Programmable Logic Controllers (PLCs) are electronic devices used to control and automate industrial processes. PLCs have become an essential tool in the automation industry, and with the advancement in technology, they have become more efficient and reliable. Siemens S7-1200 is one of the popular PLCs in the market. This article aims to provide a comprehensive guide to PLC programming from basic to advanced Siemens S7-1200.
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Table of Content:
I. Understanding PLC Programming Basics
A. Introduction to PLC Programming
B. Understanding PLC Hardware and Software
C. Programming Languages Used in PLC
D. Basic Programming Instructions
E. Programming Examples
II. Introduction to Siemens S7-1200
A. Features and Benefits of Siemens S7-1200
B. Hardware Configuration of Siemens S7-1200
C. Software Requirements for Siemens S7-1200
III. Siemens S7-1200 Programming Basics
A. Starting a New Project
B. Understanding the Project View
C. Creating Blocks and Symbols
D. Basic Programming Instructions
E. Understanding Data Types
F. Creating and Using Data Blocks
G. Downloading and Testing the Program
IV. Siemens S7-1200 Advanced Programming
A. Advanced Programming Instructions
B. Working with Timers and Counters
C. Using Analog Signals
D. Understanding Function Blocks
E. Debugging and Troubleshooting Techniques
F. Real-Time Communication
V. Conclusion
I. Understanding PLC Programming Basics
A. Introduction to PLC Programming:
PLC programming is a method of writing instructions for a PLC to control and automate industrial processes. The primary function of a PLC is to monitor inputs and outputs and make decisions based on those inputs to control the outputs. PLC programming is done using a specific language that is easy to understand and can be executed by the PLC hardware.
B. Understanding PLC Hardware and Software:
A PLC consists of two primary components: hardware and software. The hardware component includes the physical device, input/output modules, and power supply. The software component includes the programming software used to write and download the PLC program to the hardware.
C. Programming Languages Used in PLC:
PLC programming can be done using several languages, including ladder logic, function block diagrams, structured text, and sequential function charts. Ladder logic is the most common language used in PLC programming.
D. Basic Programming Instructions:
The basic programming instructions used in PLC programming include Boolean instructions, timers, counters, and comparisons. Boolean instructions are used to turn outputs on or off based on the state of the inputs. Timers and counters are used to measure time and count events, respectively. Comparisons are used to compare values and make decisions based on those values.
E. Programming Examples:
Examples of PLC programming include controlling a conveyor belt, filling a tank, and controlling the temperature of an oven. In each of these examples, the PLC is used to monitor inputs and make decisions based on those inputs to control the outputs.
II. Introduction to Siemens S7-1200
A. A. Features and Benefits of Siemens S7-1200:
The Siemens S7-1200 is a compact and powerful PLC that is designed for small to medium-sized applications. It has several features, including high processing speed, integrated communication, and a range of input/output modules. The benefits of using the Siemens S7-1200 include reduced engineering time, improved productivity, and enhanced flexibility.
B. Hardware Configuration of Siemens S7-1200:
The Siemens S7-1200 comes in different models with different input/output modules, depending on the specific application requirements. The hardware configuration of the Siemens S7-1200 consists of a CPU module, power supply module, digital input/output modules, analog input/output modules, communication modules, and expansion modules.
The CPU module is the brain of the Siemens S7-1200 and is responsible for executing the PLC program. The power supply module provides the required voltage to power the entire PLC system. Digital input/output modules are used to connect digital sensors and actuators to the PLC. Analog input/output modules are used to connect analog sensors and actuators to the PLC. Communication modules are used to establish communication between the PLC and other devices, such as HMI (Human Machine Interface) panels, SCADA (Supervisory Control and Data Acquisition) systems, and other PLCs. Expansion modules are used to add more input/output points to the PLC system.
C. Software Requirements for Siemens S7-1200:
To program the Siemens S7-1200, you need a programming software called STEP 7 Basic. STEP 7 Basic is a comprehensive engineering tool that enables you to create, test, and download the PLC program to the Siemens S7-1200. It also includes a range of features such as online monitoring, program modification, and debugging.
III. Siemens S7-1200 Programming Basics
A. Starting a New Project:
To start a new project, open the STEP 7 Basic software and create a new project. Specify the project name, location, and CPU type. Then, add the required modules to the project configuration.
B. Understanding the Project View:
The project view in STEP 7 Basic shows the various components of the PLC system, including the hardware configuration, network configuration, and program blocks. The hardware configuration shows the CPU module and the input/output modules used in the project. The network configuration shows the communication settings used in the project, such as IP addresses and protocols. The program blocks show the PLC program written in the programming language of your choice.
C. Creating Blocks and Symbols:
To create a new block, go to the project view and select the block type. You can choose from several block types, including function blocks, organization blocks, and data blocks. Once you have created the block, add symbols to the block to represent inputs, outputs, and internal variables.
D. Basic Programming Instructions:
The basic programming instructions used in Siemens S7-1200 programming include the AND, OR, NOT, timer, counter, and compare instructions. These instructions are used to create logic to control the inputs and outputs of the PLC system.
E. Understanding Data Types:
In Siemens S7-1200 programming, data types are used to define the type of data stored in variables. Common data types used in Siemens S7-1200 programming include BOOL (Boolean), INT (integer), DINT (double integer), REAL (floating-point number), and STRING (text).
F. Creating and Using Data Blocks:
Data blocks are used to store variables and data used in the PLC program. To create a data block, go to the project view and select the data block type. Add symbols to the data block to represent variables used in the PLC program. Data blocks can be shared between different program blocks, making it easier to maintain and modify the PLC program.
G. Downloading and Testing the Program:
Once you have written the PLC program, download it to the Siemens S7-1200 and test it. The testing process involves checking the program's functionality, input/output connections, and communication settings.
IV. Siemens S7-1200 Advanced Programming
Siemens S7-1200 is a programmable logic controller (PLC) used in industrial automation and control systems. It is equipped with advanced programming instructions that allow you to implement complex logic and automation tasks.
Here are some examples of advanced programming instructions in Siemens S7-1200:
- PID (Proportional Integral Derivative) Controller: This instruction is used to implement closed-loop control of a process variable, such as temperature or pressure. It calculates the control output based on the difference between the desired setpoint and the actual process variable, using a combination of proportional, integral, and derivative terms.
- High-Speed Counter: This instruction is used to count high-speed events, such as pulses from an encoder or a high-speed sensor. It can count up to 1 MHz and has configurable inputs and outputs.
- Compare and Math Instructions: These instructions allow you to perform mathematical and logical operations on data in the PLC. They include instructions for addition, subtraction, multiplication, division, bitwise operations, and comparison.
- Shift and Rotate Instructions: These instructions allow you to shift or rotate bits within a word or a double-word. They are useful for manipulating data in binary format.
- String Instructions: These instructions allow you to manipulate character strings in the PLC. They include instructions for copying, comparing, and concatenating strings.
- Timers and Counters: These instructions allow you to implement time-based and event-based logic in the PLC. They include instructions for on-delay, off-delay, pulse, and cycle timers, as well as up/down counters.
- Interrupts: These instructions allow you to handle external events, such as alarms or emergency stops, that require immediate attention. They interrupt the normal program flow and execute a specific block of code.
A. Advanced Programming Instructions:
Advanced programming instructions in Siemens S7-1200 include PID (Proportional Integral Derivative) control, motion control, and high-speed counter instructions. These instructions are used in more complex applications where precise control and high-speed processing are required.
B. Structured Text Programming:
Structured Text (ST) is a high-level programming language used in Siemens S7-1200 programming. ST programming allows for more complex programming structures and algorithms, making it easier to develop complex control systems.
C. Function Block Diagram Programming:
Function Block Diagram (FBD) programming is a graphical programming language used in Siemens S7-1200 programming. FBD programming uses function blocks to represent program logic and connections between program blocks.
D. Sequential Function Chart Programming:
Sequential Function Chart (SFC) programming is another graphical programming language used in Siemens S7-1200 programming. SFC programming is used to create sequential control systems where different stages of the process need to be executed in a specific sequence.
E. Modular Programming:
Modular programming is a programming technique used to create a program using smaller, reusable modules. In Siemens S7-1200 programming, modular programming is achieved using function blocks and data blocks. Modular programming makes it easier to maintain and modify a program as individual modules can be tested and modified independently.
F. Advanced Networking:
Siemens S7-1200 PLCs support various networking protocols such as ProfiNet, Modbus TCP, and Ethernet/IP. Advanced networking features in Siemens S7-1200 programming include remote monitoring and control, data exchange between different PLC systems, and integration with SCADA systems.
G. Debugging Techniques:
Debugging is an essential part of Siemens S7-1200 programming. The STEP 7 Basic software includes various debugging features such as online monitoring, breakpoint setting, and watch windows. Advanced debugging techniques in Siemens S7-1200 programming include tracing and logging techniques that allow for the analysis of the program's behavior over time.
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V. Conclusion
Siemens S7-1200 programming is an essential skill for industrial automation engineers and technicians. The basics of Siemens S7-1200 programming include understanding the hardware configuration, software requirements, and basic programming instructions. Advanced programming techniques in Siemens S7-1200 programming include structured text programming, function block diagram programming, sequential function chart programming, and modular programming. Advanced networking and debugging techniques are also important for developing and maintaining complex control systems. With the increasing demand for automation in industry, learning Siemens S7-1200 programming is a valuable skill that can lead to a rewarding career in automation and control engineering.
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