CA2767578C - Methods and apparatus for an improved motor control center - Google Patents
Methods and apparatus for an improved motor control center Download PDFInfo
- Publication number
- CA2767578C CA2767578C CA2767578A CA2767578A CA2767578C CA 2767578 C CA2767578 C CA 2767578C CA 2767578 A CA2767578 A CA 2767578A CA 2767578 A CA2767578 A CA 2767578A CA 2767578 C CA2767578 C CA 2767578C
- Authority
- CA
- Canada
- Prior art keywords
- functional module
- programmable logic
- motor control
- control center
- logic controller
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Active
Links
Classifications
-
- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/04—Programme control other than numerical control, i.e. in sequence controllers or logic controllers
- G05B19/042—Programme control other than numerical control, i.e. in sequence controllers or logic controllers using digital processors
- G05B19/0426—Programming the control sequence
-
- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/20—Pc systems
- G05B2219/25—Pc structure of the system
- G05B2219/25096—Detect addresses of connected I-O, modules
-
- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/20—Pc systems
- G05B2219/25—Pc structure of the system
- G05B2219/25099—Detect configuration I-O and select needed program
-
- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/20—Pc systems
- G05B2219/25—Pc structure of the system
- G05B2219/25101—Detect connected module, load corresponding parameters, variables into module
Abstract
Methods, apparatus, and systems are provided for operating a motor control center. The invention includes determining a hardware configuration of functional modules within a motor control center; downloading the hardware configuration to a programmable logic controller; configuring a program to run on the programmable logic controller based on the hardware configuration; and executing the program. Numerous additional aspects are disclosed.
Description
METHODS AND APPARATUS FOR AN IMPROVED
MOTOR CONTROL CENTER
FIELD OF THE INVENTION
The present invention generally relates to motor control centers, and more particularly to using programmable logic controllers to control and monitor motor control center components.
BACKGROUND OF THE INVENTION
Motor Control Centers (MCCs) are used to provide modular, centralized control over large industrial motors such as those used in manufacturing robots and heavy machinery. MCCs typically include various different types of functional units or modules such as motor overload sensors, soft starters, variable frequency drives, etc. The functional modules are housed in a centralized enclosure and are coupled to corresponding motors.
Such MCCs and their component modules are designed to be very.
reliable, very fast, and as inexpensive as possible.
Particularly because of the high power switching involved, MCCs must be reliable in order to be safe. Further, MCCs are typically used in real time applications and thus, MCCs must have very fast and consistent response times. . Conventionally, in order to meet these requirements, MCCs have been kept very simple and the processing capabilities have been restricted to basic functionality that can be implemented with relatively simple logic and deterministic response times. However, there is a need for more sophisticated monitoring and control over motors and the various types of functional units used within MCCs.
SUMMARY OF THE INVENTION
The embodiments of the present invention generally relate to methods and apparatus for operating MCCs, and more particularly, to operation of controllers for monitoring and controlling MCCs.
In some embodiments, the present invention provides a method of operating a motor control center. The method includes determining a hardware configuration; downloading the hardware configuration to a programmable logic controller; configuring a program to run on the programmable logic controller based on the hardware configuration; and executing the program.
In some other embodiments, the present invention provides a motor control center system. The motor control center system includes a frame adapted to provide a plurality of functional module slots; a busbar coupled to the frame and the functional
MOTOR CONTROL CENTER
FIELD OF THE INVENTION
The present invention generally relates to motor control centers, and more particularly to using programmable logic controllers to control and monitor motor control center components.
BACKGROUND OF THE INVENTION
Motor Control Centers (MCCs) are used to provide modular, centralized control over large industrial motors such as those used in manufacturing robots and heavy machinery. MCCs typically include various different types of functional units or modules such as motor overload sensors, soft starters, variable frequency drives, etc. The functional modules are housed in a centralized enclosure and are coupled to corresponding motors.
Such MCCs and their component modules are designed to be very.
reliable, very fast, and as inexpensive as possible.
Particularly because of the high power switching involved, MCCs must be reliable in order to be safe. Further, MCCs are typically used in real time applications and thus, MCCs must have very fast and consistent response times. . Conventionally, in order to meet these requirements, MCCs have been kept very simple and the processing capabilities have been restricted to basic functionality that can be implemented with relatively simple logic and deterministic response times. However, there is a need for more sophisticated monitoring and control over motors and the various types of functional units used within MCCs.
SUMMARY OF THE INVENTION
The embodiments of the present invention generally relate to methods and apparatus for operating MCCs, and more particularly, to operation of controllers for monitoring and controlling MCCs.
In some embodiments, the present invention provides a method of operating a motor control center. The method includes determining a hardware configuration; downloading the hardware configuration to a programmable logic controller; configuring a program to run on the programmable logic controller based on the hardware configuration; and executing the program.
In some other embodiments, the present invention provides a motor control center system. The motor control center system includes a frame adapted to provide a plurality of functional module slots; a busbar coupled to the frame and the functional
2 module slots; a network coupled to the frame and the functional module slots; a programmable logic controller module adapted to couple to a functional module slot; and a plurality of functional modules adapted to couple to functional modules slots. The programmable logic controller module includes a programmable logic controller adapted to receive a hardware configuration; download the hardware configuration into a memory of the programmable logic controller; configure a program to run on the programmable logic controller based on the hardware configuration; and execute the program.
In still yet other embodiments, the present invention provides a programmable logic controller module for a motor control center. The programmable logic controller module includes a programmable logic controller adapted to receive a hardware configuration; download the hardware configuration into a memory of the programmable logic controller; configure a program to run on the programmable logic controller based on the hardware configuration; and execute the program.
According to one aspect of the present disclosure, there is provided a method of operating a motor control center comprising: determining a hardware configuration, wherein the hardware configuration defines one or more functional module installed in the motor control center; downloading the hardware configuration to a programmable logic controller; configuring a resident program on the programmable logic controller based on the hardware configuration to operate with the one or more functional module defined in the hardware configuration;
executing the program; storing operational data of the one or more functional module into at least one data structure that corresponds to the one or more functional module in a known
In still yet other embodiments, the present invention provides a programmable logic controller module for a motor control center. The programmable logic controller module includes a programmable logic controller adapted to receive a hardware configuration; download the hardware configuration into a memory of the programmable logic controller; configure a program to run on the programmable logic controller based on the hardware configuration; and execute the program.
According to one aspect of the present disclosure, there is provided a method of operating a motor control center comprising: determining a hardware configuration, wherein the hardware configuration defines one or more functional module installed in the motor control center; downloading the hardware configuration to a programmable logic controller; configuring a resident program on the programmable logic controller based on the hardware configuration to operate with the one or more functional module defined in the hardware configuration;
executing the program; storing operational data of the one or more functional module into at least one data structure that corresponds to the one or more functional module in a known
3 memory location of the programmable logic controller, wherein a memory space of the known memory location defined by the data structure reflects the status of at least one parameter of the one or more functional module in real time; and determining a status of the one or more functional module in real time from the memory space of stored operational data of the one or more functional module.
According to another aspect of the present disclosure, there is provided a motor control center comprising: a frame adapted to provide a plurality of functional module slots; a busbar coupled to the frame and the functional module slots; a network coupled to the frame and the functional module slots; a programmable logic controller module adapted to couple to a functional module slot; and a plurality of functional modules adapted to couple to functional module slots, wherein the programmable logic controller module includes a programmable logic controller adapted to: receive a hardware configuration, wherein the hardware configuration defines the plurality of functional modules installed in the motor control center; download the hardware configuration into a memory of the programmable logic controller; configure a resident program on the programmable logic controller based on the hardware configuration to operate with the plurality of functional modules defined in the hardware configuration;
execute the program; store operational data of the plurality of functional modules into at least one data structure that corresponds to the plurality of functional modules in a known memory location of the programmable logic controller, wherein a memory space of the known memory location defined by the data structure reflects the status of at least one parameter of the plurality of functional modules in real time; and determine a 3a status of the plurality of functional modules in real time from the memory space of stored operational data of the plurality of functional modules.
According to still another aspect of the present disclosure, there is provided a programmable logic controller module for a motor control center, the programmable logic controller module comprising: a programmable logic controller adapted to: receive a hardware configuration, wherein the hardware configuration defines one or more functional module installed in the motor control center; download the hardware configuration into a memory of the programmable logic controller; configure a resident program on the programmable logic controller based on the hardware configuration to operate with the one or more functional module defined in the hardware configuration; execute the program; store operational data of the one or more functional module into at least one data structure that corresponds to the one or more functional module in a known memory location of the programmable logic controller, wherein a memory space of the known memory location defined by the data structure reflects the status of at least one parameter of the one or more functional module in real time; and determine a status of the one or more functional module in real time from the memory space of stored operational data of the one or more functional module.
These and other features and aspects of the present invention will become more fully apparent from the following detailed description of exemplary embodiments, the appended claims and the accompanying drawings.
3b BRIEF DESCRIPTION OF THE DRAWINGS
An artisan of ordinary skill will understand that the drawings, described below, are for illustration purposes only.
The drawings are not intended to limit the scope of the present teachings in any way.
3c FIG. 1 is a schematic view of an example motor control center according to some embodiments of the present invention.
FIG. lA is an enlarged schematic view of an example programmable logic controller module according to some embodiments of the present invention.
FIG. 2 is a block diagram depicting an example of a system architecture of a motor control center including a programmable logic controller module according to some embodiments of the present invention.
FIG. 3 is a flow chart depicting a conventional method of operating a conventional programmable logic controller according to the prior art.
FIG. 4 is a flow chart depicting an example method of operating a programmable logic controller according to some embodiments of the present invention.
FIG. 5 is a flow chart depicting details of the Operate MCC
Function of the flow chart of FIG. 4 according to some embodiments of the present invention.
FiGs. 6A, 6B, and 60 are block diagrams depicting a representation of example data structures for use with various types of functional modules according to some embodiments of the present invention.
According to another aspect of the present disclosure, there is provided a motor control center comprising: a frame adapted to provide a plurality of functional module slots; a busbar coupled to the frame and the functional module slots; a network coupled to the frame and the functional module slots; a programmable logic controller module adapted to couple to a functional module slot; and a plurality of functional modules adapted to couple to functional module slots, wherein the programmable logic controller module includes a programmable logic controller adapted to: receive a hardware configuration, wherein the hardware configuration defines the plurality of functional modules installed in the motor control center; download the hardware configuration into a memory of the programmable logic controller; configure a resident program on the programmable logic controller based on the hardware configuration to operate with the plurality of functional modules defined in the hardware configuration;
execute the program; store operational data of the plurality of functional modules into at least one data structure that corresponds to the plurality of functional modules in a known memory location of the programmable logic controller, wherein a memory space of the known memory location defined by the data structure reflects the status of at least one parameter of the plurality of functional modules in real time; and determine a 3a status of the plurality of functional modules in real time from the memory space of stored operational data of the plurality of functional modules.
According to still another aspect of the present disclosure, there is provided a programmable logic controller module for a motor control center, the programmable logic controller module comprising: a programmable logic controller adapted to: receive a hardware configuration, wherein the hardware configuration defines one or more functional module installed in the motor control center; download the hardware configuration into a memory of the programmable logic controller; configure a resident program on the programmable logic controller based on the hardware configuration to operate with the one or more functional module defined in the hardware configuration; execute the program; store operational data of the one or more functional module into at least one data structure that corresponds to the one or more functional module in a known memory location of the programmable logic controller, wherein a memory space of the known memory location defined by the data structure reflects the status of at least one parameter of the one or more functional module in real time; and determine a status of the one or more functional module in real time from the memory space of stored operational data of the one or more functional module.
These and other features and aspects of the present invention will become more fully apparent from the following detailed description of exemplary embodiments, the appended claims and the accompanying drawings.
3b BRIEF DESCRIPTION OF THE DRAWINGS
An artisan of ordinary skill will understand that the drawings, described below, are for illustration purposes only.
The drawings are not intended to limit the scope of the present teachings in any way.
3c FIG. 1 is a schematic view of an example motor control center according to some embodiments of the present invention.
FIG. lA is an enlarged schematic view of an example programmable logic controller module according to some embodiments of the present invention.
FIG. 2 is a block diagram depicting an example of a system architecture of a motor control center including a programmable logic controller module according to some embodiments of the present invention.
FIG. 3 is a flow chart depicting a conventional method of operating a conventional programmable logic controller according to the prior art.
FIG. 4 is a flow chart depicting an example method of operating a programmable logic controller according to some embodiments of the present invention.
FIG. 5 is a flow chart depicting details of the Operate MCC
Function of the flow chart of FIG. 4 according to some embodiments of the present invention.
FiGs. 6A, 6B, and 60 are block diagrams depicting a representation of example data structures for use with various types of functional modules according to some embodiments of the present invention.
4 cp, 02767578 2012-01-06 DETAILED DESCRIPTION
For the purpose of interpreting this specification, whenever appropriate, terms used in the singular will also include the plural and vice versa. The use of "or" is intended to mean "and/or" unless stated otherwise. The use of "a" herein is intended to mean "one or more" unless stated otherwise or where the use of "one or more" is clearly inappropriate. The use of "comprise," "comprises," "comprising," "include," "includes,"
and "including" are interchangeable and not intended to be limiting. Furthermore, where the description of one or more embodiments uses the term "comprising," those of ordinary skill in the art would understand that, in some specific instances, the embodiment or embodiments can be alternatively described using the language "consisting essentially of" and/or "consisting of."
While the present teachings are described in conjunction with various embodiments, it is not intended that the present teachings be limited to such embodiments. On the contrary, the present teachings encompass various alternatives, modifications, and equivalents, as will be appreciated by those of ordinary skill in the art.
The present invention provides an improved method of operating an MCC. According to embodiments of the present invention, a programmable logic controller (PLC) is provided that is adapted to detect and react to the presence or absence of functional modules and still continue to operate the MCC even if one or more functional modules are missing, mis-configured, or inoperative. Further, the PLC executes a program that is adapted to dynamically configure the MCC to use the detected ak 02767578 2012-01-06 functional modules. The program is able to draw upon a library of predefined data structures that each correspond to a different functional module and standardize communication with, and control of, the functional modules. Thus, third party interface software can access and control the functional modules in a manner similar to the way an application program may access a lower level program via a software application programming interface (API). Unlike such conventional software systems however, the present invention is adapted to facilitate access and control the functional module hardware in a real time environment within predefined timeframes.
Turning to FIG. 1, an example motor control center 100 is depicted. The example MCC 100 includes a frame 102 (e.g., a vertical structure for mounting components) that can be, for example, wall, ceiling, floor, or rack mounted. The frame 102 houses three-phase busbars (not shown) that may span the length of the frame 102 and facilitate power distribution. In some embodiments, the busbars may additionally span the MCC 100 horizontally in, for example, a top portion 104 of the MCC 100 while a bottom portion 106 of the MCC 100 may include an access area for wiring installation. In some embodiments this arrangement may be reversed and/or both the horizontal bus bars and the access area may be disposed adjacent each other at either end of the MCC 100.
Functional module slots 108 (only one labeled with a reference numeral) are disposed along- the length of the frame 102. In some embodiments, the functional module slots 108 may be arranged in multiple vertical columns (e.g., two columns are shown in the example of FIG. 1). The slots 108 are adapted to receive functional modules 110 (also known as configurable units or buckets). The functional modules 110 (only one labeled with a reference numeral in FIG. 1) may include various different types. For example, the functional modules 110 may include motor overload sensors, soft starter circuits, variable frequency drivers, low voltage breakers, power monitoring circuits, etc. Examples of such functional modules 110 include Model SIMOCODE (a motor overload sensor), Model MM440 (a variable frequency driver), Model 3RW44 (a soft starter circuit), Model 3WL (a low voltage circuit breaker), and Models PA03200 and 9300 (power monitoring devices) each of which is manufactured by, and commercially available from, Siemens Energy & Automation, Inc. headquartered in Alpharetta, Georgia. In some embodiments, the slots 108 and the corresponding functional modules 110 may have standardized dimensions (e.g., 12 or 18 inch height) and form factors to facilitate the modularity of the hardware. In other words, the MCC 100 may be adapted to allow any of the functional modules 110 to be inserted onto any of the slots 108.
By inserting a functional module 110 into a slot 108, a connection between the MCC 100 and the functional module 110 is established. This may include both a connection to the busbar as well as to a network 112 (e.g., a data network) that couples all of the slots 108 together to facilitate communication with installed functional modules 110. Thus the functional modules may include communications facilities (e.g., network communications ports, serial ports, Ethernet ports, USB ports, etc.). The network 112 may be disposed within one or more wire-ways 114 that span the length of the frame 102. In some embodiments, the wire-ways 114 may be disposed along the sides and/or in the middle of the MCC 100. In addition, the wire-ways may also contain wiring from the functional modules 110 to motors in the field.
Looking at both FIG. 1 and FIG. 1A now, the MCC 100 also includes a PLC module 116 that can be inserted into a slot 108.
Note that the PLC module 116 depicted in FIG. lA is enlarged to show the details of the PLC module 116. In some embodiments, the PLC module 116 maybe inserted into any slot 108 and in others, a special slot 108 maybe provided for the PLC module 116. The PLC module 116 may include several components. For example, the PLC module 116 may include terminals 118 for coupling to the network 112 as well as to an external network (not shown). In some embodiments, the external network may be an Ethernet network or other type of network. The terminals 118 may also include power terminals for coupling the PLC module 116 to the motors. Power terminals may include short circuit protection fuses 120. A power supply 122 for the PLC 124 itself may also be included. The PLC 124 may be, for example, a Model S7-315-2DP/PN manufactured by, and commercially available from, Siemens Energy & Automation, Inc. The PLC 124 includes a controller and internal memory for storing and executing a PLC
program which will be described in more detail below.
In some embodiments, the functional modules 110 may be inserted into any available slot. 108 and the MCC may address the functional modules 110 using a logical address and not a physical address. The use of logical addressing facilitates automated configuration of the functional modules 110. Thus, in ak 02767578 2012-01-06 such embodiments, a hardware configuration definition need not specify a physical location of the functional modules 110.
In operation, the functional modules 110 are adapted to be inserted and removed from the slots 108 without requiring shutting down power to the motors connected to the MCC 100.
Control of the PLC 124 may be accomplished via a human machine interface (HMI) 210 (see FIG. 2) that is coupled to the PLC 124 via the external network. As will be explained in more detail below, the PLC 124 is adapted to detect and gather data from the functional modules 110 via the network 112. The PLC 124 is further designed to receive control information from the HMI 210 and use the control information to operate and/or monitor the functional modules 110.
Turning now to FIG. 2, an example system architecture 200 for an MCC 100 is depicted. In some embodiments, the system 200 may be thought of as a three layer stack with a hardware layer 202 on the bottom, a PLC program. layer 204 above the hardware layer 202, and a HMI program layer 206 on top of the PLC program layer 204. In the example system 200 shown, each layer provides an abstraction of the layer below it to standardize and simplify control and monitoring of the motors coupled to the MCC. Thus, the PLC program layer 204 provides a programmatic interface to the hardware layer 202, and the HMI program. layer 206 provides a.
programmatic interface to the PLC program layer 204. In other words, use of the MCC of the present invention is simplified because knowledge of the details of interacting with the layer below the accessed layer is not required. The accessed layer takes care of those details and simply returns a requested value or effects execution of a requested action.
As discussed with reference to FIGs 1 and 1A, the hardware includes an MCC 100 which may include a number of various different types of functional modules 110 operatively coupled to a PLC 124 via a network 112. Also as mentioned above, the MMC
100 may be coupled to an HMI device 208 (e.g., a computer terminal, a personal computer, etc.) via and external network.
210. The external network 210 is adapted to allow data transfer between the HMI device 208 and the PLC 124. Note that in some embodiments, a plurality of MMCs 100 may be coupled to and controlled via one or more HMI devices 208 even though only one MCC 100 and one HMI device 208 are shown in FIG. 2. Also note that in some embodiments, the functional modules 110 within the MCC 100 may operate as network slaves to the PLC 124 which may operate as a network master. In alternative embodiments, the network 112 may be implemented as a peer to peer network wherein each node functions as a peer on the network 112.
The PLC program layer 204 includes a data management process 212 that may be embodied as a program which executes on the PLC 124 and is operative to store and retrieve data about the operation of the functional modules 110.. The data management process 212 communicates with the MCC 100 and the functional modules 110 via a logical network connection 214. In other words, logical network connection 214 logically couples the data management process 212 running on the PLC 124 and the functional modules 110 via the physical network 112.
The data management process 212 also stores the data about the operation of the functional modules 110 in the PLC 124 memory but organized in data structures 216 that correspond to the functional modules 110. Examples of these data structures ak 02767578 2012-01-06 216 are illustrated below with respect to FIGs. 6A to 6C. The memory space of the PLC 124 that stores the data structures 216 for the data management process 212 may be mapped to the functional modules 110 so that known memory locations defined by the data structures 216 reflect the status of monitored parameters of the functional modules 110 in real time.
Likewise, control of the functional modules 110 may be implemented by writing values to known memory locations defined by the data structures 216 that correspond to input parameters to the functional modules 110.
The HMI program laver 206 communicates values stored in the data structures 216 via logical connections 218 to a human operator and/or to an interface program 220 that executes on the HMI device 208. The data may be displayed on the HMI device 208 by the interface program 220 in a format easily comprehensible by an operator. In addition, the interface program 220 is adapted to receive input from an operator and to communicate the operator's selections to the PLC 124 via the data management process 212. For example, an operator can configure a functional module for a particular motor controlled and monitored by a soft start functional module 110 by, for example, activating a graphical user interface control on the HMI device 208 which is logically coupled to a configuration parameter within the data structure 216 that corresponds to the soft start functional module 110.
Although the system 200 allows for the abstraction and standardization of the functional modules 110, the response time for both control and monitoring of the functional modules desirably remains deterministic and consistent. Thus, the ak 02767578 2012-01-06 system 100 of the present invention is implemented as a hard real-time operating system (RTOS) which, despite the abstraction layers, can serve requests received via the interface program 220 in nearly real-time.
In operation, the data management process 212 retrieves data from the MCC via the network and saves the data in the PLC
124 internal memory. The HMI interface program 220 retrieves the data for the functional modules 110 from the PLC 124 via the external network 210 and then displays this data on the HMI
device 208 (e.g., on a video screen) for the operator. In addition, display and control of the data management process 212 executing on the PLC 124 is available. The present invention is adapted to facilitate both the HMI program layer 206 and the PLC
program layer 204 to react to and display data from only the functional modules 110 actually installed in the MCC 100. In other words, a missing or inoperative functional module 110 will not cause an irrecoverable error that requires an operator intervention to continue or restart operation. In addition, the system architecture 200 is adapted to function with a wide variety of HMI programs from various manufactures without requiring propriety knowledge of the MCC 100 or the data management process 212.
Turning now to FIG. 3, a flow chart depicting operation of a conventional PLC according to the prior art is depicted.
Prior art MCCs require the creation of a PLC program specific to the MCC. In other words, prior art PLCs need to be custom programmed with software that matches the particular functional modules used in the particular MCC. In Steps 302, 304, and 306, the hardware configuration of the functional modules connected ak 02767578 2012-01-06 to the PLC and the programming in the PLC custom to that hardware configuration are downloaded into the PLC for the specific MCC. In Step 308, operation of the MCC is started. If programming has been downloaded for functional modules that are not actually present in the hardware configuration (e.g., a wrong configuration), a software and/or hardware fault is generated in the PLC in Step 310, which may result in the PLC
stopping operation entirely in a fault handling process 314 which includes Steps 316 and 318. If the hardware configuration contains a definition of functional modules that are not actually present on the network, a software and/or hardware fault is generated in Step 312 that may result in the PLC
stopping operation entirely in the fault handling process 314 which includes Steps 320 and 318.
The inability of prior art systems to identify what hardware is present and verify that the hardware is properly configured inhibits prior art systems from being able to use a single PLC program that adapts to the configured hardware. In fact, due to the lack of a single adaptable PLC program, operators are typically forced to create a "template" PLC
program, then modify the hardware configuration and the PLC
programming to match the hardware configuration.
Turning to FIG. 4, a method 400 of operating an MCC
according to the present invention is provided. The present invention provides a single standardized PLC program that is able to dynamically configure itself to match the hardware configuration of the MCC. In Step 402, the hardware configuration for all attached functional modules is defined.
In some embodiments, the hardware configuration for all.
ak 02767578 2012-01-06 installed functional modules may be determined automatically based on, for example, functional module identifiers. In Step 404, the hardware configuration is downloaded to the PLC.
Notably, the step of determining PLC programming custom to the hardware configuration (Step 304 in FIG. 3) and downloading the programing is not required in the method 400 of the present invention.
In Step 406, upon booting or restarting, operation of the MCC begins. The PLC program interrogates the hardware configuration, then configures the resident PLC program for operation with the hardware that is defined in the configuration. The PLC program uses the hardware configuration to draw upon a library of data structures that include the details for each type of functional module encountered. The appropriate data structures and associated program is selected and the resident PLC program configures itself. Notably, the present invention eliminates step 310 (FIG. 3) and the fault handling process 314 (FIG. 3) of the prior art. Since the PLC
program of the present invention configures itself to match the configuration of the hardware, the prior art software required to detect and process faults that result in requiring halting operation are eliminated. If a functional module that is configured but not actually found on the network is detected in Step 408, an I/O error is noted for indication to a monitoring system, but the PLC program continues operation without faulting by looping back to Step 406.
The present invention thus provides several advantages to operators of MCCs. The PLC program no longer requires customized programming and thus, operators have a standardized interface for all their applications. This means that the number of PLC programs that need to be maintained for backup/security reasons is limited. Servicing- is simplified because the hardware configuration can be quickly and automatically be created with the standard PLC program. This insures a short downtime even in the event of severe hardware failure requiring immediate replacement of multiple functional modules. The ability of the PLC to read its own hardware configuration during boot-up/power-on facilitates these advantages and allows the elimination of software requirements such as non-standard fault handling routines and customized programming for the PLC.
Turning to FIG. 5, the details of operating the MCC in Step 406 of FIG. 4 are illustrated. In Step 502, the PLC is started.
In Step 504, the PLC requests the list of functional modules installed in the MCC. This is part of the hardware configuration created in Step 402 (FIG. 4). In Step 506, the PLC
loops through the list of functional modules. In Step 508, for each module listed in the hardware configuration, a data structure is selected from a. library of data. structures and a pointer table is created in the PLC memory defining the valid functional modules on the network to process and how to process them. The table is populated with, for example, an input/output (I/O) address of the functional module, an I/O size of the functional module, and a device type identifier. This is repeated for each functional module until the end of the functional module list is reached, at which point the PLC enters into run mode in Step 510. In run mode, the PLC actively scans data from all of the attached functional modules. In Step 512, the PLC loops through the list of functional modules. For each module found, the PLC software manages the data transfer between the PLC and the functional module in Step 514. If a module is not available, the PLC goes to the next module. If the end of list is reached, the PLC loops back to the beginning of the list.
Turning to FIGs. 6A through 6C, three example data structures 602, 604, 606, for different types of functional modules are illustrated. These data structures 602, 604, 606 are complex data types that are updated during ,each read of data from the corresponding functional module. In addition, in some embodiments, configuration data may be sent back to the functional module from the PLC to adjust the Configuration without the use of external programming software. The example data structure 602 of FIG. 6A is for use with a motor overload functional module. .This example data structure 602 includes fields for storing metering data (e.g., current, voltage, power, etc.); an event log; diagnostic data, and device configuration data. The example data structure 604 of FIG. 6B is for use with a soft starter functional module. This particular example data structure 604 includes fields for storing metering data (e.g., current, voltage, power, etc.); an event log; diagnostic data;
device configuration data; a trip log; an error log; and statistical data. The data structure of FIG. 6C is for use with a variable frequency drive (VFD) functional module. This particular example data structure 606 includes fields for storing metering data (e.g., current, voltage, power, etc.); and device configuration data. Numerous other data structure formats may be used and many additional data structures for different types of functional modules may be employed.
The embodiments of the teachings have been described in an illustrative manner. It is to be understood that the terminology, which has been used, is intended to be in the nature of words of description rather than of limitation.
Many modifications and variations of the embodiments are possible in light of the above teachings. Therefore, within the scope of the appended claims, the embodiments can be practiced other than as specifically described.
For the purpose of interpreting this specification, whenever appropriate, terms used in the singular will also include the plural and vice versa. The use of "or" is intended to mean "and/or" unless stated otherwise. The use of "a" herein is intended to mean "one or more" unless stated otherwise or where the use of "one or more" is clearly inappropriate. The use of "comprise," "comprises," "comprising," "include," "includes,"
and "including" are interchangeable and not intended to be limiting. Furthermore, where the description of one or more embodiments uses the term "comprising," those of ordinary skill in the art would understand that, in some specific instances, the embodiment or embodiments can be alternatively described using the language "consisting essentially of" and/or "consisting of."
While the present teachings are described in conjunction with various embodiments, it is not intended that the present teachings be limited to such embodiments. On the contrary, the present teachings encompass various alternatives, modifications, and equivalents, as will be appreciated by those of ordinary skill in the art.
The present invention provides an improved method of operating an MCC. According to embodiments of the present invention, a programmable logic controller (PLC) is provided that is adapted to detect and react to the presence or absence of functional modules and still continue to operate the MCC even if one or more functional modules are missing, mis-configured, or inoperative. Further, the PLC executes a program that is adapted to dynamically configure the MCC to use the detected ak 02767578 2012-01-06 functional modules. The program is able to draw upon a library of predefined data structures that each correspond to a different functional module and standardize communication with, and control of, the functional modules. Thus, third party interface software can access and control the functional modules in a manner similar to the way an application program may access a lower level program via a software application programming interface (API). Unlike such conventional software systems however, the present invention is adapted to facilitate access and control the functional module hardware in a real time environment within predefined timeframes.
Turning to FIG. 1, an example motor control center 100 is depicted. The example MCC 100 includes a frame 102 (e.g., a vertical structure for mounting components) that can be, for example, wall, ceiling, floor, or rack mounted. The frame 102 houses three-phase busbars (not shown) that may span the length of the frame 102 and facilitate power distribution. In some embodiments, the busbars may additionally span the MCC 100 horizontally in, for example, a top portion 104 of the MCC 100 while a bottom portion 106 of the MCC 100 may include an access area for wiring installation. In some embodiments this arrangement may be reversed and/or both the horizontal bus bars and the access area may be disposed adjacent each other at either end of the MCC 100.
Functional module slots 108 (only one labeled with a reference numeral) are disposed along- the length of the frame 102. In some embodiments, the functional module slots 108 may be arranged in multiple vertical columns (e.g., two columns are shown in the example of FIG. 1). The slots 108 are adapted to receive functional modules 110 (also known as configurable units or buckets). The functional modules 110 (only one labeled with a reference numeral in FIG. 1) may include various different types. For example, the functional modules 110 may include motor overload sensors, soft starter circuits, variable frequency drivers, low voltage breakers, power monitoring circuits, etc. Examples of such functional modules 110 include Model SIMOCODE (a motor overload sensor), Model MM440 (a variable frequency driver), Model 3RW44 (a soft starter circuit), Model 3WL (a low voltage circuit breaker), and Models PA03200 and 9300 (power monitoring devices) each of which is manufactured by, and commercially available from, Siemens Energy & Automation, Inc. headquartered in Alpharetta, Georgia. In some embodiments, the slots 108 and the corresponding functional modules 110 may have standardized dimensions (e.g., 12 or 18 inch height) and form factors to facilitate the modularity of the hardware. In other words, the MCC 100 may be adapted to allow any of the functional modules 110 to be inserted onto any of the slots 108.
By inserting a functional module 110 into a slot 108, a connection between the MCC 100 and the functional module 110 is established. This may include both a connection to the busbar as well as to a network 112 (e.g., a data network) that couples all of the slots 108 together to facilitate communication with installed functional modules 110. Thus the functional modules may include communications facilities (e.g., network communications ports, serial ports, Ethernet ports, USB ports, etc.). The network 112 may be disposed within one or more wire-ways 114 that span the length of the frame 102. In some embodiments, the wire-ways 114 may be disposed along the sides and/or in the middle of the MCC 100. In addition, the wire-ways may also contain wiring from the functional modules 110 to motors in the field.
Looking at both FIG. 1 and FIG. 1A now, the MCC 100 also includes a PLC module 116 that can be inserted into a slot 108.
Note that the PLC module 116 depicted in FIG. lA is enlarged to show the details of the PLC module 116. In some embodiments, the PLC module 116 maybe inserted into any slot 108 and in others, a special slot 108 maybe provided for the PLC module 116. The PLC module 116 may include several components. For example, the PLC module 116 may include terminals 118 for coupling to the network 112 as well as to an external network (not shown). In some embodiments, the external network may be an Ethernet network or other type of network. The terminals 118 may also include power terminals for coupling the PLC module 116 to the motors. Power terminals may include short circuit protection fuses 120. A power supply 122 for the PLC 124 itself may also be included. The PLC 124 may be, for example, a Model S7-315-2DP/PN manufactured by, and commercially available from, Siemens Energy & Automation, Inc. The PLC 124 includes a controller and internal memory for storing and executing a PLC
program which will be described in more detail below.
In some embodiments, the functional modules 110 may be inserted into any available slot. 108 and the MCC may address the functional modules 110 using a logical address and not a physical address. The use of logical addressing facilitates automated configuration of the functional modules 110. Thus, in ak 02767578 2012-01-06 such embodiments, a hardware configuration definition need not specify a physical location of the functional modules 110.
In operation, the functional modules 110 are adapted to be inserted and removed from the slots 108 without requiring shutting down power to the motors connected to the MCC 100.
Control of the PLC 124 may be accomplished via a human machine interface (HMI) 210 (see FIG. 2) that is coupled to the PLC 124 via the external network. As will be explained in more detail below, the PLC 124 is adapted to detect and gather data from the functional modules 110 via the network 112. The PLC 124 is further designed to receive control information from the HMI 210 and use the control information to operate and/or monitor the functional modules 110.
Turning now to FIG. 2, an example system architecture 200 for an MCC 100 is depicted. In some embodiments, the system 200 may be thought of as a three layer stack with a hardware layer 202 on the bottom, a PLC program. layer 204 above the hardware layer 202, and a HMI program layer 206 on top of the PLC program layer 204. In the example system 200 shown, each layer provides an abstraction of the layer below it to standardize and simplify control and monitoring of the motors coupled to the MCC. Thus, the PLC program layer 204 provides a programmatic interface to the hardware layer 202, and the HMI program. layer 206 provides a.
programmatic interface to the PLC program layer 204. In other words, use of the MCC of the present invention is simplified because knowledge of the details of interacting with the layer below the accessed layer is not required. The accessed layer takes care of those details and simply returns a requested value or effects execution of a requested action.
As discussed with reference to FIGs 1 and 1A, the hardware includes an MCC 100 which may include a number of various different types of functional modules 110 operatively coupled to a PLC 124 via a network 112. Also as mentioned above, the MMC
100 may be coupled to an HMI device 208 (e.g., a computer terminal, a personal computer, etc.) via and external network.
210. The external network 210 is adapted to allow data transfer between the HMI device 208 and the PLC 124. Note that in some embodiments, a plurality of MMCs 100 may be coupled to and controlled via one or more HMI devices 208 even though only one MCC 100 and one HMI device 208 are shown in FIG. 2. Also note that in some embodiments, the functional modules 110 within the MCC 100 may operate as network slaves to the PLC 124 which may operate as a network master. In alternative embodiments, the network 112 may be implemented as a peer to peer network wherein each node functions as a peer on the network 112.
The PLC program layer 204 includes a data management process 212 that may be embodied as a program which executes on the PLC 124 and is operative to store and retrieve data about the operation of the functional modules 110.. The data management process 212 communicates with the MCC 100 and the functional modules 110 via a logical network connection 214. In other words, logical network connection 214 logically couples the data management process 212 running on the PLC 124 and the functional modules 110 via the physical network 112.
The data management process 212 also stores the data about the operation of the functional modules 110 in the PLC 124 memory but organized in data structures 216 that correspond to the functional modules 110. Examples of these data structures ak 02767578 2012-01-06 216 are illustrated below with respect to FIGs. 6A to 6C. The memory space of the PLC 124 that stores the data structures 216 for the data management process 212 may be mapped to the functional modules 110 so that known memory locations defined by the data structures 216 reflect the status of monitored parameters of the functional modules 110 in real time.
Likewise, control of the functional modules 110 may be implemented by writing values to known memory locations defined by the data structures 216 that correspond to input parameters to the functional modules 110.
The HMI program laver 206 communicates values stored in the data structures 216 via logical connections 218 to a human operator and/or to an interface program 220 that executes on the HMI device 208. The data may be displayed on the HMI device 208 by the interface program 220 in a format easily comprehensible by an operator. In addition, the interface program 220 is adapted to receive input from an operator and to communicate the operator's selections to the PLC 124 via the data management process 212. For example, an operator can configure a functional module for a particular motor controlled and monitored by a soft start functional module 110 by, for example, activating a graphical user interface control on the HMI device 208 which is logically coupled to a configuration parameter within the data structure 216 that corresponds to the soft start functional module 110.
Although the system 200 allows for the abstraction and standardization of the functional modules 110, the response time for both control and monitoring of the functional modules desirably remains deterministic and consistent. Thus, the ak 02767578 2012-01-06 system 100 of the present invention is implemented as a hard real-time operating system (RTOS) which, despite the abstraction layers, can serve requests received via the interface program 220 in nearly real-time.
In operation, the data management process 212 retrieves data from the MCC via the network and saves the data in the PLC
124 internal memory. The HMI interface program 220 retrieves the data for the functional modules 110 from the PLC 124 via the external network 210 and then displays this data on the HMI
device 208 (e.g., on a video screen) for the operator. In addition, display and control of the data management process 212 executing on the PLC 124 is available. The present invention is adapted to facilitate both the HMI program layer 206 and the PLC
program layer 204 to react to and display data from only the functional modules 110 actually installed in the MCC 100. In other words, a missing or inoperative functional module 110 will not cause an irrecoverable error that requires an operator intervention to continue or restart operation. In addition, the system architecture 200 is adapted to function with a wide variety of HMI programs from various manufactures without requiring propriety knowledge of the MCC 100 or the data management process 212.
Turning now to FIG. 3, a flow chart depicting operation of a conventional PLC according to the prior art is depicted.
Prior art MCCs require the creation of a PLC program specific to the MCC. In other words, prior art PLCs need to be custom programmed with software that matches the particular functional modules used in the particular MCC. In Steps 302, 304, and 306, the hardware configuration of the functional modules connected ak 02767578 2012-01-06 to the PLC and the programming in the PLC custom to that hardware configuration are downloaded into the PLC for the specific MCC. In Step 308, operation of the MCC is started. If programming has been downloaded for functional modules that are not actually present in the hardware configuration (e.g., a wrong configuration), a software and/or hardware fault is generated in the PLC in Step 310, which may result in the PLC
stopping operation entirely in a fault handling process 314 which includes Steps 316 and 318. If the hardware configuration contains a definition of functional modules that are not actually present on the network, a software and/or hardware fault is generated in Step 312 that may result in the PLC
stopping operation entirely in the fault handling process 314 which includes Steps 320 and 318.
The inability of prior art systems to identify what hardware is present and verify that the hardware is properly configured inhibits prior art systems from being able to use a single PLC program that adapts to the configured hardware. In fact, due to the lack of a single adaptable PLC program, operators are typically forced to create a "template" PLC
program, then modify the hardware configuration and the PLC
programming to match the hardware configuration.
Turning to FIG. 4, a method 400 of operating an MCC
according to the present invention is provided. The present invention provides a single standardized PLC program that is able to dynamically configure itself to match the hardware configuration of the MCC. In Step 402, the hardware configuration for all attached functional modules is defined.
In some embodiments, the hardware configuration for all.
ak 02767578 2012-01-06 installed functional modules may be determined automatically based on, for example, functional module identifiers. In Step 404, the hardware configuration is downloaded to the PLC.
Notably, the step of determining PLC programming custom to the hardware configuration (Step 304 in FIG. 3) and downloading the programing is not required in the method 400 of the present invention.
In Step 406, upon booting or restarting, operation of the MCC begins. The PLC program interrogates the hardware configuration, then configures the resident PLC program for operation with the hardware that is defined in the configuration. The PLC program uses the hardware configuration to draw upon a library of data structures that include the details for each type of functional module encountered. The appropriate data structures and associated program is selected and the resident PLC program configures itself. Notably, the present invention eliminates step 310 (FIG. 3) and the fault handling process 314 (FIG. 3) of the prior art. Since the PLC
program of the present invention configures itself to match the configuration of the hardware, the prior art software required to detect and process faults that result in requiring halting operation are eliminated. If a functional module that is configured but not actually found on the network is detected in Step 408, an I/O error is noted for indication to a monitoring system, but the PLC program continues operation without faulting by looping back to Step 406.
The present invention thus provides several advantages to operators of MCCs. The PLC program no longer requires customized programming and thus, operators have a standardized interface for all their applications. This means that the number of PLC programs that need to be maintained for backup/security reasons is limited. Servicing- is simplified because the hardware configuration can be quickly and automatically be created with the standard PLC program. This insures a short downtime even in the event of severe hardware failure requiring immediate replacement of multiple functional modules. The ability of the PLC to read its own hardware configuration during boot-up/power-on facilitates these advantages and allows the elimination of software requirements such as non-standard fault handling routines and customized programming for the PLC.
Turning to FIG. 5, the details of operating the MCC in Step 406 of FIG. 4 are illustrated. In Step 502, the PLC is started.
In Step 504, the PLC requests the list of functional modules installed in the MCC. This is part of the hardware configuration created in Step 402 (FIG. 4). In Step 506, the PLC
loops through the list of functional modules. In Step 508, for each module listed in the hardware configuration, a data structure is selected from a. library of data. structures and a pointer table is created in the PLC memory defining the valid functional modules on the network to process and how to process them. The table is populated with, for example, an input/output (I/O) address of the functional module, an I/O size of the functional module, and a device type identifier. This is repeated for each functional module until the end of the functional module list is reached, at which point the PLC enters into run mode in Step 510. In run mode, the PLC actively scans data from all of the attached functional modules. In Step 512, the PLC loops through the list of functional modules. For each module found, the PLC software manages the data transfer between the PLC and the functional module in Step 514. If a module is not available, the PLC goes to the next module. If the end of list is reached, the PLC loops back to the beginning of the list.
Turning to FIGs. 6A through 6C, three example data structures 602, 604, 606, for different types of functional modules are illustrated. These data structures 602, 604, 606 are complex data types that are updated during ,each read of data from the corresponding functional module. In addition, in some embodiments, configuration data may be sent back to the functional module from the PLC to adjust the Configuration without the use of external programming software. The example data structure 602 of FIG. 6A is for use with a motor overload functional module. .This example data structure 602 includes fields for storing metering data (e.g., current, voltage, power, etc.); an event log; diagnostic data, and device configuration data. The example data structure 604 of FIG. 6B is for use with a soft starter functional module. This particular example data structure 604 includes fields for storing metering data (e.g., current, voltage, power, etc.); an event log; diagnostic data;
device configuration data; a trip log; an error log; and statistical data. The data structure of FIG. 6C is for use with a variable frequency drive (VFD) functional module. This particular example data structure 606 includes fields for storing metering data (e.g., current, voltage, power, etc.); and device configuration data. Numerous other data structure formats may be used and many additional data structures for different types of functional modules may be employed.
The embodiments of the teachings have been described in an illustrative manner. It is to be understood that the terminology, which has been used, is intended to be in the nature of words of description rather than of limitation.
Many modifications and variations of the embodiments are possible in light of the above teachings. Therefore, within the scope of the appended claims, the embodiments can be practiced other than as specifically described.
Claims (27)
1. A method of operating a motor control center comprising:
determining a hardware configuration, wherein the hardware configuration defines one or more functional module installed in the motor control center;
downloading the hardware configuration to a programmable logic controller;
configuring a resident program on the programmable logic controller based on the hardware configuration to operate with the one or more functional module defined in the hardware configuration;
executing the program;
storing operational data of the one or more functional module into at least one data structure that corresponds to the one or more functional module in a known memory location of the programmable logic controller, wherein a memory space of the known memory location defined by the data structure reflects the status of at least one parameter of the one or more functional module in real time; and determining a status of the one or more functional module in real time from the memory space of stored operational data of the one or more functional module.
determining a hardware configuration, wherein the hardware configuration defines one or more functional module installed in the motor control center;
downloading the hardware configuration to a programmable logic controller;
configuring a resident program on the programmable logic controller based on the hardware configuration to operate with the one or more functional module defined in the hardware configuration;
executing the program;
storing operational data of the one or more functional module into at least one data structure that corresponds to the one or more functional module in a known memory location of the programmable logic controller, wherein a memory space of the known memory location defined by the data structure reflects the status of at least one parameter of the one or more functional module in real time; and determining a status of the one or more functional module in real time from the memory space of stored operational data of the one or more functional module.
2. The method of claim 1, further comprising:
detecting a functional module, of the one or more functional module, that is defined in the hardware configuration but is not available in the motor control center;
and continuing with executing the program.
detecting a functional module, of the one or more functional module, that is defined in the hardware configuration but is not available in the motor control center;
and continuing with executing the program.
3. The method of claim 2, wherein the detected functional module of the one or more functional module comprises a functional module that is absent from the motor control center, mis-configured, or inoperative.
4. The method of claim 2 or claim 3, further comprising:
noting an error responsive to the detecting.
noting an error responsive to the detecting.
5. The method of claim 1 wherein the one or more functional module is from the group consisting of one of a motor overload module, a variable frequency drive module, or a soft start module that is installed in the motor control center.
6. The method of claim 1 wherein the one or more functional module installed in the motor control center include communications ports for coupling to a network within the motor control center.
7. The method of claim 1 wherein configuring the resident program includes accessing a library of data structures, each data structure corresponding to a type of functional module for use within the motor control center.
8. The method of claim 1 wherein configuring the resident program includes generating a pointer table in a memory space of the programmable logic controller that defines valid functional modules accessible by the programmable logic controller.
9. The method of claim 8 wherein the pointer table is populated with at least one of an input/output address of the functional module, and input/output size of the functional module, and a device type identifier.
The method of claim 5 wherein the functional modules are addressable by the programmable logic controller using a logical address.
11. The method of claim 10 wherein the programmable logic controller is not aware of a physical location or address of the functional modules.
12. A motor control center comprising:
a frame adapted to provide a plurality of functional module slots;
a busbar coupled to the frame and the functional module slots;
a network coupled to the frame and the functional module slots;
a programmable logic controller module adapted to couple to a functional module slot; and a plurality of functional modules adapted to couple to functional module slots, wherein the programmable logic controller module includes a programmable logic controller adapted to:
receive a hardware configuration, wherein the hardware configuration defines the plurality of functional modules installed in the motor control center;
download the hardware configuration into a memory of the programmable logic controller;
configure a resident program on the programmable logic controller based on the hardware configuration to operate with the plurality of functional modules defined in the hardware configuration;
execute the program;
store operational data of the plurality of functional modules into at least one data structure that corresponds to the plurality of functional modules in a known memory location of the programmable logic controller, wherein a memory space of the known memory location defined by the data structure reflects the status of at least one parameter of the plurality of functional modules in real time; and determine a status of the plurality of functional modules in real time from the memory space of stored operational data of the plurality of functional modules.
a frame adapted to provide a plurality of functional module slots;
a busbar coupled to the frame and the functional module slots;
a network coupled to the frame and the functional module slots;
a programmable logic controller module adapted to couple to a functional module slot; and a plurality of functional modules adapted to couple to functional module slots, wherein the programmable logic controller module includes a programmable logic controller adapted to:
receive a hardware configuration, wherein the hardware configuration defines the plurality of functional modules installed in the motor control center;
download the hardware configuration into a memory of the programmable logic controller;
configure a resident program on the programmable logic controller based on the hardware configuration to operate with the plurality of functional modules defined in the hardware configuration;
execute the program;
store operational data of the plurality of functional modules into at least one data structure that corresponds to the plurality of functional modules in a known memory location of the programmable logic controller, wherein a memory space of the known memory location defined by the data structure reflects the status of at least one parameter of the plurality of functional modules in real time; and determine a status of the plurality of functional modules in real time from the memory space of stored operational data of the plurality of functional modules.
13. The motor control center of claim 12, wherein the programmable logic controller is further adapted to:
detect a functional module, of the plurality of functional modules, that is defined in the hardware configuration but is not available in the motor control center;
and continue to execute the program.
detect a functional module, of the plurality of functional modules, that is defined in the hardware configuration but is not available in the motor control center;
and continue to execute the program.
14. The motor control center of claim 13, wherein the detected functional module of the plurality of functional modules comprises a functional module that is absent from the motor control center, mis-configured, or inoperative.
15. The motor control center of claim 13 or claim 14, wherein the programmable logic controller is further adapted to:
note an error responsive to detecting the functional module, of the plurality of functional modules, that is defined in the hardware configuration but is not available in the motor control center.
note an error responsive to detecting the functional module, of the plurality of functional modules, that is defined in the hardware configuration but is not available in the motor control center.
16. The motor control center of claim 12 wherein the plurality of functional modules is from the group consisting of one of a motor overload module, a variable frequency drive module, or a soft start module that is installed in the motor control center.
17. The motor control center of claim 16 wherein the functional modules installed in the motor control center include communications ports for coupling to the network.
18. The motor control center of claim 12 wherein configuring the resident program includes accessing a library of data structures, each data structure corresponding to a type of functional module for use within the motor control center.
19. The motor control center of claim 12 wherein configuring the resident program includes generating a pointer table in the memory of the programmable logic controller that defines valid functional modules accessible by the programmable logic controller.
20. The motor control center of claim 19 wherein the pointer table is populated with at least one of an input/output address of the functional module, and input/output size of the functional module, and a device type identifier.
21. The motor control center of claim 16 wherein the functional modules are addressable by the programmable logic controller using a logical address.
22. The motor control center of claim 21 wherein the programmable logic controller is not aware of a physical location or address of the functional modules.
23. A programmable logic controller module for a motor control center, the programmable logic controller module comprising:
a programmable logic controller adapted to:
receive a hardware configuration, wherein the hardware configuration defines one or more functional module installed in the motor control center;
download the hardware configuration into a memory of the programmable logic controller;
configure a resident program on the programmable logic controller based on the hardware configuration to operate with the one or more functional module defined in the hardware configuration;
execute the program;
store operational data of the one or more functional module into at least one data structure that corresponds to the one or more functional module in a known memory location of the programmable logic controller, wherein a memory space of the known memory location defined by the data structure reflects the status of at least one parameter of the one or more functional module in real time; and determine a status of the one or more functional module in real time from the memory space of stored operational data of the one or more functional module.
a programmable logic controller adapted to:
receive a hardware configuration, wherein the hardware configuration defines one or more functional module installed in the motor control center;
download the hardware configuration into a memory of the programmable logic controller;
configure a resident program on the programmable logic controller based on the hardware configuration to operate with the one or more functional module defined in the hardware configuration;
execute the program;
store operational data of the one or more functional module into at least one data structure that corresponds to the one or more functional module in a known memory location of the programmable logic controller, wherein a memory space of the known memory location defined by the data structure reflects the status of at least one parameter of the one or more functional module in real time; and determine a status of the one or more functional module in real time from the memory space of stored operational data of the one or more functional module.
24. The programmable logic controller module of claim 23, wherein the programmable logic controller is further adapted to:
detect a functional module, of the one or more functional module, that is defined in the hardware configuration but is not available in the motor control center;
and continue to execute the program.
detect a functional module, of the one or more functional module, that is defined in the hardware configuration but is not available in the motor control center;
and continue to execute the program.
25. The programmable logic controller module of claim 24, wherein the detected functional module of the one or more functional module comprises a functional module that is absent from the motor control center, mis-configured, or inoperative.
26. The programmable logic controller module of claim 24 or claim 25, wherein the programmable logic controller is further adapted to:
note an error responsive to detecting the functional module, of the one or more functional module, that is defined in the hardware configuration but is not available in the motor control center.
note an error responsive to detecting the functional module, of the one or more functional module, that is defined in the hardware configuration but is not available in the motor control center.
27. The programmable logic controller module of claim 23 wherein the one or more functional module includes a motor overload module, a variable frequency drive module, or a soft start module that are installed in the motor control center.
Applications Claiming Priority (5)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US22409309P | 2009-07-09 | 2009-07-09 | |
US61/224,093 | 2009-07-09 | ||
US12/832,956 US8670859B2 (en) | 2009-07-09 | 2010-07-08 | Methods and apparatus for an improved motor control center |
US12/832,956 | 2010-07-08 | ||
PCT/US2010/041464 WO2011006030A1 (en) | 2009-07-09 | 2010-07-09 | Methods and apparatus for an improved motor control center |
Publications (2)
Publication Number | Publication Date |
---|---|
CA2767578A1 CA2767578A1 (en) | 2011-01-13 |
CA2767578C true CA2767578C (en) | 2017-07-04 |
Family
ID=43031498
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
CA2767578A Active CA2767578C (en) | 2009-07-09 | 2010-07-09 | Methods and apparatus for an improved motor control center |
Country Status (6)
Country | Link |
---|---|
US (1) | US8670859B2 (en) |
EP (1) | EP2452236A1 (en) |
CN (1) | CN102483616B (en) |
CA (1) | CA2767578C (en) |
MX (1) | MX2012000464A (en) |
WO (1) | WO2011006030A1 (en) |
Families Citing this family (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE102012010537A1 (en) * | 2012-05-29 | 2013-12-05 | Robert Bosch Gmbh | Programming template for distributed application programs |
CN103064367B (en) * | 2012-12-12 | 2016-01-13 | 攀钢集团工程技术有限公司 | Based on electric machine control system and the control method thereof of intelligent electric machine control center |
US10353366B2 (en) | 2015-12-22 | 2019-07-16 | Panasonic Intellectual Property Management Co., Ltd. | Customization method of motor control device and motor control device |
KR101847127B1 (en) * | 2016-07-14 | 2018-04-09 | 주식회사 루텍 | Digital LOP using Integration Module and System for Motor Control Center icluding them |
US10366033B2 (en) | 2016-09-15 | 2019-07-30 | General Electric Company | Automated retrofit installation tool for replacement of one or more pre-existing dedicated input/output (I/O) modules and terminal boards with one or more universal I/O modules |
SE1751114A1 (en) * | 2017-09-13 | 2019-03-14 | Beijer Electronics Ab | A method of configuring an automation system |
CN113196644A (en) * | 2018-11-09 | 2021-07-30 | 施耐德电气美国股份有限公司 | System and method for distributed and dynamically configurable motor control |
Family Cites Families (18)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5267277A (en) * | 1989-11-02 | 1993-11-30 | Combustion Engineering, Inc. | Indicator system for advanced nuclear plant control complex |
US5225987A (en) * | 1991-05-20 | 1993-07-06 | Westinghouse Electric Corp. | System for implementing a PC computer configuration system for assembling and mounting of a complex product in situ |
GB9308656D0 (en) * | 1993-04-27 | 1993-06-09 | Gec Alsthom Ltd | Improvements in and relating to electronic control apparatus |
US6032203A (en) * | 1997-04-07 | 2000-02-29 | General Electric Company | System for interfacing between a plurality of processors having different protocols in switchgear and motor control center applications by creating description statements specifying rules |
DE19800448C2 (en) | 1998-01-08 | 2000-04-27 | Caradon Esser Gmbh | Monitoring system |
US6160365A (en) * | 1999-03-11 | 2000-12-12 | Eaton Corporation | Interface module for a motor control system |
US6252365B1 (en) * | 1999-08-17 | 2001-06-26 | General Electric Company | Breaker/starter with auto-configurable trip unit |
US6556950B1 (en) * | 1999-09-30 | 2003-04-29 | Rockwell Automation Technologies, Inc. | Diagnostic method and apparatus for use with enterprise control |
AU4227501A (en) | 2000-03-01 | 2001-09-12 | Siemens Aktiengesellschaft | Method and device for processing data of an automation system for a building system engineering installation |
US6901316B1 (en) * | 2000-09-28 | 2005-05-31 | Rockwell Automation Technologies, Inc. | Electrical control system configuration method and apparatus |
US20020174264A1 (en) * | 2001-05-17 | 2002-11-21 | David Fuller | System and method for obtaining driver software and documentation for a detected hardware and software configuration |
DE10233211A1 (en) * | 2002-07-22 | 2004-02-19 | Siemens Ag | Computer system for configuring automation device firmware, uses database with data model, input devices for data model entities and processor devices to create data packets |
US7092771B2 (en) | 2002-11-14 | 2006-08-15 | Rockwell Automation Technologies, Inc. | Industrial control and monitoring method and system |
US7262943B2 (en) * | 2003-09-15 | 2007-08-28 | General Electric Company | Configuration unit and methods for configuring centrally controlled power distribution systems |
US7180253B2 (en) * | 2003-09-30 | 2007-02-20 | Rockwell Automation Technologies, Inc. | Method and system for generating multi-dimensional motion profiles |
US8645569B2 (en) | 2004-03-12 | 2014-02-04 | Rockwell Automation Technologies, Inc. | Juxtaposition based machine addressing |
EP1632825B1 (en) * | 2004-09-03 | 2008-10-29 | Derek Ward | Improvements in or relating to programmable logic controller and related electronic devices |
US7689727B2 (en) | 2006-01-24 | 2010-03-30 | National Instruments Corporation | System and method for automatically updating the memory map of a programmable controller to customized hardware |
-
2010
- 2010-07-08 US US12/832,956 patent/US8670859B2/en active Active
- 2010-07-09 MX MX2012000464A patent/MX2012000464A/en active IP Right Grant
- 2010-07-09 WO PCT/US2010/041464 patent/WO2011006030A1/en active Application Filing
- 2010-07-09 CN CN201080040252.7A patent/CN102483616B/en active Active
- 2010-07-09 CA CA2767578A patent/CA2767578C/en active Active
- 2010-07-09 EP EP10737406A patent/EP2452236A1/en not_active Withdrawn
Also Published As
Publication number | Publication date |
---|---|
US20110022751A1 (en) | 2011-01-27 |
CN102483616A (en) | 2012-05-30 |
CN102483616B (en) | 2015-02-18 |
MX2012000464A (en) | 2012-01-27 |
WO2011006030A1 (en) | 2011-01-13 |
US8670859B2 (en) | 2014-03-11 |
CA2767578A1 (en) | 2011-01-13 |
EP2452236A1 (en) | 2012-05-16 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
CA2767578C (en) | Methods and apparatus for an improved motor control center | |
JP4375697B2 (en) | Electronic control for a device that generates compressed air or vacuum | |
CA2573723C (en) | Html driven embedded controller | |
US9696704B2 (en) | Plug and play motor control system | |
US9584585B2 (en) | Drive with server | |
US8000815B2 (en) | Method for the supplying and installation of device-specific functionalities and/or data for the field devices of a distributed system | |
EP2874033B1 (en) | Device class information support for multi-option devices | |
WO1998036335A9 (en) | Process control system using a layered-hierarchy control strategy distributed into multiple control devices | |
WO1998036335A2 (en) | Process control system using a layered-hierarchy control strategy distributed into multiple control devices | |
US20120182285A1 (en) | System for the visualization of status information of field devices | |
CN103201690B (en) | For many local control network network processor (LCNP) emulators for control system | |
US20100039952A1 (en) | System for monitoring, control and data acquisition of technical processes | |
US20100145484A1 (en) | System and method for monitoring computerized numerical control devices | |
US20200218220A1 (en) | Method and data processing device for the computer-supported providing of information, available in the form of computer code, for a process module, and computer program product for carrying out the method | |
CN111788816B (en) | Method for establishing network communication in automation system | |
CN107017703A (en) | A kind of Auto-Test System Alternating Current Power Supply management and environmental monitoring installation | |
US20210072719A1 (en) | Method for Operating an Application Program for Executing in an Electric Control Unit for a Drive System, Electric Control Unit, Drive System and System | |
US20220011735A1 (en) | Support apparatus, non-transitory computer readable medium, and control apparatus | |
RU2719456C1 (en) | Method for integrated control of electrical systems using a computer for controlling power networks | |
US20220012333A1 (en) | Controller system, control apparatus, and non-transitory computer readable medium | |
Tufan et al. | MONITORING PARAMETERS FROM AN AUTOMATED SYSTEM | |
CN115964049A (en) | Method, system, device and storage medium for realizing action customization through BMC | |
US20200326675A1 (en) | Systems and methods for emulating a network device | |
CN114936898A (en) | Management system, method, equipment and storage medium based on spot supply | |
CN112805637A (en) | Design, configuration and maintenance of drive equipment |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
EEER | Examination request |