Control system covers all aspects of automation

Paul Boughton
Pilz is launching the PSS4000 automation system for all machine control and safety technology functions, including motion control, diagnostics and visualisation. The aim is to simplify the decentralisation of control functions and reduce the engineering effort. A new software platform, known as PAS4000 (Pilz Automation Suite) plays a key role, enabling users to retain a centralised view of decentralised, distributed control structures. The PSS4000 can be used across a range of industries and for applications of almost any size.

With the PSS4000 concept Pilz has taken into account customers' requirements for a complete system that is easy to operate and considers the requirements for safety of man and machine from the outset. The PSS4000 enables users to reap the benefits of a decentralised control structure without the increased complexity this would normally involve, and the interface problems associated with the connection of multiple control systems are eliminated.

As a result, decentralisation can help achieve a higher level of reusability and increase the level of standardisation when identical control programs and subfunctions are used. This, in turn, allows machine elements to have a modular structure so that identical components can be reused with a minimum of effort. The benefits can be seen in greater availability and higher productivity due to improved diagnostics.

The tools within the PAS4000 software platform for programming and parameter setting functions are fully compatible, with standard data and user interfaces. Not only does this make it easier to start working with or upgrade to the PAS4000, it also means that multiple entries can be avoided, thereby minimising the sources of error that are often associated with manual data entry. PAS4000 offers established programming languages in accordance with IEC 61131-3. Furthermore, Pilz has further developed the proven, easy-to-use configuration tool for the PNOZmulti safety system and, with PASmulti, provides its own user-friendly editor.

Component-oriented programming is a key aspect of PAS4000. Tested software blocks for common functions are available in a library, which can be expanded at will. A new feature is the ability to expand this library with a customer's own choice of components. The benefit can be seen in the high reusability of predefined functions and the reduced programming and engineering work. Working with components means that programming can be separated from the hardware design, so that projects can be processed in parallel. Once the machine functions have been standardised by creating components within libraries, it is said to be quite simple to design the overall structure of the machine, based on the initial information. Detailed function can be determined later.

With PAS4000, standard control functions and, it is said, for the first time safety functions too, can be created and managed symbolically. This mapping will be extended to the hardware at a later stage. All Safetynet p devices will have direct access to this system-wide mapping table, resulting in exceptional flexibility when implementing an application. This will have a positive impact not just during commissioning but also when changes are made later, because there will be no need to change the wiring. Neither will there be any problem exchanging hardware. Symbolic descriptions and addressing of periphery signals, programs and devices can be implemented across the board. Self-explanatory descriptions make it so much easier to find your way round the plant or machine when programming and during subsequent service functions.

The PSS4000 automation system is based on the proven, decentralised PSSuniversal I/O system. Head modules in various performance ratings have been developed for the PSS4000's first expansion phase; these are available for all safety-related and standard control functions. Safetynet p, the real-time Ethernet protocol, lies at the heart of the PSS3000 concept, being used to network all the control components and transfer safety-related and non-safety-related data, as well as data for diagnostics, visualisation and motion control.

For more information, visit www.pilz.de

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