Redesign Distributed PLC Control Systems Using IEC 61499 Function Blocks

Wenbin Dai

doi:10.1109/TASE.2012.2188794

Redesign Distributed PLC Control Systems Using IEC 61499 Function Blocks

2012-04-01

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DOI：10.1109/TASE.2012.2188794

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The IEC 61499 Function Block architecture is considered as the next generation of programmable control technology promoting distributed control in automation. In this paper, the redesign methodologies from the PLC control to the event-driven architecture of IEC 61499 function blocks are proposed. A general set of translation steps and mapping rules for redesigning applications from IEC 61131-3 PLC to IEC 61499 Function Blocks is provided. Three different redesign approaches are proposed: object-oriented conversion approach, object-oriented reuse approach, and class-oriented approach. These approaches are to be applied for different design styles of the source PLC code. The data handling efficiency of all approaches is investigated. An airport baggage handling system is chosen as the case study for the redesign process. The rules and limitations are summarized and guidelines for the redesign process are provided. Note to Practitioners-This paper is motivated by the issue of insufficient PLC performance in an airport baggage handling system. When trying to deploy distributed control to PLC based baggage handling systems and provide intelligence to each PLC for sorting bags and malfunction detection, the efficiency and performance problems occur. Also, the PLC is not capable of reconfiguring the program during the operation. The performance of data update on a fieldbus deteriorates when more PLCs are connected to it. This paper suggests to use IEC 61499 standard and distributed control to solve those problems and proposes a way to migrate to IEC 61499 from IEC 61131-3 PLCs. By applying the proposed object-oriented and class-oriented design patterns for combining IEC 61499 with IEC 61131-3, the migration of centrally controlled baggage handling systems to distributed control systems is feasible. In this paper, we present a general translation methodology for both object-oriented and class-oriented approaches. Also, the data handling efficiency over the distributed control system network is investigated and suggestions are made for minimize the processing time for data handling. The real airport baggage handling system example is used for illustration of our migration method. The limitations of both approaches are provided and recommendations for how to apply each approach are also given. In the future work, we will focus on the negotiation between distributed notes and runtime reconfiguration for distributed notes by applying the IEC 61499 standard.

Keyword:

Data handling in distributed system

distributed control systems design

IEC 61131-3

IEC 61499

programmable logical controllers (PLC)

Redesign Distributed PLC Control Systems Using IEC 61499 Function Blocks

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