Linux-Based PLC for Industrial Control

What Linux is doing for the highly proprietary embedded systems market is what the PuffinPLC will do for industrial automation.
The Vitrine

This simple, curses-based display can show the status of PuffinPLC points as they change. The data in the plc point may be in any of several integer formats or a 32-bit float. Support for basic graph drawing, based on the values of plc points, is currently being added. While in some ways the vitrine may be considered a stop-gap, many applications will not need the full power of a graphical interface and will appreciate the lower CPU demands of plain text.

The Keyboard Module

This is an I/O module or, more precisely, an input-only module. It maps the states of keyboard keys to PuffinPLC points. It is intended primarily for debugging and demonstration purposes.

The Parallel Port Module

The parallel port module was written to provide support for cheap, physical I/O. It will allow users with low budgets to evaluate the potential of the PuffinPLC or use it in simple settings. The parallel port provides eight LS TTL level inputs/outputs, five LS TTL level inputs and four TTL open collector outputs. These last four outputs can sometimes also work as inputs when placed in their high impedance state.

The Modbus Modules

Two modules support the modbus protocols, one for modbus_tcp and another for modbus_rtu. These modules allow the PuffinPLC to communicate with the real world by Ethernet (modbus_tcp) or a serial port (modbus_rtu).

The DIO48 Card Module

Physical I/O is also possible using extra I/O boards. Currently the CIO-DIO(48, 96, 192) digital I/O boards are supported by the DIO48 module. These cards are based on the 8255 integrated circuit. The 8255 chip is used in most industrial PC I/O boards, so this module covers a great range of relatively high-speed I/O.

The Hilscher Card Modules

We will soon start work on supporting fieldbus network cards made by Hilscher (http://www.hilscher.com/), as they have kindly made some of their cards available to the project. These cards will allow the PuffinPLC to communicate with practically any networked device on the factory floor. They support ASI, CANopen, ControlNet, DeviceNet, InterBus, ModConnect, ProfiBus and SDS communication protocols.

The Allen Bradley PLC5 Language Emulator

With the help of its original author, Hugh Jack, we will be porting an AB PLC5 emulator as a PuffinPLC module. This will allow the PuffinPLC to execute existing AB PLC5 programs, easing the transition to a PuffinPLC.

Code for the PuffinPLC can be obtained from the project's CVS server at our web site, http://www.puffinplc.org/. A first full release is expected shortly. In the meantime, the project is evolving in many directions, including support for other hardware and communication protocols.

Although the project is still in its infancy, it is already possible to identify some of the hurdles we face. It has not been easy to get people from the automation industry involved in writing code, mainly because of time limitations and sometimes due to a lack of Linux-based programming knowledge. Nevertheless, we have a large, silent following that will prove very useful when the time comes for debugging the beta releases. Another obstacle is obtaining copies of communication protocol standards. Some are very expensive; some standards bodies require an official organization to represent the PuffinPLC as a member; and some standards require expensive conformance testing to use their protocol name. This is why we do not expect to directly support, in the near future, many of the communication protocols used in factory automation. For now, we will support commercial add-on cards that implement these protocols.

Despite these obstacles, the industry has already begun to provide support for this project. Help has come from integrators interested in the success of the project and PC hardware vendors that want their hardware to work with the PuffinPLC.

I would like to finish by thanking Jiri Baum for coming up with the basic PuffinPLC architecture and for having written many modules besides the initial version of the library. He is still actively contributing to the project. I would also like to thank David Campbell (IEC compiler) and Philip Costigan (Modbus modules) for their continuing contributions. I also appreciate the help of Curt Wuollet, the project's founder, Jiri, for having written the article's introduction and the staff at Control.com for helping out with the drawings.

Whose Project Is It, Anyway?

The Petri Net Model

Mario de Sousa, an electrical engineer, is currently a lecturer on industrial automation systems in Porto University's engineering faculty. He is the proud father of two-month-old Catarina, who seems to be taking up most of his spare (and non-spare) time. He can be reached by e-mail at msousa@fe.up.pt.

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