| Today, speed and flexibility in programming and configuring of automation control systems has become essential for industrial productivity. However, the programming of controller systems such as Programmable Logic controllers (PLCs) still very much relies on trial-and-error and lacks systematic and scientific approaches. In addition, continuing growth of the program size is certain in today's automation systems and increases complexity of the design process.; The goal of this research is, therefore, to develop a design methodology that facilitates systematic and effective software design for modern manufacturing systems, particularly for PLC operated automation systems. This research involves studies of current practices and concepts, model formalism based on discrete event system (DES) theory and recent developments in design methodology. Prevailing design theories, such as axiomatic design (AD), seems suitable for directing the design of large-scale and complex systems because of its recursive design process and its general applicable design principles. Advancing this theory into the software design domain is currently a challenge in research of engineering design.; A design methodology for PLC program design is proposed with: (i) defining a framework of a systematic design methodology in PLC operated automation systems, (ii) identifying and deriving formal modeling notations underlying the descriptive expression of the design object, i.e. , the PLC program, (iii) developing a prescriptive design process that facilitates the mapping from the functional requirements to the design specification, or design parameters, (iv) developing an effective “blue print”, a representation for the design, assuring the repeatability and reusability of the design outputs, and (v) the validation of this design methodologies by applying real-world examples. In addition, due to the increasing demand for higher flexibility, reconfiguration design and design automation, i.e., code generation rules will be formulated. The proposed systematic programming methodology aims at improving the development of PLC operated automation systems for a wide range of applications. It will also reduce the uncertainty of managing the PLC software development, and facilitate the use of simulation technology for systems validation. |
