Automation with multiple subsystems

SKILLS / MAIN GOALS

At the end of this module the students will be capable of developing automation systems for machines and/or processes that are composed of several subsystems.

Processes, machines and systems
Splitting a machine in several smaller machines
Structuring the application in function blocks
Using parametric function blocks
Develop of a system with subsystems
Organization, structuring and good practices
Programmable controllers: counters, multibit instructions, libraries and function blocks, analysis and diagnostic resources

GAMIFIED CONTEXT

In this module the student needs to develop an automation system for an automatic warehousing system with 10 columns and 5 floors. To do that the student will learn how to divide the project in small functional parts, implement their unitary controls and integrate everything.

MATERIALS AND METHODS

Students will learn the contents by developing automation systems for equipment with interconnected and interlocked subsystems. They will be provided with all the instructions, theory and contents required.

TECHNOLOGY OPTIONS

In this module, the professor may use tools such as Codesys Development, that is free, WinPCL7 which has demo and lite free versions, Simatic Manager, TIA Portal or Logix5000. Naturally, if the institution decides to use a Rockwell or Siemens system, it needs to provide licenses to the students.

Importante note: TIA Portal can be downloaded and used fully operational for 21 days in trial mode, and it’s possible for a student to do all the module in that time period if the student is dedicated exclusivelly to the module.

CHALLENGE/TASK VALIDATION

In this module the students are required to answers questions in forms, as well as to upload small videos with limited duration, and attach the link when delivering the tasks.

MODULE STRUCTURE IN CHALLENGES

CHALLENGE 1

SEMI-AUTOMATIC OPERATION OF THE WAREHOUSE SYSTEM

Project: the student is required to develop a solution to enable semi-automatic operation of the equipment.

Tasks:

Understanding the application
Initial organization
Manual operation
Moving to pre-defined positions
Moving with speed control
Moving to user-defined positions

Automation contents: indirect addressing, inspection of objects, POUs, IEC61131-3, function X functional block, multibit operations.

CHALLENGE 2

SAFE OPERATION IN MULTI USER

SCADA SYSTEM

Project: the student is required to implement feature to define the operators who are responsible for operating specific machines, so that one operator will not operate the wrong machine by mistake. That’s necessary because the same SCADA system is used by many operators, to operate different machines.