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IntroductionofProgrammablecontrollers
Fromasimpleheritage,theseremarkablesystemshaveevolvedtonotonlyreplaceelectromechanicaldevices,buttosolveanever-increasingarrayofcontrolproblemsinbothprocessandnonprocessindustries.Byallindications,thesemicroprocessorpoweredgiantswillcontinuetobreaknewgroundintheautomatedfactoryintothe1990s.
HISTORY
Inthe1960s,electromechanicaldevicesweretheorderofthedayassfarascontrolwasconcerned.Thesedevices,commonlyknownasrelays,werebeingusedbythethousandstocontrolmanysequential-typemanufacturingprocessesandstand-alongmachines.Manyoftheserelayswereinuseinthetransportationindustry,morespecifically,theautomotiveindustry.Theserelaysusedhundredsofwiresandtheirinterconnectionstoeffectacontrolsolution.Theperformanceofarelaywasbasicallyreliable-atleastasasingledevice.Butthecommonapplicationsforrelaypanelscalledfor300to500ormorerelays,andthereliabilityandmaintenanceissuesassociatedwithsupportingthesepanelsbecameaverygreatchallenge.Costbecameanotherissue,forinspiteofthelowcostoftherelayitself,theinstalledcostofthepanelcouldbequitehigh.Thetotalcostincludingpurchasedparts,wiring,andinstallationlabor,couldrangefrom$30~$50perrelay.Tomakemattersworse,theconstantlychangingneedsofaprocesscalledforrecurringmodificationsofacontrolpanel.
Withrelays,thiswasacostlyprospect,asitwasaccomplishedbyamajorrewiringeffortonthepanel.Inadditionthesechangesweresometimespoorlydocumented,causingasecond-shiftmaintenancenightmaremonthslater.Inlightofthis,itwasnotuncommontodiscardanentirecontrolpanelinfavorofanewonewiththeappropriatecomponentswiredinamannersuitedforthenewprocess.Addtothistheunpredictable,andpotentiallyhigh,costofmaintainingthesesystemsasonhigh-volumemotorvehicleproductionlines,anditbecameclearthatsomethingwasneededtoimprovethecontrolprocess一tomakeitmorereliable,easierto
troubleshoot,andmoreadaptabletochangingcontrolneeds.
Thatsomething,inthelate1960s,wasthefirstprogrammablecontroller.Thisfirst‘revolutionary’systemwandevelopedasaspecificresponsetotheneedsofthemajorautomotivemanufacturersintheUnitedStates.Theseearlycontrollers,orprogrammablelogiccontrollers(PLC),representedthefirstsystemsthat1couldbeusedonthefactoryfloor,2couldhavethere‘logic’
changedwithoutextensiverewiringorcomponentchanges,and3wereeasytodiagnoseandrepairwhenproblemsoccurred.
Itisinterestingtoobservetheprogressthathasbeenmadeinthepast15yearsintheprogrammablecontrollerarea.Thepioneerproductsofthelate1960smusthavebeenconfusingandfrighteningtoagreatnumberofpeople.Forexample,whathappenedtothehardwiredand
electromechanicaldevicesthatmaintenancepersonnelwereusedtorepairingwithhandtools?Theywerereplacedwith‘computers’disguisedaselectronicsdesignedtoreplace
relays.Eventheprogrammingtoolsweredesignedtoappearasrelayequivalentpresentations.Wehavetheopportunitynowtoexaminethepromise,inretrospect,thattheprogrammablecontrollerbroughttomanufacturing.
AllprogrammablecontrollersconsistofthebasicfunctionalblocksshowninFig.10.1.We’llexamineeachblocktounderstandtherelationshiptothecontrolsystem.Firstwelookatthecenter,asitistheheart(oratleastthebrain)ofthesystem.Itconsistsofamicroprocessor,logicmemoryforthestorageoftheactualcontrollogic,storageorvariablememoryforusewithdatathatwillordinarilychangeasafunctionpowerfortheprocessorandmemory.NextcomestheI/Oblock.ThisfunctiontakesthecontrollevelsignalsfortheCPUandconvertsthemtovoltageandcurrentlevelssuitableforconnectionwithfactorygradesensorsandactuators.TheI/Otypecanrangefromdigital(discreteoron/off),analog(continuouslyvariable),oravarietyofspecialpurpose‘smart’I/Owhicharededicatedtoacertainapplicationtask.Theprogrammerisshownhere,butitisnormallyusedonlytoinitiallyconfigureandprogramasystemandisnotrequiredforthesystemtooperate.Itisalsousedintroubleshootingasystem,andcanprovetobeavaluabletoolinpinpointingtheexactcauseofaproblem.ThefielddevicesshownhererepresentthevarioussensorsandactuatorsconnectedtotheI/O.Thesearethearms,legs,eyes,andearsofthesystem,includingpushbuttons,limitswitches,proximityswitches,photosensors,thermocouples,RTDS,positionsensingdevices,andbarcodereaderasinput;andpilotlights,displaydevices,motorstarters,DCandACdrives,solenoids,andprintersasoutputs.Nosingleattemptcouldcoveritsrapidlychangingscope,butthreebasiccharacteristicscanbeexaminedtogiveclassifyanindustrialcontroldeviceasaprogrammablecontroller.
Itsbasicinternaloperationistosolvelogicfromthebeginningofmemorytosomespecifiedpoint,suchasendofmemoryorendofprogram.Oncetheendisreached,theoperationbeginsagainatthebeginningofmemory.Thisscanningprocesscontinuesfromthetimepowerissuppliedtothetimeititremoved.
Theprogramminglogicisaformofarelayladderdiagram.
Normallyopen,normallyclosedcontacts,andrelaycoilsareusedwithinaformatutilizingaleftandarightverticalrail.Powerflow(symbolicpositiveelectronflow)isusedtodeterminewhichcoiloroutputsareenergizedordeenergized.
Themachineisdesignedfortheindustrialenvironmentfromitsbasicconcept;thisprotectionisnotaddedatalaterdate.TheindustrialenvironmentincludesunreliableACpower,hightemperatures(0to60degreeCelsius),extremesofhumidity,vibrations,RFnoise,andothersimilarparameters.Generalapplicationareas
PinDescription
Description
Theprogrammablecontrollerisusedinawidevarietyofcontrolapplicationstoday,manyofwhichwerenoteconomicallypossiblejustafewyearsago.Thisistruefortwogeneralreasons:1therecosteffectiveness(thatis,thecost
perI/Opoint)hasimproveddramaticallywiththefallingpricesofmicroprocessorsandrelatedcomponents,and2theabilityofthecontrollertosolvecomplexcomputationandcommunicationtaskshasmadeitpossibletouseitwhereadedicatedcomputerwaspreviouslyused.
Applicationsforprogrammablecontrollerscanbecategorizedinanumberofdifferentways,includinggeneralandindustrialapplicationcategories.Butitisimportanttounderstandtheframeworkinwhichcontrollersarepresentlyunderstoodandusedsothatthefullscopeofpresentandfutureevolutioncanbeexamined.Itisthroughthepowerofapplicationsthatcontrollerscanbeseenintheirfulllight.Industrialapplicationsincludemanyinbothdiscretemanufacturingandprocessindustries.Automotiveindustryapplications,thegenesisoftheprogrammablecontroller,continuetoprovidethelargestbaseofopportunity.Otherindustries,suchasfoodprocessingandutilities,providecurrentdevelopmentopportunities.
Therearefivegeneralapplicationareasinwhichprogrammablecontrollersareused.Atypicalinstallationwilluseoneormoreoftheseintegratedtothecontrolsystemproblem.Thefivegeneralareasareexplainedbrieflybelow.
TheAT89C51isalow-power,high-performanceCMOS8-bitmicrocomputerwith4KbytesofFlashprogrammableanderasablereadonlymemory(PEROM).ThedeviceismanufacturedusingAtmel’shigh-densitynonvolatile
memorytechnologyandiscompatiblewiththeindustry-standardMCS-51instructionsetandpinout.Theon-chipFlashallowstheprogrammemorytobereprogrammedin-systemorbyaconventionalnonvolatilememory
programmer.Bycombiningaversatile8-bitCPUwithFlashonamonolithicchip,theAtmelAT89C51isapowerfulmicrocomputerwhichprovidesahighly-flexibleandcost-effectivesolutiontomanyembeddedcontrolapplications.
Functioncharacteristic
TheAT89C51providesthefollowingstandardfeatures:4KbytesofFlash,128bytesofRAM,32I/Olines,two16-bittimer/counters,afivevectortwo-levelinterruptarchitecture,afullduplexserialport,on-chiposcillatorandclockcircuitry.Inaddition,theAT89C51isdesignedwithstaticlogicforoperationdowntozerofrequencyandsupportstwosoftwareselectablepowersavingmodes.TheIdleModestopstheCPUwhileallowingtheRAM,timer/counters,serialportandinterruptsystemtocontinuefunctioning.ThePower-downModesavestheRAMcontentsbutfreezestheoscillatordisablingallotherchipfunctionsuntilthenexthardwarereset.
VCC:Supplyvoltage.
GND:Ground.
Port0:
Port0isan8-bitopen-drainbi-directionalI/Oport.Asanoutputport,eachpincansinkeightTTLinputs.When1sarewrittentoport0pins,thepinscanbeusedashighimpedanceinputs.Port0mayalsobeconfiguredtobethemultiplexedloworderaddress/databusduringaccessestoexternalprogramanddatamemory.InthismodeP0hasinternalpullups.Port0alsoreceivesthecodebytesduringFlashprogramming,andoutputsthecodebytesduringprogramverification.Externalpullupsarerequiredduringprogramverification.
Port1
Port1isan8-bitbi-directionalI/Oportwithinternalpullups.ThePort1outputbufferscansink/sourcefourTTLinputs.When1sarewrittentoPort1pinstheyarepulledhighbytheinternalpullupsandcanbeusedasinputs.Asinputs,Port1pinsthatareexternallybeingpulledlowwillsourcecurrent(IIL)becauseoftheinternalpullups.Port1alsoreceivesthelow-orderaddressbytesduringFlashprogrammingandverification.
Port2
Port2isan8-bitbi-directionalI/Oportwithinternalpullups.ThePort2outputbufferscansink/sourcefourTTLinputs.When1sarewrittentoPort2pinstheyarepulledhighbytheinternalpullupsandcanbeusedasinputs.Asinputs,Port2pinsthatareexternallybeingpulledlowwillsourcecurrent,becauseoftheinternalpullups.Port2emitsthehigh-orderaddressbyteduringfetchesfromexternalprogrammemoryandduringaccessestoexternaldatamemorythatuse16-bitaddresses.Inthisapplication,itusesstronginternalpullupswhenemitting1s.Duringaccessestoexternaldatamemorythatuse8-bitaddresses,Port2emitsthecontentsoftheP2SpecialFunctionRegister.Port2alsoreceivesthehigh-orderaddressbitsandsomecontrolsignalsduringFlashprogrammingandverification.
Port3
Port3isan8-bitbi-directionalI/Oportwithinternalpullups.ThePort3outputbufferscansink/sourcefourTTLinputs.When1sarewrittentoPort3pinstheyarepulledhighbytheinternalpullupsandcanbeusedasinputs.Asinputs,Port3pinsthatareexternallybeingpulledlowwillsourcecurrent(IIL)becauseofthepullups.Port3alsoservesthefunctionsofvariousspecialfeaturesoftheAT89C51aslistedbelow:
Port3alsoreceivessomecontrolsignalsforFlashprogrammingandverification.
RST
Resetinput.Ahighonthispinfortwomachinecycleswhiletheoscillatorisrunningresetsthedevice.
ALE/PROG
AddressLatchEnableoutputpulseforlatchingthelowbyteoftheaddress
duringaccessestoexternalmemory.Thispinisalsotheprogrampulseinput(PROG)duringFlashprogramming.InnormaloperationALEisemittedataconstantrateof1/6theoscillatorfrequency,andmaybeusedforexternaltimingorclockingpurposes.Note,however,thatoneALEpulseisskippedduringeachaccesstoexternalDataMemory.
Ifdesired,ALEoperationcanbedisabledbysettingbit0ofSFRlocation8EH.Withthebitset,ALEisactiveonlyduringaMOVXorMOVCinstruction.Otherwise,thepinisweaklypulledhigh.SettingtheALEdisablebithasnoeffectifthemicrocontrollerisinexternalexecutionmode.
PSEN
ProgramStoreEnableisthereadstrobetoexternalprogrammemory.WhentheAT89C51isexecutingcodefromexternalprogrammemory,PSENisactivatedtwiceeachmachinecycle,exceptthattwoPSENactivationsareskippedduringeachaccesstoexternaldatamemory.
EA/VPP
ExternalAccessEnable.EAmustbestrappedtoGNDinordertoenablethedevicetofetchcodefromexternalprogrammemorylocationsstartingat0000HuptoFFFFH.Note,however,thatiflockbit1isprogrammed,EAwillbeinternallylatchedonreset.EAshouldbestrappedtoVCCforinternalprogramexecutions.Thispinalsoreceivesthe12-voltprogrammingenablevoltage(VPP)duringFlashprogramming,forpartsthatrequire12-voltVPP.
XTAL1
Inputtotheinvertingoscillatoramplifierandinputtotheinternalclockoperatingcircuit.
XTAL2
Outputfromtheinvertingoscillatoramplifier.
OscillatorCharacteristics
XTAL1andXTAL2aretheinputandoutput,respectively,ofaninvertingamplifierwhichcanbeconfiguredforuseasanon-chiposcillator,asshowninFigure1.Eitheraquartzcrystalorceramicresonatormaybeused.Todrivethedevicefromanexternalclocksource,XTAL2shouldbeleftunconnectedwhileXTAL1isdrivenasshowninFigure2.Therearenorequirementsonthedutycycleoftheexternalclocksignal,sincetheinputtotheinternalclockingcircuitryisthroughadivide-by-twoflip-flop,butminimumandmaximumvoltagehighandlowtimespecificationsmustbeobserved.
Figure1.OscillatorConnectionsFigure2.ExternalClockDriveConfiguration
IdleMode
Inidlemode,theCPUputsitselftosleepwhilealltheonchipperipheralsremainactive.Themodeisinvokedbysoftware.Thecontentoftheon-chip
RAMandallthespecialfunctionsregistersremainunchangedduringthismode.Theidlemodecanbeterminatedbyanyenabledinterruptorbyahardwarereset.Itshouldbenotedthatwhenidleisterminatedbyahardwarereset,thedevice
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