Programming Logic Controllers (SPS), TIA Portal

 

INTRODUCTION

 

This report provides an overview of the TIA (Totally Integrated Automation) Portal software from Siemens. The TIA which stands for the “Totally Integrated Automation” concept allows using uniformly all automation components and instrumentations which is using a single system platform and tools with simultaneous operator interfaces.[3]

In the field of industrial automation and control, TIA Portal Siemens software stands as the symbol of excellence. This integrated development environment empowers engineers to seamlessly design, program and manage industrial control and automation projects.

 

 

What is Siemens TIA Portal?

 

TIA Portal (Totally Integrated Automation Portal) combines different automation components into a single platform and offers automation engineers a wide range of functions. Before the release of the TIA portal, the work of engineers was really difficult. Because they had to use different types of applications. But today, thanks to this program created by Siemens engineers, it is possible to perform several different tasks with just one program. As we can see the name of this program, TIA Portal is an integrated version of several programs. Here are the main features of TIA Portal:

·       Project Management: TIA Portal allows you to easily create, edit and manage automation projects. Project management includes processes such as hardware configuration, programming and simulation.

·       Modularity: TIA Portal has a modular structure, which allows you to break down projects and manage them more easily. This is especially useful for large and complex automation projects.

·       PLC Programming: TIA Portal is used to program Siemens SIMATIC PLCs. This is essential for creating and programming industrial control systems. For instance, we can use Siemens S7-1200 PLC family for small and medium application and Siemens S7-1500 PLC family for bigger applications. In addition to that, as I mentioned before, TIA Portal also support different PLC Programming Languages. For example, Ladder logic, Function Block Diagram, Structured Text and etc.

 

Here is some examples of this program:

Fig.1 Project view and User Interface of TIA Portal

 

In this page PLCs, HMIs can be added. Also, users can be program them inside the Main OB1 block. OB stands for Organization Block. All of the programming things is happened here. Also, we can make communication among the PLCs and HMIs in the Devices & Networks field by using the different kind of

communication protocols where the protocols are spread, among them are PROFIBUS, Modbus, AS-Interface, CAN, HART, IOLINK, PROFINET,

EtherCAT, EtherNet/IP and so on.[1]

Fig.2 Portal view of TIA Portal

 

This section mostly about the hardware things and components. Here, we can save our project, Create new project, some visualization things, make troubleshooting or online Diagnostics and so on.

·       HMI Design: TIA Portal simplifies human-machine interface (HMI) design with a user-friendly interface. You can create interfaces for operators to monitor and control production processes.

 

If users want to add some HMI Screen they have to use this field called “Add New Device” :

Fig. 3 Interface of adding new device

 

After that they supposed to click the HMI Button :

 

Fig. 4 Some HMI Products of Siemens

 

Fig. 5 View of Simple HMI Programming and Design screen

 

 

·       Data Management and Communication: TIA Portal facilitates data sharing and communication between different automation components. This ensures proper functioning of the entire system.

Fig. 6 Table of PLC tags for Data Management

 

Key components of TIA Portal

 

At the heart of the TIA Portal are various components, each of which is designed for a specific function. In this section, we will explore the main elements that make up the TIA Portal and detail their respective roles. These components include:

·       Simatic Manager: The project management tool that facilitates organization and configuration.

·       Step 7: The platform for PLC programming, enabling the creation of automation logic. Generally, Siemens PLC S7-300, S7-1200, S7-1500 (SIMATIC S7-1500 controllers has the capability to be scaled in terms of processing speed and configuration limits. They also provide networking facilities via different communications standards ^[2]) and HMI KTP family called STEP 7 family.

·       WinCC: A tool for designing Human-Machine Interfaces (HMIs) and overseeing control systems. In the simualtion of HMI and PLC mostly we can use the “WinCC Audit Runtime Advanced” software.

 

 

 

Here is how PLC/HMI simulation looks like:

Fig. 7 HMI simulation screen with WinCC RT (Run Time)

 

Blocks in TIA Portal

There are different kinds of blocks in TIA Portal. The main function of these blocks is to make a simple program for the industrial automation.

Fig. 8 Add New Block section

 

Here we can see 4 different kinds of blocks, which they have some differences.

Organization block:

An "Organization Block" is a sort of block in the Siemens TIA Portal that helps you arrange and structure our program code. It serves as a container for other program blocks and functions rather than a block that holds logic or data directly. An organization block's function is to give our program a higher level of structure and organization by assisting us in managing and organizing our code in a more modular and manageable manner.

Here are some essential details regarding to Organization Block:

Structural Organization: The program is divided into many sections using the Organization Block, which facilitates the management of complicated and large- scale projects. Also we can write most of our programme in here by using Ladder Logic, Function Block Diagram and other kind of programming language.

Block Storage: Within an Organization Block, you can nest Program, Function, and Data blocks. This permits us to group related objects and codes.

Block-to-Block Communication: Because they are a part of the same organizational structure, blocks that are members of the same organizational block can readily communicate with one another. Your code may become more modular and reusable as a result.

Enhanced readability: It's simpler to maintain and comprehend the structure of your project when you use organization blocks to divide your software into logical pieces.

  Fig. 9 Some different organization blocks

Function and Function Block:

The main aim of Function and Function Block approximately same. But there are same differences also:

 

Function:

 

 

Fundamental Logic: In the TIA Portal, a function denotes a fundamental logic unit. It is a set of commands and procedures that carry out a certain job.

Not Modular: The modular nature of functions is not inherent. They don't contain data; instead, they are stand-alone entities.

Single Instance: Functions are usually called from the main application as stand- alone procedures. A function can only be used once in your application; instances are not an intrinsic concept.

Absence of Internal Memory: Internal memory is absent from functions. For input and output, they make use of global variables or parameters.

 

Function Block:

 

 

Modular and Reusable: The modular and reusable nature of Function Blocks is built in. They contain logic and data (internal memory) in one single unit.

Data Encapsulation: Because Function Blocks have internal memory, or instance data, they can include the data and logic related to a particular functionality.

Several Instances: A Function Block may be used in your application in several instances, each of which may include a different set of data.

Function Blocks can be parameterized, which enables you to build instances with various starting points or behaviors.

Function Blocks support an organized programming methodology, which facilitates code management and comprehension, particularly in bigger projects.

Data Block:

A Data Block in the Siemens TIA Portal is a structure for data management and organization in PLC (Programmable Logic Controller) projects. As opposed to Function Blocks and Functions, Data Blocks do not include logic; instead, their main functions are data kinds, variable storage, and memory management.

 

Here are some key features:

 

Variable Storage: To define and arrange variables, utilize data blocks. Process values, counters, timers, flags, and any other data that must be saved and retrieved while a program is running can all be represented by these variables.

Memory Organization: You can arrange the locations of variables in memory using Data Blocks. For every variable, this can involve specifying the data type, starting values, and addressing scheme.

Global Accessibility: Within a PLC program, variables defined in a Data Block are usually globally accessible. This implies that they can be applied to other program blocks, including FCs (Function Blocks), FBs (Functions Blocks), and OBs (Organization Blocks).

Parameterization: Data Blocks are parameterizable, just like Function Blocks are. This implies that a Data Block can be created in several instances, each with a unique combination of variables and memory allocation. When managing several instances of the same machinery or procedure, this can be helpful.

Absence of Direct Logic: Data Blocks lack programmable logic, in contrast to Function Blocks and Functions. Data management and organization are their main concerns.

Advantages and Challenges of TIA Portal

 

TIA Portal Siemens software offers a number of advantages that make it an attractive choice for industrial automation projects. However, it is also important to recognize potential problems that users may encounter during its implementation. Here is Advantages of TIA Portal;

·       Integration: TIA Portal's greatest strength is its seamless integration of various automation components, making it a one-stop solution for automation projects. This streamlines the engineering process, reduces compatibility issues, and enhances overall efficiency.

·       Modularity: TIA Portal's modular structure allows engineers to break down complex projects into manageable components. This modularity makes the system easier to maintain and expand.

·       Efficiency: With a user-friendly interface and numerous built-in features, TIA Portal accelerates project development. Engineers can save time and reduce errors during configuration and programming.

·       Data Management: TIA Portal offers robust data management and communication capabilities, allowing for real-time data exchange between different components of the automation system.

 

Here is the some data types in PLC Programming world:

 

Data Type	Bits	Range of Values	Adress Example in PLC
Bool	1	0-1	I0.0, Q0.0, M0.0, Q6.1
BYTE	8	0-255	MB0,MB4,MB6
WORD	16	0-65535	MW0,MW4,MW8

 

 

 

 

INT 16 -32768-32767 MW0,MW4,MW8 DWORD 32 0-4294967295 MD0,MD8 DINT 32 -2147483648-2147483648 MD0,MD8

Tab. 1 Data types in the TIA Portal software Disadvantages of TIA Portal:

·       Learning Curve: For new users, TIA Portal may have a steep learning curve due to its feature-rich environment. Adequate training or courses may be necessary to unlock its full potential.

 

·       Hardware Compatibility: While TIA Portal is designed for Siemens hardware, it may pose compatibility challenges with hardware from other manufacturers, potentially limiting options for users. But it is useful for all manufacturers soon.

·       Cost: Overall, TIA Portal program package is more expensive than the other companies. Licensing and initial setup costs can be significant, particularly for smaller companies or projects with budget constraints.

·       System Resources: This program contains a lot of other things by itself and as a result program need more powerful computer system for running properly. Complex automation projects may demand substantial system resources, which can affect performance and necessitate powerful hardware.

·       Maintenance and Support: Like any software, TIA Portal may require updates, maintenance, and ongoing technical support. Ensuring access to these resources is crucial for the smooth operation of automation systems.

 

In summary, TIA Portal Siemens software offers a lots of advantages that streamline industrial automation projects, but users should be aware of potential

challenges. A comparative analysis with alternative automation solutions can help in determining whether TIA Portal aligns with the specific requirements and constraints of a given project.

 

 

Conclusion and Recommendations

 

To wrap up this report, I will summarize the key takeaways and provide some useful information, shedding light on why TIA Portal Siemens is a formidable asset in the world of industrial automation.

In Siemens TIA Portal there are some steps that need to be done to connect the PLC to Factory I/O. It is important to make sure that in the general configuration of the device, in “Protection” tab, the “no protection” option is the one selected and check the option “Permit access with PUD/GET communication from remote partner (PLC, HMI, OPC…)”.[4]

I think that the best way to learn how to use the TIA Portal is using different kind of simulation programs. PLC SIM, WinCC and of course FACTORY IO. This way of learning also highly recommended by professionals. Factory IO is really useful not only for beginners but also for professional PLC Programmers. Users can simulate real work environment with this software.

Fig. 10 Real environment simulation with Factory IO

 

 

In this application, I simulated control of Filling and Draining valves with TIA Portal and WinCC runtime HMI KTP-400.

 

Fig. 11 Sorting of boxes by its size and counting them

 

In this project, I counted the large and small boxes using a counter and sensors. The conveyor stops when the number of both small and large boxes reaches 5.

 

 

Conclusion

In conclusion, TIA Portal Siemens software enables automation professionals to implement industrial control and automation projects with efficiency and reliability. As we continue to witness advancements in automation, TIA Portal remains a symbol of excellence in simplifying complex automation tasks and ensuring seamless operation of industrial systems. Nowadays, Siemens TIA Portal is the best PLC Programming software in the world.

Variables for Lab 1,2 and 3

 

 

 

 

 

 

 

LAB1

 

Configuration PLC

I utilized a PLC setup with 140 CPU 434 12A/U 03.20 to complete the aforementioned method. Figure 1 displays the arrangement.

Since I have two outputs and four inputs in my simulation, DDM390 00 fits my demands. The fact that these inputs are digital is crucial to understand. Additionally, I used CPS 211 00 as the power source.

Figure1: Configuration PLC

 

Inventory of Function Blocks and Used Variables, Together with Their Types

 

The variables that are used are listed in Figure 1.2. BOOLEAN type variables are all that I used in the application. EBOOLEAN-type program sections are used.

 

 

Algorithm

Initialization:

 

Set initial conditions, reset any memory bits.

Define variables for inputs (START button, STOP button, EMERGENCY button, FUSE) and outputs (Alarm, Contactor).

Figure2: PLC components

Main Program:

 

Step 1 (Alarm):

 

If the START button is pressed and the EMERGENCY button is not pressed:

Turn ON the Alarm output.

Set a timer for 10 seconds.

If the timer is done (10 seconds passed):

Turn OFF the Alarm output.

Move to the next step.

 

 

Step 2 (Delay):

 

If the START button is still pressed and the EMERGENCY button is not pressed:

Set a timer for the desired delay (if any).

If the timer is done:

Move to the next step.

Step 3 (Contactor/Motor Start):

 

If the START button is still pressed and the EMERGENCY button is not pressed:

Turn ON the Contactor/Motor output.

 

Step 4 (STOP Button):

 

If the STOP button is pressed:

Turn OFF the Contactor/Motor output.

 

Step 5 (EMERGENCY Button):

 

If the EMERGENCY button is pressed:

Turn OFF the Alarm output.

Turn OFF the Contactor/Motor output.

Reset all timers.

Go back to Step 1.

 

Step 6 (FUSE):

If the FUSE input is active (similar to EMERGENCY):

Turn OFF the Alarm output.

Turn OFF the Contactor/Motor output.

Reset all timers.

Go back to Step 1.

LAB1 LD

 

 

 

 

 

 

 

 LAB1 FBD

 

  

 

 

LAB1 ST                                                                          LAB1 IL

 

 

 

LAB2

Configuration PLC

I have two digital inputs and one output in this software. I thus utilized the PLC configuration 140 CPU 434 12A/U 03.20. The power and input/output combinations are chosen in accordance with Figure 3.

Figure3: Configuration PLC

Algorithm

Figure4: PLC Components

1. Understand the Motor Direction:

Imagine there are two special buttons called "x0" and "x1" that tell us about the motor direction. We want to check if both x0 and x1 are OFF (LOW) or both are ON (HIGH). I created two special signs, "DoubleDark" and "DoubleLight to remember these conditions.

2. Detect Motor Direction:

If both x0 and x1 are OFF (LOW), set " DoubleDark " to remember it's one way.

If both x0 and x1 are ON (HIGH), set " DoubleLight " to remember it's the other way.

The next time we check, we will know the motor's direction based on the remembered conditions.

3. Show Motor Direction with Lamp:

Imagine there's a lamp that shows if the motor is turning right or left.

If " DoubleDark " is remembered (meaning the motor is turning right), make the lamp blink.

If " DoubleLight " is remembered (meaning the motor is turning left), keep the lamp constantly ON.

Putting it Together:

Check x0 and x1 to see their values.

If both are OFF, set "DoubleDark." If both are ON, set " DoubleLight "

If " DoubleDark " is set, make the lamp blink (motor turning right). If " DoubleLight " is set, keep the lamp ON (motor turning left).

Repeat:

Keep checking x0 and x1 to see if the motor's direction changes.

If it changes, update " DoubleDark " or " DoubleLight " accordingly.

Adjust the lamp based on the updated condition.

LAB2 LD

 

 

LAB2 FBD

 

LAB2 ST 

LAB2 IL

 

 

LAB3

140 CPU 434 12A/U 03.20 is what I chose. I have two digital inputs (J1, J2) and one output (LAMP) in this application. As a result, Figure 2.1's input/output and power configurations are chosen. I am able to have 8 inputs and 4 outputs in this arrangement. Figure 5 displays the arrangement.

 

 

Algorithm

Figure6: PLC Algorithm

 

Initialize Variables:

Set counters for J1 and J2 to zero.

Create a variable to store the difference between J1 and J2 (diff).

 

Main Loop:

Enter a continuous loop to repeat the process.

 

Counting Pulses:

Increment counters for J1 and J2 every time a pulse is detected.

 

Compare Every 100 Pulses:

If the counters for J1 and J2 reach 100 pulses:

Calculate the difference: diff = |J1 - J2|.

Reset counters for J1 and J2 to zero.

 

Determine Operation Mode:

If diff is less than or equal to 2:

Set the mode to NO SLIP.

Set the status to TOGGLING.

If diff is greater than 2:

Set the mode to SLIP.

Set the status to ON.

 

Perform Operations Based on Mode:

If the mode is NO SLIP:

Execute operations as if the machine is toggling.

If the mode is SLIP:

Execute operations as if the machine is on.

Repeat the Process:

 

Go back to the main loop and keep counting pulses, comparing, and performing operations.

AB3 LD

 

 

 LAB3 FBD

 

 LAB3 ST

 

 

 LAB3 IL

 LAB6

PLC Configuration

In Figure 7, the setup is displayed.

Figure7: PLC Configuration

Algorithm

Figure8: PLC Algorithm

Initialize Variables:

Set variables to track conveyor status (moving or not moving).

Set variables to track the direction of conveyor movement (right, left, or none).

Start the System:

Upon starting the program, the conveyor is assumed to be not moving.

 

Place/Remove Items:

Items can be placed on or removed from the conveyor only when it's not moving.

Move Conveyor to the Right (Ein Rechts - E3/E4):

 

 

If Ein Rechts (E3 or E4) is pressed:

Check if the conveyor is not moving.

If true, activate A1 (right movement output) and set a timer for a 1.5-second delay.

Stop Conveyor (AUS - E1/E2):

 

If AUS (E1 or E2) is pressed:

Deactivate A1 and A2 (stop movement outputs).

Automatic Stop by Light Barriers (B1/B2):

 

If light barriers B1 or B2 detect an obstacle:

Deactivate A1 and A2 (stop movement outputs).

Move Conveyor to the Left (Ein Links - E5/E6):

 

If Ein Links (E5 or E6) is pressed:

Check if the conveyor is not moving.

If true, activate A2 (left movement output) and set a timer for a 1.5-second delay.

Start Continuous Right Movement (E7/E8):

 

If E7 or E8 is pressed:

Check if the conveyor is not moving.

If true, activate A1 and set the conveyor to continuously move to the right as long as E7 or E8 is pressed.

Automatic stop by B1 or B2.

 

Deactivate Manual Control (E7/E8):

If E7 or E8 is pressed:

Deactivate Ein Rechts (E3/E4) and Ein Links (E5/E6) buttons.

 

Enable E7/E8 Only at Conveyor Halt:

E7/E8 can only be activated if the conveyor is not moving.

 

Outputs A1 and A2:

A1 and A2 control the movements to the right and left, respectively.

 

Repeat the Process:

The system continuously repeats the conveyor control process based on user inputs and sensor feedback.

 

Putting it Together:

Users can place or remove items only when the conveyor is not moving.

Buttons control movements: E3/E4 for right, E5/E6 for left, and E7/E8 for continuous right.

Conveyor stops automatically if AUS is pressed or light barriers detect obstacles.

Manual control buttons (Ein Rechts, Ein Links) are deactivated when continuous right movement is initiated.

E7/E8 can only be pressed when the conveyor is at a halt.

 

LAB6 ST

 LAB7

Configuration PLC

In Figure 9, the setup is displayed.

Figure9: PLC Configuration

 

Algorithm

Figure10: PLC Algorithm

 

 

 

Initiation:

Press the "Freigabe" button to start the process.

 

 

Box Placement and Bottle Transportation:

Upon pressing "Freigabe," position the box and transport bottles to the filling location.

 

Filling Process:

If the bottle reaches the filling position:

Stop the conveyor immediately.

Lower the dosing head to the appropriate level.

 

Valve Activation:

Activate the filling valve for a specific duration (5 seconds) to fill the bottle.

 

Completion of Filling:

After the set time, the dosing head ascends, indicating the completion of the filling process.

 

Bottle Transfer to the Box:

Move the filled bottle to the designated box.

 

Cycle Reiteration:

Repeat the entire cycle with a 1-second delay before starting the next cycle.

Cycle Counting:

Keep track of the number of cycles.

If 12 cycles are completed (12 filled bottles), proceed to the box replacement step.

 

Box Replacement:

Press the "Freigabe" button again to initiate the box replacement process.

 

End of Algorithm:

The algorithm concludes, and the system is ready for the next set of cycles.

 

LAB7 FBD

 

LAB8

 

Configuration PLC

In Figure 11, the setup is displayed.

Figure11: PLC Configuration

 

Algorithm

Figure12: PLC Algorithm

 

Initialize Variables:

Set a variable to track the current mode (Manual or Semi-automatic).

Initialize variables for log sizes (small, medium, long).

Start the System:

Upon starting the program, logs begin to move through three light barriers.

 

Log Sorting Process:

Logs are transported through the light barriers for detection.

If a log is small, it goes to Box 1. If medium, it goes to Box 2. If long, it needs processing elsewhere.

 

 

 

Ensure Sequential Sorting:

The next log can only be taken if the current log is sorted. Detection is performed by the light barriers.

 

Manual Mode:

If the system is in Manual Mode:

Logs are sorted when the start button is manually pressed.

Long logs cannot be sorted even if the button is pressed.

 

Semi-automatic Mode:

If the system is in Semi-automatic Mode:

Short and medium logs are automatically sorted after the start button is pressed.

Long logs are automatically sorted.

 

Change Log Size Processing:

If a change is needed in log size processing (e.g., different processing for long logs), the system should be configured accordingly.

 

Repeat the Process:

The system continually repeats the log sorting process, ensuring sequential sorting and adherence to the selected mode.

 

Putting it Together:

Logs move through light barriers for detection.

Based on the mode (Manual or Semi-automatic), logs are sorted accordingly.

Long logs are processed elsewhere.

The system continuously repeats the sorting process based on the selected mode.

 LAB8 LD