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page 1
Integration and Automation
of
Manufacturing Systems
by: Hugh Jack
© Copyright 1993-2001, Hugh Jack
page 2
PREFACE
1.
INTEGRATED AND AUTOMATED MANUFACTURING . . . .13
1.1
INTRODUCTION
13
1.1.1
Why Integrate?
13
1.1.2
Why Automate?
14
1.2
THE BIG PICTURE
16
1.2.1
CAD/CAM?
17
1.2.2
The Architecture of Integration
17
1.2.3
General Concepts
19
1.3
PRACTICE PROBLEMS
22
2.
AN INTRODUCTION TO LINUX/UNIX . . . . . . . . . . . . . . . . . . .23
2.1
OVERVIEW
23
2.1.1
What is it?
23
2.1.2
A (Brief) History
24
2.1.3
Hardware required and supported
25
2.1.4
Applications and uses
25
2.1.5
Advantages and Disadvantages
26
2.1.6
Getting It
26
2.1.7
Distributions
27
2.1.8
Installing
27
2.2
USING LINUX
28
2.2.1
Some Terminology
28
2.2.2
File and directories
29
2.2.3
User accounts and root
31
2.2.4
Processes
33
2.3
NETWORKING
34
2.3.1
Security
35
2.4
INTERMEDIATE CONCEPTS
35
2.4.1
Shells
35
2.4.2
X-Windows
36
2.4.3
Configuring
36
2.4.4
Desktop Tools
37
2.5
LABORATORY - A LINUX SERVER
37
2.6
TUTORIAL - INSTALLING LINUX
38
2.7
TUTORIAL - USING LINUX
40
2.8
REFERENCES
41
3.
AN INTRODUCTION TO C/C++ PROGRAMMING . . . . . . . . .43
3.1
INTRODUCTION
43
3.2
PROGRAM PARTS
44
3.3
CLASSES AND OVERLOADING
50
3.4
HOW A ‘C’ COMPILER WORKS
52
page 3
3.5
STRUCTURED ‘C’ CODE
53
3.6
COMPILING C PROGRAMS IN LINUX
54
3.6.1
Makefiles
55
3.7
ARCHITECTURE OF ‘C’ PROGRAMS (TOP-DOWN)
56
3.7.1
How?
56
3.7.2
Why?
57
3.8
CREATING TOP DOWN PROGRAMS
58
3.9
CASE STUDY - THE BEAMCAD PROGRAM
59
3.9.1
Objectives:
59
3.9.2
Problem Definition:
59
3.9.3
User Interface:
59
Screen Layout (also see figure):
59
Input:
60
Output:
60
Help:
60
Error Checking:
61
Miscellaneous:
61
3.9.4
Flow Program:
62
3.9.5
Expand Program:
62
3.9.6
Testing and Debugging:
64
3.9.7
Documentation
65
Users Manual:
65
Programmers Manual:
65
3.9.8
Listing of BeamCAD Program.
65
3.10
PRACTICE PROBLEMS
66
3.11
LABORATORY - C PROGRAMMING
66
4.
NETWORK COMMUNICATION . . . . . . . . . . . . . . . . . . . . . . . . .68
4.1
INTRODUCTION
68
4.2
NETWORKS
69
4.2.1
Topology
69
4.2.2
OSI Network Model
71
4.2.3
Networking Hardware
73
4.2.4
Control Network Issues
75
4.2.5
Ethernet
76
4.2.6
SLIP and PPP
77
4.3
INTERNET
78
4.3.1
Computer Addresses
79
4.3.2
Computer Ports
80
Mail Transfer Protocols
81
FTP - File Transfer Protocol
81
HTTP - Hypertext Transfer Protocol
81
4.3.3
Security
82
Firewalls and IP Masquerading
84
4.4
FORMATS
85
page 4
4.4.1
HTML
85
4.4.2
URLs
87
4.4.3
Encryption
88
4.4.4
Clients and Servers
88
4.4.5
Java
89
4.4.6
Javascript
89
4.4.7
CGI
89
4.5
NETWORKING IN LINUX
89
4.5.1
Network Programming in Linux
91
4.6
DESIGN CASES
102
4.7
SUMMARY
103
4.8
PRACTICE PROBLEMS
103
4.9
LABORATORY - NETWORKING
104
4.9.1
Prelab
105
4.9.2
Laboratory
107
5.
DATABASES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
5.1
SQL AND RELATIONAL DATABASES
109
5.2
DATABASE ISSUES
114
5.3
LABORATORY - SQL FOR DATABASE INTEGRATION
114
5.4
LABORATORY - USING C FOR DATABASE CALLS
116
6.
COMMUNICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
6.1
SERIAL COMMUNICATIONS
119
6.1.1
RS-232
122
6.2
SERIAL COMMUNICATIONS UNDER LINUX
125
6.3
PARALLEL COMMUNICATIONS
129
6.4
LABORATORY - SERIAL INTERFACING AND PROGRAMMING
130
6.5
LABORATORY - STEPPER MOTOR CONTROLLER
130
7.
PROGRAMMABLE LOGIC CONTROLLERS (PLCs) . . . . . . .134
7.1
BASIC LADDER LOGIC
136
7.2
WHAT DOES LADDER LOGIC DO?
138
7.2.1
Connecting A PLC To A Process
139
7.2.2
PLC Operation
139
7.3
LADDER LOGIC
141
7.3.1
Relay Terminology
144
7.3.2
Ladder Logic Inputs
146
7.3.3
Ladder Logic Outputs
147
7.4
LADDER DIAGRAMS
147
7.4.1
Ladder Logic Design
148
7.4.2
A More Complicated Example of Design
150
7.5
TIMERS/COUNTERS/LATCHES
151
page 5
7.6
LATCHES
152
7.7
TIMERS
153
7.8
COUNTERS
157
7.9
DESIGN AND SAFETY
159
7.9.1
FLOW CHARTS
160
7.10
SAFETY
160
7.10.1
Grounding
161
7.10.2
Programming/Wiring
162
7.10.3
PLC Safety Rules
162
7.10.4
Troubleshooting
163
7.11
DESIGN CASES
164
7.11.1
DEADMAN SWITCH
164
7.11.2
CONVEYOR
165
7.11.3
ACCEPT/REJECT SORTING
165
7.11.4
SHEAR PRESS
166
7.12
ADDRESSING
168
7.12.1
Data Files
169
Inputs and Outputs
172
User Numerical Memory
172
Timer Counter Memory
172
PLC Status Bits (for PLC-5s)
173
User Function Memory
174
7.13
INSTRUCTION TYPES
174
7.13.1
Program Control Structures
175
7.13.2
Branching and Looping
175
Immediate I/O Instructions
179
Fault Detection and Interrupts
181
7.13.3
Basic Data Handling
182
Move Functions
182
7.14
MATH FUNCTIONS
184
7.15
LOGICAL FUNCTIONS
191
7.15.1
Comparison of Values
191
7.16
BINARY FUNCTIONS
193
7.17
ADVANCED DATA HANDLING
194
7.17.1
Multiple Data Value Functions
195
7.17.2
Block Transfer Functions
196
7.18
COMPLEX FUNCTIONS
198
7.18.1
Shift Registers
198
7.18.2
Stacks
199
7.18.3
Sequencers
200
7.19
ASCII FUNCTIONS
202
7.20
DESIGN TECHNIQUES
203
7.20.1
State Diagrams
203
7.21
DESIGN CASES
206
7.21.1
If-Then
207
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