Trend charts for process variables in PLC Programming

Introduction

Trend charts help you see how process values change over time. They make it easy to spot problems or patterns.

Monitoring temperature changes in a machine during operation.

Tracking pressure levels in a pipeline to detect leaks.

Observing flow rates in a water treatment plant.

Checking voltage or current trends in electrical equipment.

Recording humidity levels in a storage room.

Syntax

PLC Programming

1. Define variables to store process values.
2. Use a timer or cycle count to sample values regularly.
3. Store sampled values in an array or buffer.
4. Use a display or HMI function to plot the stored values as a chart.

Sampling frequency affects how smooth and detailed the trend looks.

Buffers usually have a fixed size; old data is replaced by new data.

Examples

This example stores temperature readings in a 10-value array, updating the index each cycle.

PLC Programming

// Define array to hold 10 samples
VAR
  TempSamples: ARRAY[1..10] OF REAL;
  SampleIndex: INT := 1;
  CurrentTemp: REAL;
END_VAR

// On each cycle
CurrentTemp := ReadTemperatureSensor();
TempSamples[SampleIndex] := CurrentTemp;
SampleIndex := SampleIndex MOD 10 + 1;

This example uses a timer to sample temperature every second and store it in a 20-value array.

PLC Programming

// Using a timer to sample every second
VAR
  Timer1: TON;
  TempSamples: ARRAY[1..20] OF REAL;
  SampleIndex: INT := 1;
END_VAR

Timer1(IN:=TRUE, PT:=T#1S);
IF Timer1.Q THEN
  TempSamples[SampleIndex] := ReadTemperatureSensor();
  SampleIndex := SampleIndex MOD 20 + 1;
  Timer1(IN:=FALSE);
END_IF

Sample Program

This program simulates reading temperature values 10 times, stores the last 5 in a circular buffer, and prints them.

PLC Programming

VAR
  TempSamples: ARRAY[1..5] OF REAL := [0,0,0,0,0];
  SampleIndex: INT := 1;
  CurrentTemp: REAL;
  CycleCount: INT := 0;
END_VAR

// Simulate reading temperature and storing samples
FOR CycleCount := 1 TO 10 DO
  CurrentTemp := 20.0 + CycleCount * 0.5; // Simulated temperature
  TempSamples[SampleIndex] := CurrentTemp;
  SampleIndex := SampleIndex MOD 5 + 1;
END_FOR

// Print stored samples
FOR SampleIndex := 1 TO 5 DO
  Print('Sample ' + INT_TO_STRING(SampleIndex) + ': ' + REAL_TO_STRING(TempSamples[SampleIndex]));
END_FOR

Important Notes

Trend charts need regular sampling to show accurate changes.

Use circular buffers to keep memory use small and recent data available.

Display functions depend on your PLC or HMI system capabilities.

Summary

Trend charts show how process variables change over time.

Store samples regularly in arrays or buffers.

Use timers or cycle counts to control sampling frequency.

Practice

1. What is the main purpose of a trend chart in PLC programming for process variables?

easy

A. To show how process variables change over time

B. To control the speed of the PLC processor

C. To reset the PLC memory automatically

D. To display error messages only

Solution

1. Step 1: Understand the role of trend charts

   Trend charts are used to visualize data changes over time, especially for process variables like temperature or pressure.

2. Step 2: Eliminate unrelated options

   Options about controlling processor speed, resetting memory, or showing errors do not relate to trend charts.

3. Final Answer:

   To show how process variables change over time -> Option A

4. Quick Check:

   Trend charts = show variable changes over time [OK]

Hint: Trend charts visualize data changes over time [OK]

Common Mistakes:

• Confusing trend charts with control functions
• Thinking trend charts reset PLC memory
• Assuming trend charts only show errors

2. Which of the following is the correct way to declare an array to store 10 samples of a process variable in a PLC program?

easy

A. ARRAY samples[10] REAL;

B. samples = [10] REAL;

C. VAR samples: REAL[10]; END_VAR

D. VAR samples: ARRAY[1..10] OF REAL; END_VAR

Solution

1. Step 1: Recognize PLC array declaration syntax

   In many PLC languages, arrays are declared with VAR, specifying index range and type, e.g., ARRAY[1..10] OF REAL.

2. Step 2: Check each option

   VAR samples: ARRAY[1..10] OF REAL; END_VAR matches correct syntax. Options A, B, and D use incorrect or invalid syntax for PLC arrays.

3. Final Answer:

   VAR samples: ARRAY[1..10] OF REAL; END_VAR -> Option D

4. Quick Check:

   Correct PLC array syntax = VAR samples: ARRAY[1..10] OF REAL; END_VAR [OK]

Hint: Use VAR and ARRAY with index range for PLC arrays [OK]

Common Mistakes:

• Using incorrect brackets or missing VAR keyword
• Confusing array syntax with other languages
• Not specifying index range properly

3. Given the following PLC code snippet that samples a temperature every cycle and stores it in an array of size 5, what will be the content of the array after 7 cycles?

VAR samples: ARRAY[1..5] OF REAL; index: INT := 1; temp: REAL; END_VAR

// On each cycle:
temp := ReadTemperature();
samples[index] := temp;
index := index + 1;
IF index > 5 THEN
  index := 1;
END_IF

medium

A. The array is empty because index resets too early

B. The array contains the first 5 temperature samples from cycles 1 to 5

C. The array contains the last 5 temperature samples from cycles 3 to 7

D. The array contains only the temperature from cycle 7 repeated

Solution

1. Step 1: Understand the circular buffer logic

   The index increments each cycle and resets to 1 after 5, so the array stores the last 5 samples in a loop.

2. Step 2: Analyze after 7 cycles

   After 7 cycles, index has wrapped around once. The array holds samples from cycles 3 to 7, overwriting the first two samples.

3. Final Answer:

   The array contains the last 5 temperature samples from cycles 3 to 7 -> Option C

4. Quick Check:

   Circular buffer stores last 5 samples = The array contains the last 5 temperature samples from cycles 3 to 7 [OK]

Hint: Index resets after max size to overwrite oldest samples [OK]

Common Mistakes:

• Thinking array holds first 5 samples only
• Assuming array is empty due to index reset
• Believing array repeats last sample only

4. Identify the error in this PLC code snippet intended to sample a pressure value every 10 cycles and store it in an array:

VAR samples: ARRAY[1..5] OF REAL; counter: INT := 0; index: INT := 1; pressure: REAL; END_VAR

counter := counter + 1;
IF counter = 10 THEN
  samples[index] := ReadPressure();
  index := index + 1;
  counter := 0;
  IF index > 5 THEN
    index := 1;
  END_IF
END_IF

medium

A. The counter increments every cycle but sampling happens only when counter equals 10

B. The index reset condition should be inside the first IF block

C. The counter should reset after index increments, not before

D. The index reset condition is outside the sampling IF block, causing incorrect indexing

Solution

1. Step 1: Review index reset placement

   The index reset IF was outside the sampling IF, causing it to run every cycle and reset index prematurely.

2. Step 2: Correct placement

   Moving the index reset condition inside the sampling IF block ensures index resets only after a new sample is stored, preventing incorrect indexing.

3. Final Answer:

   The index reset condition should be inside the first IF block -> Option B

4. Quick Check:

   Index reset must be inside sampling block [OK]

Hint: Keep index reset inside sampling condition to avoid errors [OK]

Common Mistakes:

• Placing index reset outside sampling condition
• Resetting counter at wrong time
• Misunderstanding counter increment logic

5. You want to create a trend chart that samples a flow rate every 5 seconds and stores the last 12 samples. Which approach correctly implements this in a PLC program?

hard

A. Use a timer that triggers every 5 seconds to read flow rate, store it in a 12-element array, and use a circular index to overwrite oldest samples.

B. Sample flow rate every cycle without timing, store in a 12-element array, reset index after 12 cycles.

C. Use a timer to sample every 12 seconds, store in a 5-element array, and reset index after 5 samples.

D. Sample flow rate only once at start, store in a 12-element array, then never update.

Solution

1. Step 1: Match sampling frequency and storage size

   The requirement is to sample every 5 seconds and keep last 12 samples, so timer interval and array size must match.

2. Step 2: Use circular buffer logic

   Using a timer to trigger sampling every 5 seconds and a circular index to overwrite oldest samples in a 12-element array fits the need.

3. Final Answer:

   Use a timer that triggers every 5 seconds to read flow rate, store it in a 12-element array, and use a circular index to overwrite oldest samples. -> Option A

4. Quick Check:

   Timer + circular buffer = correct trend sampling [OK]

Hint: Timer triggers sampling; circular buffer stores last samples [OK]

Common Mistakes:

• Sampling every cycle without timing control
• Using wrong timer interval or array size
• Not overwriting oldest samples properly