The Impact of PLC

Program Architecture
on Production Line
Efficiency
Standards
Certification Case Study of a Control System
Education & Training
Publishing Rewrite
Conferences & Exhibits
Presenters

George Walters Eric Bryla

Principal Engineer President
Walters Controls NexCtrl Inc.
Slippery Rock, PA West Lawn, PA

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Introduction

• PLCs are becoming more sophisticated

• Programmers are becoming more sophisticated
• PLC software is different than most other software

Often seen by the end-user

Often used as a troubleshooting tool

Developers must program with the end-user in mind
• Case study: Control system rewrite

Food production line

Same PLC and I/O, completely new program

Same equipment, same process, same operators

Production efficiency up 5.5%

Rewrite paid for itself in a few months

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Outline

• Architecture Comparison
• Benefits of the New Program
• Looking Ahead

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Original Architecture:
Control of Output Devices

• Device classes

Two-way valve, reversing motor starter, VFD, etc.
• User-Defined Datatype (UDT) for each device class
• Subroutine for each device class
• For each device:

Create data tag, type is the device class UDT

Program inputs in the data tag

Call subroutine

Assign outputs in the data tag to real-world outputs

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New Architecture:
Control of Output Devices

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Original Architecture:
Hand / Off / Auto Control

• Device UDT has DINT (32-bit integer) named HOA

0 = Off mode

1 = Auto mode

2 = Hand mode
• HMI writes mode requests to a table
• Device subroutine

Processes requests

Sets new mode

Writes mode back to table for HMI

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New Architecture:
Hand / Off / Auto Control

• Global tables of bits

Requests: request hand, request off, request auto

Status: in hand, in off, in auto
• Centralized handler

Processes requests

Sets status

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Original Architecture:
Alarm Handling

• UDT for alarms

• UDT for device class includes alarm tag
• Device subroutine

Programs fields in the alarm tag

Condition bit

Alarm timer

Acknowledge bit

Calls alarm subroutine

Sets ALM bit

Reacts to alarm

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New Architecture:
Alarm Handling

• Global alarm table

• Logic for latching alarms, grouped by areas
• Centralized handler

Alarm acknowledge

Alarm silence

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Benefits of the New Program:
Overall Control System is Simpler

• Simplified PLC Code Matches Skills of Labor Pool

• Benefit

Reduced downtime

Faster Change Over Time

Leveraged Maintenance and Engineering Training

Flexibility for Modification and Improvements at the Plant Level
• Recipe functions migrated to existing plant-wide system
• Benefit

Eliminated custom software that could not be modified

Leverages existing, proven recipe system

Recipe Data Maintained and not Modified

Recipe Download and Batch Scheduler Data Transfer faster

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Benefit of Minimal Screen Changes, Phase
Changes, and Recipe Changes.

• Operators Needed Limited Training

• Changes were Focused on PLC Architecture
• S88 Phases Layout was Maintained

Old Screen New Screen

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Benefits of the New Program:
PLC Memory Usage Reduced

• Functionality was moved into the PLC

Batch and Recipe execution Related logic

Reused All Batch Reporting SQL Stored Procedures

PLC via HMI instead of a Custom Batch Manager Program
initiated the SQL Procedures.
• Still, memory size reduced by 14%
• Memory could be reduced even further if needed
• Original program

Using device subroutines saved some memory

UDT-based data tag for each device and alarm wasted memory
• Benefit

More memory available for expansion

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Benefits of the New Program:
PLC Scan Time Reduced

• Scan time reduced from approx 220ms to 18ms

• More than an order of magnitude faster!

Eliminated subroutine jumps for each device and alarm

Efficient, table based handling of hand/off/auto and alarms
• Benefit

PID loops updated faster

Faster and more consistent response to inputs

More logic can be added without worrying about scan time

Better Product Quality with improved loop control

Better Recipe and Batching Data Transfer to SQL Server

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Benefits of the New Program:
PLC Program Better for Troubleshooting

• Each area of the line has three program routines

Auto logic

Output logic

Alarm logic
• Other code is in separate routines

Hand/off/auto handler

Alarm handler
• Benefit

Easy to browse logic

All three routines can be viewed at the same time

End-user not distracted by code they are not interested in

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Benefits of the New Program:
PLC Program is Simpler

• No indexed addressing in code the end-user sees

• Subroutines only used to organize code

No subroutines called more than once per scan

No subroutines called with parameters
• Logic for devices and alarms is simple and easy to find
• Benefits

Easy for technicians to use the program for troubleshooting

Easier for developers too!

Easy to startup: Better product and faster production the first day

Reduced material and product waste

Programming that matches training courses

5.5% Increase in Line Productivity

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Looking Ahead

• Original program and new program both follow sound,

legitimate programming philosophies
• This case study suggests:

PLC architecture can have a significant impact on efficiency

Simplicity has advantages over sophistication
• We are not claiming the best way to write PLC programs
• This merits further study

What should programs look like?

How do you use increasing power, yet keep programs simple?

Can we eliminate the need for end-users to use the program?

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Conclusion

• Natural inclination: programming style oriented more

toward the developer than the end-user
• End-users ability to use the program impacts efficiency
• New program favors simplicity over sophistication
• Line is 5.5% more efficient with new program
• PLC program architecture merits further study

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