by robot controller commands eg for origin, running, point position and so on. Instead the robot controller is also a signal origin, busy, current position, error and so on.

Yamaha robot system configuration

Color Sensor

2011-08-04T08:35:00.001-07:00

Color sensor is a sensor that is used to detect the color of an object.

This color sensor as actually a photo electric sensor that has a special character combination of color red (R) green (G) and blue (B). For that reason, color sensor often called the RGB color sensor.

Colorsight 9000 RGB
by Allen Bradley

The above image is a color sensor that detects the true color made by Allen Bradley. Several other makers are Keyence and Omron.
In industry, color sensor is used to detect an appropriate product specification or to distinguish between good and no good. That is the way to register the color target compared with the no good color of product.

Floatless Sensor

2011-08-03T08:01:00.000-07:00

Floatless sensor or Floatless switch is the sensor to detect level of liquid which is detected through electrodes submerged in the liquid.

This sensor is usually widely used in chemical industry primarily to detect liquid level. As an illustration, the following image is an image of floatless sensor made by Omron:

PS-.S(R) Electrode
by Omron

61F-G Floatless Controller
by Omron

Like the others sensors, this sensor would consist of sensor head and controller or amplifier. The controller consist of circuit relay and transformer, which relay will be in the " ON status" when electrodes are connected by a liquid/fluid. The following image is an internal circuit of floatless controller:

61FG Floatless Sensor
by Omron

S0: O Volt or common supply for 110/220 Volt
S1: 110 Volt supply, S2 : 220 Volt Supply
E3, E2, E1 : Electrode terminal
Here is the example of application of this sensor. Refer the application model that will be used to do with the choice of the controller. The following application is controlling the water supply. Pump ON-OFF will be determined by the level of the pump that is read by the controller through the electrode.

Automatic water supply control
Floatless 61F-G by Omron

The working principle of the circuit above can be explained as follows:

Working principle of Automatic
water supply control by Omron

Proximity Sensor

2011-08-02T05:39:00.000-07:00

Proximity Sensor is a sensor to detect the object without touching the object being detected. The detected object can be either metal and non metal.

Proximity Capacitive 875C, 875CP
Tubular by Allen Bradley

This sensor type is widely used because when compared with photoelectric sensor, this sensor is more stable, especially not effected by dirt or dust. Regarding the detection distance, there are two models with fixed detection range and adjustable range detection.
If viewed from the principle of work, or object that is detected is devided into two types:

Inductive type, work on the principle of inductive or magnetic field which generated by electric current. while the object that detected is metal. example : all metal products (eg. car).
Capacitive type, work on the principle of capacitive. This type can detect both metal and non-metal. example : wood, plastic etc.

E2K-L Capacitive
Proximity by Omron

TLN,TLQ,TLG Inductive
Proximity by Omron

Two pictures above are an example of two type of proximity sensor. Can be seen for type E2K-L functioned as liquid level sensor.
About the maker of this sensor, there are several makers such Allen Bradley, Keyence, Omron, and Fuji. Basically the same type produced. some variations as follows:

integrated amplifier and sensor head, This type usually has a fixed detection range.
Separate amplifier and sensor head, the detection range usually can be set using amplifier.
Amplifier in cable, It's compact proximity with fix range detection. As the example can be seen in the picture below.

EM Series proximity
sensor by Keyence

Finally, it can be concluded that in choosing the type of proximity will be based on the object (metal-non metal), distance of object as well as possible size according to available space.

Temperature sensor

2011-08-02T00:50:00.000-07:00

Temperature sensor is a sensor to detect the temperature of an object or room.

Temperature sensors are very widely used both in industry and daily life due to temperature or thermal parameters are very influential in the process.

At the first, the temperature sensor is a thermometer, and with the development and automation needs of particular temperature sensor was made. In the field of automation, temperature sensor is usually called temperature control because it serves not only detect the temperature but also can regulate the temperature by controlling the ON-OFF of heater.

E5CN Temperature control
by Omron

To detect and to control the temperature, a temperature control consists of itself and termocouple. Termocouple will produce a voltage proportional to temperature changes. And the voltage will be processed by temperature controller to be displayed or signal digital output.

Termocouple E52
by Omron

Thre are various types of termocouple based on the material and the temperature measurement range. The type are, K,E,J,N, platinum type B,R,S, T, C and M. In general, only the K and J type are widely used in industri or automation for reasons of character, measurement range, and price.
About each type of termocouple can be explained as follows:

Type K, range: -200 to 1350 degree Celcius, material: chromel,alumel.
Type E, material : chromel, constantan.
Type J, range : -40 to 750 degree Celcius, material : iron, constantan
Type N, range : upper 1200 degree Celcius , material : Nicrosil, Nisil.
Type T, range : -200 to 350 degree Celcius, material : copper, constantan.
Type C, range : 0 to 2320 degree Celcius, material : tungsten, rhenium.
Type M, range: max 1400 degree Celcius, material : Nickel
Type B, range : max 1800 degree Celcius, material : Platinum, rhodium.
Type S, range : max 1600 degree Celcius, material : Platinum, rhodium.
Type R, range : max 1600 degree Celcius, material : Platinum, rhodium.

The selection of termocouple type of coure can be done based on the temperature range to be measured.

Encoder for Position Detection

2011-08-01T07:54:00.000-07:00

Rotary Encoder is a sensor or device for detecting the direction of rotation, the angle position, and rotational position.

E6CP-A Absolute
Encoder by Omron

E6B2-C Incremental
Encoder by Omron

There are two types of rotary encoder :

Absolute encoder, this encoder uses the code at the time of output the absolute rotation angle, and to read the position of rotation is done by reading that code.
Incremental encoder, this encoder output the pulse during the rotation. The number of pulsa used to calculate the rotation number.

Absolute encoder is usually paired with a device called cam positioner. This circuit was used as the signal position of 360 or 720 degree rotation . It is helpfull if a machine requires a complex application or needed more position timing. Try to imagine if the positioning or timing marker used by the sensor/mechanical cam. Surely it would be complicated and difficult.

3F88L-160/162 Cam
Positioner by Omron

For incremental encoder is usually used as detector of rotation, if a rotating device as far as the intended target or not. And through the PLC program can do calculations or conversions about how the number of pule output by the encoder.

Limit switch sensor

2011-08-01T01:44:00.000-07:00

Limit switch sensor is one of the earliest type of sensor that work mechanically. This sensor basically a switch that can be in a state of ON or OFF as a result of mechanical movement.

Limit switches are basically formed from basic switch are then packaged in single unit to be used in accordance with particular application.

Basic switch A series
by Omron

Picture below are some basic types of switches are widely used. Due to reasons of the development or application needs, the basic switch is changed to limit switches as shown in the following figure:

VCL-5000 by Yamatake

WL/WLM Series
by Omron

NO Contact (Normally Open) and NC Contact (Normally close)
In general limit switch sensor has two pairs of contacts are 1 pair of NO contact and 1 pair of NC cotact. However for other types, there are also only have one contact which has only one common.

NO and NC contact
on Limit switch

Furthermore, the important thing from this contact is about the current and voltage that can be used for contact. It can be read on the nameplate located on the body limit switch or manual.
We already know, that the ability of current conductivity must be tailored to the ability of the contact. For safe installation are advised not to directly connect to load, but as much possible is passed through the relay.

Pressure Sensor

2011-07-31T05:36:00.000-07:00

Pressure sensor is the sensor to detect the pressure both positive pressure and negative pressure.Positive pressure is pressurized air generated by the compressor, while the negative pressure or vacuum is generated by air suction vacuum pump.

Analog Pressure switch
PGS10 by Wika

In the beginning, the pressure sensor is apressure gauge is an indicator of the pressure using the needle(mechanical/analog). As the needs and developments of automation, pressure gauge is equipped with contact switch that function as a signal as pressure marker has reached the specified value. Until now, although many use the pressure switch has digital indicator, but the type with needle indicator or analog is still used.
However, for electronic or digital pressure switch has several advantages compared with analog type:

Accuracy, electronic type has high accuracy because it is supported by the electronic system without the influence of mechanical or phisical changes.
High speed response, of course electronic type has faster response because without the need to perform mechanical movements.
Life time, Electronic type has longer life time. Another case where analog type, mechanical movement will cause rapid deterioration component proportional to the time of usage.

As explained previously, pressure switch detect the positive pressure and negative pressure. Several types of pressure switch in the market such as production of Keyence or Omron capable of detecting both positive or negative pressure. Whereas some others only detect the positive pressure only, or vacuum only. Type with the ability to detect both are often reffered as pressure switch " compound type".
A pressure unit used on the pressure switch are, Pa, kgf/cm2, bar and Psi. With refference to the pressure unit, the following pressure switch categories are based on pressure area. As an example is the pressure switch made by Keyence ie type compound AP30W:

AP-C30W by Keyence

Pressure area categories:

Pressure switch(positive): 0 to +100.0 kPa
Compound/multirange : +101.3 to -101.3 kPa
Vacuum switch (negative) : 0 TO -101.3 kPa

Regarding other categories, some models based on application needs. Such as the type with separate sensor head and amplifier is widely used in many areas contains oil. And afor type with one package commonly used in clean area that electronic circuit on the amplifier will be safe.

Separated type AP-40
by Keyence

As the end of this chapter, output signal from this sensor is in the form of digital output (ON-OFF) or in the form of analog signal (4-20 mA). Some of the type posessed both, but there is also the only one of these functions.

Photo Electric Sensor

2011-07-30T22:15:00.001-07:00

Referring the definition of photo electric sensor that has been described previously, Photo electric sensor is the sensor that detect the object by transmitting a beam with intensity that has been determined. The beam can be infra red or photo electric. All object can be detected by these sensors, because the sensor detects the light emitted by the object being detected.

Photoelectric
by Keyence

Easy description as shown the figure above, photo electric is formed from two parts, transmitter and reciever:

1. Transmitter , emits light to the object detected
2. Receiver, receiving the beam after the object is detected.

Categories of this sensor can be distinguised based on the transmitter emits the light into object and received it. Based on this, there are three kinds of models as shown below:

3 models of Photoelectric E3Z by Omron

Through-beam, Transmitter and receiver separated or opposite, object detected by how much lights is received by the receiver as the result of obstruction of light by the oject.
Retro-reflextive, Transmitter and receiver is in one side. After passing through the object, light reflected through the reflector and then received by the receiver. Reflector ussually is a mirrow.
Difuse-reflective, Transmitter and receiver is in one side. Almost as retro-reflective, but this model directly detect the intensity of light reflected by the object.

Various models of photoelectric sensors on the market. Some of the maker that there is such Keyence, Omron, Fuji and so on. There are categories or variations of the models that would fit with existing applicationa. As with any model with a separate amplifier and the sensor head, amplifier and sensor head in one package, built in amplifier and so on.
" Light ON and Dark ON" mode on Photoelectric sensor:
One of the important things in the photoelectric sensor is how free condition at the time of detecting object. Free condition is when the sensor is free from object.
As a simple illustration, the following picture describes the " Light ON and Dark ON",

1. Light ON mode:

Condition A, conditions with no object then the sensor output is ON.
Condition B, condition with object then the sensor output is OFF.

2. Dark ON mode:

Condition A, conditions with no object then the sensor output is OFF.
Condition B, condition with object then the sensor output is ON.

Seen from the above description that the Light On and Dark On is the opposite condition. Selection of this mode is largely determined by the object being detected or safety reasons.

Conversion of GP Series Digital Proface Touch Screen

2011-07-30T06:27:00.000-07:00

The following chapter is how to do the conversion the touch panel Digital Proface GP2000 series to GP 3000 series.

GP 2000 by Proface

GP 3000 by Proface

Basically, this conversion is to change the file .prw into the file .prx. File .prw is the format of the GP PRO/PB3 for window, while the file .prx is the format of the GP Pro-Ex.

Software required : GP Pro-Ex (Example: version 2.6)

1. Through the window start, open the GP Pro-Ex and select " Project Converter "

2. After " Project Converter " selected, and then will displayed as follows:

3. Select file tobe converted and destination( Covert-From and Convert-To),
then press convert

4. Option will appear, and select the desired type of GP3000

5. Conversion starts, and wait until the conversion is complate

6. Conversion is complate

7. Check the file conversion with GP Pro-Ex to ensure the conversion result.

Conversion of Omron NT Touch Screen

2011-07-29T08:35:00.000-07:00

Omron NT touch screen is currently difficult to be purchased. or even this has been discontinued model. NT series has been substituted with the new touch screen NS series.

NT Series by Omron

NS Series by Omron

And about the old program of NT series can be used by converting with a program conversion. It's easy, we do not need to create a new program again. The following steps will explain about how to convert NT to NS:

Software required: NT serie support tool ( Example: Version 4.73 ), CX Designer (Example : Version 3.2).
A. With NT Support Tool, changing file format to " mmi " :
1. As the example file name to be converted is " MACHINE_D ".
With NT support tool, open file MACHINE_D

2. After opened, Select File an then " Save as ":

3. Select save as type " mmi ", and folder name (Example: Test) to save:

4. Select OK, if it appears following message and it's successfully stored in " mmi " format

B. With CX Designer, Conversion of mmi format into NS:

1. Through the start , goto CX Designer and select NT31C_631C Conversion Support Tool

2. Will look as follows, edit parameters required (conversion source/destination etc)

3. Press the " arrow" to start conversion

4. The conversion process is complate.

By using CX Designer, open the file conversion results. File found on the red box as in the step No.2. If needed, make a check and editing of NS program which is the result of the conversion .

Servo Motor for Positioning Accuracy

2011-07-27T06:45:00.000-07:00

Servo motor is motor that can perform the rotation with high accuracy where the servo has a feedback sensor (encoder) for correction of mechanical rotation.

SMARTSTEP servo motor by Omron

Servo motor is very different from the induction motor. Induction motor is controlled simply by a magnetic contactor to disconnect the power supply, while the servo motor is controlled with a special driver that regulates rotation so that the mechanical movement, speed, acceleration, decceleration and other parameters can be controlled entirely accurately.
There are a lot of servomotor maker used on automation such as Siemans, Omron, Allan Bradley, Mitsubishi, Fuji and so on. Each has its own character so that for each brand between the motor and servo driver must be matched with their own brand. For example Omron servo can not be paired with Mitsubishi servo driver. As an important note, of course, quite different from the servo motor with induction motor in which all the induction motor can be paired with all brands of inverter.
Back to the discussion of servo motor. To be running a servo driver and motor must be controlled by pulse train generator, or often called positioning unit. Positioning unit will issued a pulse wave, which is parameter number of pulse and speed (frequency) will determine how much rotation, direction and rotation speed. The larger the pulse the more rotation. Likewise for the speed parameter.
The following image is an example application of the arrangement of the connection between servo motor and positioning unit. From the figure shows that the positioning unit issued a pulse which controls servo driver.

Example of connection of
servo motor and positioning unit by Omron

In the application, servo motor is widely used as rotation motion or converted into linear motion. One of common application is of linear linear motion on robot which has high accuracy and smooth motion.The following image is an example of servo motors in robot Yamaha. Rotation of motor is converted into forward-return through the screw.

Robot F14H by Yamaha

Type of Sensors in Automation

2011-07-23T05:29:00.001-07:00

Sensors is a device used to detect an object, and the result of the detection variable will be processed into an output signal of digital status (ON-OFF) or analog signal.
There are many sensors maker such as Omron, Keyence, Fuji, Siemans, Allan Bradley and so on. The following image is an example of sensor made by Omron:

Photo Electric E3JK by Omron

Especially in the field of automation with PLC, a sensor is functioning as a part of input. These sensors will issue a digital or analog signal to then to be processed by the CPU or PLC program.
There are various kind of sensors based on the following categories:

Based on the voltage supply:

Sensor with AC supply voltage, which means working on AC voltage is usually 100 Volts or 220 volts.
Sensor with DC supply voltage, This sensor usually works with voltage 24 volt.

Based on the output type:

Especially for the sensor with a DC voltage supply and output signal is digital. This category relates to the connection type used in the PLC input devices:

Output PNP, Signal output voltage will be positive (+) 24 volts DC.
Output NPN, signal output voltage will be negative (-) 24 volts DC.

Based on the detected object or working principle:

Limit switch, It's the beginning of sensor that works mechanically (switch).
Photo Electric Sensor, Sensor that detect the object by transmitting a beam with intensity that has been determined. The beam can be an infrared or photoelectric. object: metal and non-metal.
Laser Sensor, similarly with photo electric, but laser is used.
Proximity Sensor, Sensor that detect the object without touching the object being detected. object : metal and non metal.
Pressure Sensor, Sensor that detects the pressure both compressor (positive) and vacuum (negative).
Temperature Sensor, Sensor To detect the temperature of an object or room.
Encoder, Position sensor/Cam Positioner, Sensor is used to calculate position or position angle. It can be 360 degrees or 720 degrees.
Touch switch sensor, Sensor that will operate if touched by a particular object.
Vision, Camera sensor, Detecting an image by differentiating the intensity of color, light-dark, paterns and so on.
Floatless sensor, Sensor which equipped with electrodes usually to detect the liquid level.
Flow sensor, Sensor to detect the flow of liquid.