11th International Conference Research and Development in Mechanical Industry

RaDMI 2011

15 - 18 September 2011, Sokobanja, Serbia

INTERNET ACCESS TO PLC WITH INTEGRATED WEB SERVER Slobodan Aleksandrov1, Stanimir ajetinac 2, Zoran Jovanovi3 Engineering School Trstenik, Trstenik, SERBIA, E-mail: aleksandrovs@yahoo.com 2 College of Applied Engineering, Trstenik, SERBIA, E-mail: caja.dublje@ gmail.com 3 Faculty of Electrical Engineering, Ni, SERBIA, E-mail: zoran.jovanovic@elfak.ni.ac.rs
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Summary: The paper presents a model of remote access to distributed systems by Internet by means of free Internet browsers. Electro-pneumatic system of the elevator platform is controlled by the PLC with integrated Web server. The PLC is connected to the local computer network by network cable, whereas the network router provides the Internet access. Any controlling PLC, regardless of its type or manufacturer, can be accessed by means of standard Ethernet, Transmission Control Protocol/Internet Protocol (TCP/IP), and Internet browser. Keywords: Web-server, PLC, Ethernet, TCP/IP, Web-enabled PLC 1. INTRODUCTION Modern programmable logic controllers (PLC) have a serious power, are excellently equipped with plenty of RAM, which allows their use under demanding applications. Development of computer networks, new technologies, networking PLC is increasing, and the use of TCP/IP has become standard in industrial automation. High-speed computer networks, development of the Internet and new networking standard provide access to modern industrial systems from any geographical location. The ability to connect PLC in industrial networks enables successful implementation of distributed computer control. The problem of different types of industrial networks, their different characteristics and incompatibility, submit to brake by applying new technologies. A common feature for all manufacturers and types of PLC's possession serial port RS232 or RS485, and the newer models are almost the standard that the user has an Ethernet port RJ-45. The purpose of these ports is to connect computers and operating panel with PLC to program changes to existing programs and maintenance of automatic system. The system of providing technical support, increasingly rely on Internet technology to reduce costs of maintenance and servicing, as well as short service time. Thanks to high speed Internet, it is possible to access remote computers and control their work, use their resources in real time [1]. Distributed control development of the Internet can be used in almost all branches of industry and communications. TCP/IP protocol is the standard for Internet communications. Thanks to its great capabilities, the implementation of this protocol in distributed computer systems, allows you to connect all the devices at different levels of automation. The use of Ethernet, TCP/IP and fast Internet, communication in modern automation allows the development of distributed computer control in real time. Access to PLC devices from a remote location to allow:

Accessing and program real PLC Test their programs and remove detected faults The ability to access video Download and send file On-line communication with PLC Access to PLC on weekends

2. HARDWARE ORGANIZATION The paper describes a mechatronical system at the modular development panel with electro-pneumatic systems. The system simulates the elevator platform which elevators objects. The electro-pneumatic system is controlled by PLC Festo FC-34 which has an installed Web server. The system parameters, the state of input sensors and actuators are monitored by Internet browser. Figure 1 shows the system of elevator platform. (3)

PUP
(4) (2 )

I sprat
(1)

package prizemlj

PDN LUP LDN B3

Figure 1: Elevator platform The lifting platform is activated by two-way pnenumatic cylinder. Lifting and lowering are done by activation of electro-magnetic valve ElevatorUP (LUP=ON) and ElevatorDN (LDN=ON), respectively. Electro-magnetic valves are not active at the initial position. The elevator position is detected by two boundary micro switches PUP and PDN. Upper micro switch closes (PUP=ON) when the elevator reaches the first floor, while the lower micro switch (PDN=ON) closes when the elevator reaches the ground floor. The presence of package at the elevator platform is detected by optical sensor B3. The sensor becomes ON when the package is placed on the platform, and it becomes OFF when the package is removed. The initial position of the elevator platform is the ground floor. When the package is placed at the elevator platform (step 1) the elevator is lifted to the first floor (step 2) and it remains that position until the package is removed from the platform (step3), and then it is lowered to the ground floor (step 4). This is the algorithm of the platform operation: 1. The condition for activating the elevator upwards is set (F0.0) when the micro switch of lower position is active (PDN=ON) and when optical sensor detecting the object is active (B3=ON). 2. When the elevator platform reaches the first floor, the upper micro switch is activated (PUP=ON) and the condition F0.0 is reset. 3. The condition for activating the elevator downwards is set (F0.1) when the micro switch of upper position is active (PUP=ON) and when optical sensor detecting the object is not active (B3=OFF). 4. When the elevator platform reaches the ground floor, the lower micro switch is activated (PDN=ON) and the condition F0.1 is reset.

Figure 2: List of defined inputs/outputs The list of defined inputs/outputs and PLC parameters is shown in figure 2. The programme is realized by Ladder diagram and its part is shown in figure 3.

Figure 3: Program code realized in LADDER

3. PLC AS WEB SERVER Web server enables direct access to PLC through the Internet from any geographical location. The Internet and WWW (World Wide Web) offer an easy way to deliver data through hypertext links. A safe access is a very important component and it is a part of network infrastructure. The combination of Web browser and PLC provides a simple graphical interface for accessing the PLC data and for controlling PLC from any place worldwide. Industrial standard Ethernet, TCP/IP and HTTP are integral parts of data organization within PLC. Festo controller does not mark discs like a PC. It has two discs designated as A and B. The data on disc A cannot be changed while the disc B is used for storing the project and data and it can be accessed. The content of dics B is accessible and changeable. Web pages presented in the browser are located in the subdirectory WEB at the controller disc B as shown in figure 7. The data exchangebetween the computer and PLC is done in two manners: 1. by specialized Festo software, and 2. by TCP/IP application. Festo Web server has formed page index.htm which can be edited and changed in some of the HTML editors. Web server enables special HTML tags identified by the controller. It is necessary to add drivers TCP/IP and WEB_SRVR so that Festo PLC could operate as Web server (figure 4).

Figure 4: Driver configuration of Festo controller

Figure 5: Identification of PLC network parameters PLC network parameters are identified upon addition of network drivers. This procedure is presented in figure 5. PLC gets unique IP address, e.g. 192.168.0.58, IP netmask 255.255.255.0 and IP default gateway. When these parameters are added into the PLC controlling program, the program is transferred from the computer to PLC.

Figure 6. Files copied from the computer to PLC and vice versa When PLC is restarted, Web server is accessible either through the local computer network or the Internet. PLC network address is inserted/entered in the Internet browser and the home page of Web server is loading. The name reserved for its home page is main.htm and it is presented in figure 6. Festo Web server checks each demand if the page main.htm exists. If it exists, it is shown in the browser. If it does not exist, the page index.htm, which is always present at the Web server, is shown. All values of variable controllers can be accessed through this page. The home page contains links which give us the wanted information on the inputs, outputs, timers, counters and other PLC parameters.

Figure 7: Access to the Web server by the Internet browser Monitoring of PLC parameters is done in real time because the screen is refreshed each 5 seconds. When the value of some PLC variables or parameters changes, its value is automatically updated and presented at the browser display. The access to variables of the process has a high significance for monitoring the production process. The elevator platform is an example how the process states can be monitored and how the system failure can be detected in a simple manner without expensive software. Micro switches and sensors, which are at the elevator platform, give information on the position of the elevator and whether the elevator is full or empty. The program may contain the time intervals during 5

which the usage of elevator is forbidden, and it may contain counters which in the controller memory count how many cycles the system had during the day, month or year. The state of counter and timer is available through the Internet browser. The system can also be applied to more complex processes having a large number of inputs and outputs. The solution described enables only the system monitoring through the local computer network or through the Internet, regardless of the operators geographical position. For complete testing and diagnostics of the system from far locations one uses the software for PLC programming which is called Festo software tools 4.10.50 and which implies the program language for PLC programming. 4. CONCLUSION The application of the Internet and WAN newtork provide remote access to PLC no matter where the user is. The described model for PLC monitoring through the Internet is a free solution which can be used to monitor a wide range of PLCs made by different manufacturers. If standard Ethernet, Transmission Control Protocol/Internet Protocol (TCP/IP) and Internet browser are used, any controlling PLC can be accessed regardless of PLC type or producer. Apart from HTML, XML technologies offer huge possibilities when creating controlling applications. A special emphasis should be laid on protection from unallowable access through the Internet network. 5. REFERENCES [1] Aleksandrov, S.; Jovanovi, Z.; ajetinac, S.; Stoimenov L.: Access to PLC in real-time software package Team Viewer, X Triennial International SAUM Conference on Systems, Automatic Control and Measurements, Ni, Serbia, November 10th-12th, 2010. [2] Aleksandrov, S; ajetinac, S.; elija, D.: Didactic system Festo MPS-sorting station and its application in the field of mechatronics. 10th International Conference Research and Development in Mechanical Industry RaDMI 2010, 16 - 19 September 2010, Donji Milanovac, Serbia [3] Festo software tools, Automating with FST, 682300, en0402HN [4] Laget H.; Valle, F.; Tadeo F.: Web based remote control of an electro-pneumatic process. Dpto.Ingenieria de sistemas y Automatica, 47005 Valladolid, Spain. [5] Chaabene M.; Mkaouar, K.; Ouali M.: Web based interactive real laboratory for process engineering education. Journal of Computer Science 3 (7):540-545, 2007, ISSN 1549-3636. [6] Baker R.: Three Web server architectures aid plant-floor, enterprise integration, Control Engineering, Marc 1, 2001.