Combining the controller with visualisation to simplify machine design
03/10/2012 Lenze Ltd
All-in-one panel controllers reduce build costsOften modern production machinery requires a controller in the form of a PLC or Soft PLC plus a HMI for operator control. Using two devices means increased purchase logistics, more space in the machine and more time to install and cable. The new Lenze p500 controller does away with these increased costs by combining touchscreen visualisa-tion with CoDeSys 3 based PLC control. An additional option adds mo-tion control to PLCopen Parts 1 and 2. Available with 7", 10.4" and 15" screens, the p500 is maintenance free, robust and versatile. It combines with an advanced software package for control, motion and visualisa-tion to reduce the cost of machine building.
The p500 takes advantage of recent developments in control technology to deliver high performance and user-friendly features. A 1.6 GHz Atom™ pro-cessor from Intel® and 1GB of internal RAM guarantee the kind of perfor-mance that can easily cope with even complex control and visualisation ap-plications. The chip, which was specially developed for battery-operated products, is extremely economical in terms of power usage. This means that the p500 does not require a fan so it can be installed in areas where cooling is virtually impossible, furthermore the front face is enclosed to IP65. As it does not use a conventional hard drive, there are no rotating parts making it particularly resistant to shock and vibrations. However, this is not the only aspect that makes the p500 virtually maintenance-free, as two other features also have a part to play. Firstly, the buffer battery typically used in industrial PCs has been replaced by a SuperCap capacitor, meaning that it is no longer necessary to replace the battery every two years. Secondly, LEDs are used for backlighting the touch-sensitive TFT display instead of conventional fluo-rescent tubes. Not only does LED technology offer the key advantage of con-suming less power, it also allows for a more compact design, improved screen contrast and a very long life. These factors guarantee good readabil-ity, even under the most unfavourable of lighting conditions.
A 2 GB internal flash memory has been integrated for mass storage in place of a hard disc. This flash memory is used for the operating system and other files such as drivers. However, the project data (including the retain data) is stored on an SD card. This makes it very easy to replace a unit or easily commission a new one.
Easy connectivity is important to give flexibility in system design. Standard equipment includes two 100 MBit Ethernet interfaces with an integrated switch. This means that both star and daisy-chain wiring are possible without the need for an additional switch. In addition to this, the controllers have one EtherCAT interface (master) and two USB ports. The latter can, for example, be used to connect a mouse or to backup the software to a USB flash drive. The modular design of the p500 can also be equipped with further communi-cation buses. An expansion card with two synchronised CAN buses that sup-port CANopen is available, also a PROFIBUS card.
Windows CE offers real-time capability and long availability
The choice of operating system is based on real-time performance and a long lifetime. Windows CE 6.0 is not only the Microsoft operating system with the longest availability (based on Microsoft's end-of-life schedule, OEMs can continue to install Windows CE 6.0 on their products up to 28 February 2022), it is also the only real-time capable system offered by Microsoft. It therefore allows users to enjoy a familiar standard operating system without having to sacrifice the determinism required for control applications.
The all-in-one engineering solution
Combining visualisation and control in a single panel controller offers several advantages. Firstly, since the separate controller is then dispensed with alto-gether, this saves valuable space in the control cabinet. Fewer automation components also mean less cost for design, during installation and when commissioning the machine. At the same time, the reliability of the complete system is increased, for example because fewer cable connections are re-quired.
The p500 exhibits its strengths for integration of visualisation and control functions on machines that use complex motion sequences. The integrated EtherCAT master is the key. Since the (optional) PROFIBUS and standard EtherCAT interface work in parallel, the p500 is also particularly well suited to cases in which automated system components are to be integrated using PROFIBUS, but which require a modern, fast motion control bus such as EtherCAT and a powerful control system.
The handling of retain data also serves to underline the advanced controller design. This data is not saved internally, but rather on the SD card, which makes commissioning particularly easy should a controller need to be re-placed. Without the programmer having to worry about it, an integrated UPS saves the retain data automatically in the event of a loss of power and there-by ensures that the system is ready to run. The internal UPS can also be ex-tended with an optional external UPS allowing extended time periods without current and larger data volumes to be saved.
A powerful software package
Software for visualisation and control is based around international standards with user-friendly adaptation. VisiWinNET® ranks among the most modern visualisation systems currently available on the market. It can be used for fast and effective implementation of even complex SCADA systems or FDA-compliant control centres. The system's exceptional strength lies in its com-plete integration into Microsoft® Visual Studio.NET. This guarantees optimum interoperability with all Windows functions - including access to multimedia content, databases and office applications. Modern object-oriented pro-gramming languages such as C# and Visual Basic.NET are also available. These allow software to be efficiently adapted to individual requirements and dedicated control elements and functions to be developed.
At the control level, applications are created using the IEC61131-compliant PLC Designer 3 programming environment, which is based on the CoDeSys 3 programming system for PLCs and industrial controllers. The standard sys-tem is modified here to secure reliable operation in automation systems. As such, Lenze is one of the first manufacturers to allow users to employ this new version of CoDeSys. Compared to pure CoDeSys 3, the PLC Designer offers a range of further functions, which are tailored precisely to the hard-ware. For example, the timing has been optimised and matched to the CAN card MC-CAN2, guaranteeing improved packing density for the best possible utilisation of bus performance on the CAN bus. Furthermore, the system has been extended to include a gateway function, which permits engineering software to gain access from the controller all the way to field level.
For implementation of motion control functionality, the PLC Designer contains libraries with certified motion modules based on PLCopen Part I and II, as well as functions for implementation of electronic cam discs, electronic cam groups or 3D numeric control.
Summary
Lenze's new p500 panel controller offers everything needed to cater to the system with regard to computing power, ease of operation, energy efficiency and handling. Logic control (PLC), motion control and visualisation are com-bined in a compact single platform. This approach offers cost advantages over traditional solutions with dedicated motion and sequence controls and reduces costs through both its simplified engineering and increased reliabil-ity. Long term security is assured by compliance with industrial standards. The new range of panel controllers fits seamlessly into Lenze's product port-folio, allowing users to implement precisely tailored decentralised and central architectures.
For further information, please contact Geoff Spear:
Lenze Ltd
Fraser Road, Priory Business Park
Bedford MK44 3WH
Phone: +44 1234 321321
Fax: +44 1234 355299
sales@Lenze.co.uk
Web: www.lenze.co.uk
Print this articleShare article:
Process and Control Today are not responsible for the content of submitted or externally produced articles and images. Click here to email us about any errors or omissions contained within this article.