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What is PLC

 

 

A programmable logic controller (PLC) or programmable controller is an industrial computer that has been ruggedized and adapted for the control of manufacturing processes, such as assembly lines, machines, robotic devices, or any activity that requires high reliability, ease of programming, and process fault diagnosis. If you want to know the specifications and prices of PLC, please contact us!

 

Advantages of PLC
 

More Performance, Less Space
PLCs offer a robust means of delivering complex control based on complex computation, capable of acting on inputs from the many devices and sensors found in modern, industrial settings. Since the logical operations previously carried out by relays and timers are now managed in software, the physical space within a control panel required to provide this control is reduced, in turn saving space on site. In addition, the computational power of the PLC means that much more advance control can be achieved than would previously have been the case.

 

Communication
PLCs can provide the ability for a system to be monitored remotely, providing detailed information on the performance of a system, or condition monitoring data to a central control location. This location could be in the same building or hundreds of miles away. By using this capability, the operator can maximise the performance of their system without the need to be physically present.
For those occasions when physical interaction is required, then PLCs can be used to control displays mounted on the control panel, providing an advanced human machine interface (HMI) to de-bug, monitor and improve the performance of the control panel in-situ. PLCs can also be networked, allowing the performance of the control panel and the system it controls to be monitored.

 

Reliability
Once software has been written, debugged and tested it will run reliably with no degradation over time due to the aging of components. As such, systems controlled by PLCs offer greater reliability than their predecessors. In addition, the reduced number of electrical connections provide less opportunity for error in manufacture and commissioning.

 

Flexibility and Maintainability
The requirements of industrial applications often develop over time with system improvements and up-grades. Having a software-based control solution provides greater flexibility to accommodate developments, wiring changes can be minimised and downtime reduced. In addition, the ability for PLCs to communicate with other systems can allow software up-dates to be implemented remotely. Debugging of changes is also simplified, since the programme can easily be downloaded and visualised by the engineers responsible.

 

Reduced Cost
Where multiple versions of the same system are deployed, cost can be saved through the reuse of software. Once a programme has been developed and proven to work on the first implementation of a system, it does not need to be re-written on subsequent implementations of the same system. Such repeatable control can be delivered for just the cost of the hardware elements of the system.

 

Types of PLC

Mini PLCs
They are small, low-cost controllers that are ideal for simple control applications. They typically have fewer input/output (I/O) points than larger controllers and can be programmed using ladder logic or other programming languages. Mini PLCs offer fast installation due to their small size and often come with built-in I/O capabilities such as digital inputs, analog outputs, and pulse outputs.


Modular PLCs
They consist of a base unit that contains the processor module and communications ports, along with smaller modules that can be added to extend the system's functionality. Modular systems offer more flexibility than fixed systems since they allow users to mix different types of I/O modules to meet their specific application requirements.


Fixed PLCs
They are designed for dedicated tasks and cannot easily be modified once installed; however, they provide cost-efficient solutions for many repetitive tasks. Fixed systems are suitable for straightforward process control applications where parameters do not need to change frequently or rapidly during operation.

Micro PLCs

They offer an intermediate level of complexity between mini models and modular designs; they are usually compact devices capable of controlling multiple processes simultaneously without requiring additional hardware components like expansion cards or rack units found in some modular models. Microcontrollers can also feature integrated communication functions such as Ethernet networking protocols for easy integration into a distributed automation system architecture.

Nano PLCs

They represent the latest generation of programmable logic controllers – these ultra-compact devices use advanced microcontrollers combined with specialized programming software tools to reduce costs while providing high levels of processing speed and accuracy. Nano PLCs are even used in highly complex applications involving multiple axes movement or sophisticated machine vision operations like object recognition algorithms & pattern matching techniques.

Safety PLC

A Safety PLC is designed to implement safety functions in industrial automation. It ensures the protection of personnel, equipment, and the environment by adhering to international safety standards like IEC 61508. Safety PLCs incorporate redundancy, and diagnostic capabilities, and are assigned Safety Integrity Levels (SIL) to ensure high reliability and fault tolerance.

 

PLC Applications in Our Everyday Lives
 

Road Traffic Signals

It's difficult to picture our modern world without traffic signals. Those three colored streetlights are used and understood by people all around the world. This simple but ingenious application of the PLC has a long history in major cities and small towns all around the world, since their first application traffic control in 1926 in London, England. These traffic lights, that we take for granted every day are monitored and controlled by PLC hardware and software, running dependably and without fuss 24/7/365 days a year.
Have you ever noticed when you travel at rush hours on a busy street, it is an entirely different experience than at low traffic periods? If a pedestrian pressd the button to cross at an intersection, how does that affect flow of the vehicles? Do traffic lights actually "see" an emergency vehicle and allow it to blaze through an intersection? Using emergency vehicle transponders, sensors, and plc circuits to control the traffic lights, traffic flow is coordinated and managed to allow for more timely and direct rescue services.

The Automatic Car Wash

In any busy metropolis where car traffic is present, there are many gas stations accompanied by automatic or "touch-less" car wash stations. As you take a trip inside the touch-free carwash, you will find the water mixed with cleaning solutions, blasting the surface of the vehicle and spinning wipers for scrubbing. Every process is calculated and carefully controlled, from how many litres/gallons of soap is used, to the length of time those tall rotating wipers spin. These time and work saving services are completely automated by PLCs, with little human interaction other than a press of button at the entrance.

The Elevator

The elevator industry is on the rise; pun intended. In every multifloor building, an elevator is present, no matter how short or tall. Recall those times when the elevator door opens and you step inside to find that it was headed in the wrong direction? Has this ever made you wonder who or what is controlling it to do so? To give you a clue, there is a defined program running in a PLC that detects the different floors requesting the elevator and directing the elevators in their required direction. These programs are sets of ladder logic instructions that are loaded into the PLC controlling the lift. The controllers are usually not located in the elevator itself but at a specific location on the roof of the building or in a nearby control room. I once naively believed that summoning an elevator to my floor was performed on a first come, first serve basis but this is not the case, if the elevator is already in motion. Most elevators are programmed and controlled by PLCs to take the most optimized route through any pending button calls and make their directional decisions based on that.

Automatic Doors

Do you recall a time not too long ago when a person might be hit by an automatic door swinging open? Luckily today, there are better PLC controls with better built-in sensor on both sides of the door to prevent such occurrences. There are a many ways for an automatic door to function but in general they operate by way of a detector, for example a beam of light being broken, causing the system to identify something in front of, or between, the doors.

Conveyer Belts

When paying for your purchases at your neighborhood supermarket, the lowly conveyer belt moves your purchases into the reach of a friendly cashier. Imagine the inconvenience, if a plc was not there helping control the belt, making the process of checking out simple and painless. Bigger conveyer belts can be found in airports where they transport people or put your luggage on carousel until you claim it. There are even giant conveyor belts that transfer construction materials. Conveyor belts are also used in most manufacturing plants due to their convenience and uniform motion.

Roller Coasters

Many people love exploring new heights and pushing themselves towards the thrill of a near death experience, on you guessed it, the PLC controlled roller coaster. Whether or not you scream at the top of your lungs is a different story.
Typically, the PLC control in roller coasters is for bringing it upwards before the big drop. It is also used for safety measures so that the cars do not reverse in direction. Imagine travelling backwards on the huge dip; it wouldn't be as thrilling as the gravitational force pulling down.
Almost everywhere you look today, PLCs are playing an important part controlling the technology that supports our hi-tech lifestyles. From traffic lights to roller coasters they provide us with robust and reliable control mechanisms that improve our lives. PLC technicians work to maintain and support these technologies, providing a critical service that keeps us safe and moving through our busy lives.

 

 
Component of PLC
 

 

 
Power Supply

The power supply converts facility electrical distribution voltage, such as 230 VAC, 120 VAC or 125 VDC to signal level voltage used by the plc processor and other modules.

 
Processor

The processor module contains the microprocessor that performs control functions and computations, as well as the memory required to store the program.

 
Input/Output (I/O)

These modules provide the means of connecting the processor to the field devices. Examples of these modules are Analog Input Module, Analog output module, Digital input module, Digital output module etc.
These are used to connect devices between plc and field devices like flow transmitters, pressure transmitters, control valves, analyzers, substation feeders for motor control etc.

 
Communication

Communications modules are available for a wide range of industry-standard communication network connections. These allow digital data transfer between PLCs and to other systems within the facility.
The most commonly used modules are Modbus communication cards or Serial communication.
Some PLCs have communications capability built-in to the processor, rather than using separate modules.

 
Communication Media and Protocols

The most common communication media used are copper-wire, coaxial, fiber-optics, and wireless. The most common "open" communication protocols are Ethernet, Ethernet/IP, and DeviceNet.
"Open" systems generally provide "plug and play" features in which the system software automatically recognizes and communicates to any compatible device that is connected to it.
Other widely accepted open protocols are Modbus, Profibus, and ControlNet.

 
Redundancy

Many PLCs are capable of being configured for redundant operation in which one processor backs up another.
This arrangement often requires the addition of a redundancy module, which provides status confirmation and control assertion between the processors. In addition, signal wiring to redundant racks is an option.

 

 

Frequently Asked Questions

 

Q: What is the PLC used for?

A: A Programmable Logic Controller, or PLC, is a ruggedized computer used for industrial automation. These controllers can automate a specific process, machine function, or even an entire production line.

Q: What is the function of a PLC?

A: PLCs act as the physical interfaces between devices on the plant or manufacturing floor and a SCADA or HMI system. PLCs can communicate, monitor, and control complex automated processes such as conveyors, temperature control, robot cells, and many other industrial machines.

Q: What is PLC and its working principle?

A: A PROGRAMMABLE LOGIC CONTROLLER (PLC) is an industrial computer control system that continuously monitors the state of input devices and makes decisions based upon a custom program to control the state of output devices.

Q: Why is PLC needed?

A: PLCs are the preferred method of controlling, measuring, and carrying out tasks in complex manufacturing and industrial applications because they play nicely with other systems. PLCs work well with PCs, PACs (programmable automation controllers), motion control devices, and HMIs.

Q: How is PLC used today?

A: The PLC is also commonly used in civil applications such as in washing machines and for controlling traffic signals and elevators. They are used in many industries to monitor and control production processes and building systems.

Q: What language does PLC use?

A: Conclusion. The five most popular PLC Programming Languages are Ladder Logic, Structured Text, Function Block Diagrams, Sequential Flow Charts and Instruction Lists. These methods of programming are available on most platforms.

Q: Why is the PLC important?

A: The primary goal of a PLC is to foster a collaborative culture where educators work together to improve their instructional practices, share ideas, analyze data, and support each other in meeting the needs of all students.

Q: Why do people use PLC?

A: The PLC provided several advantages over earlier automation systems. It tolerated the industrial environment better than the former systems and was more reliable, compact, and required less maintenance than relay systems. It was easily extensible with additional I/O modules.

Q: What is the primary purpose of the PLC?

A: Fundamentally, a PLC's job is to control a system's functions using the internal logic programmed into it. Businesses around the world use PLCs to automate their most important processes. A PLC takes in inputs, whether from automated data capture points or from human input points such as switches or buttons.

Q: Why do people still use PLCs?

A: From traffic lights to roller coasters they provide us with robust and reliable control mechanisms that improve our lives. PLC technicians work to maintain and support these technologies, providing a critical service that keeps us safe and moving through our busy lives.

Q: Which PLC is widely used?

A: Siemens Simatic PLC: Siemens takes the crown as the most popular PLC, boasting the Simatic series. Known for its reliability and robust features, Simatic PLCs have become the go-to choice for a myriad of industrial applications.

Q: Is PLC programming easy?

A: PLC programming is much easier to grasp than most other modern programming languages. However, the job of a PLC programmer is broader in scope than PLC programming alone.

Q: How to write PLC code?

A: The most common way to write PLC programs is using ladder logic, which is a graphical language that resembles electrical schematics. Each line of ladder logic is called a rung, and each rung has one or more conditions and one or more actions.

Q: Why PLC is better than computer?

A: PLCs are typically more compact and rugged than PCs, and they are optimized for real-time control tasks with no extras. This technology has been hardened over decades for safety and durability.

Q: Why are PLCs so popular?

A: PLCs have proven to be reliable enough for accuracy and consistency in this fast-paced sector. As they are more reliable than relay systems, downtime, and production delays are rare.

Q: How can I learn PLC fast?

A: Read the PLC programming manuals: Read the manuals provided by the manufacturer of your PLC system. These manuals will give you a better understanding of the specific system you are working with. Practice, practice, practice: The best way to improve your PLC programming skills is to practice.

Q: What is the main role of PLC?

A: The fundamental role of a PLC is to automate processes by sending programmed control functions to output devices based on signals received from connected input devices. An input device measures and transmits data from your system, such as a sensor, switch, thermometer, or relay.

Q: How can a PLC fail?

A: Common reasons why PLC control systems fail include module failure, power outages and bad network connections. PLC failure issues can also stem from overheating, moisture and electromagnetic interference.

Q: Is PLC still used today?

A: It is utilized in many modern manufacturing facilities today. Different PLC platforms are preferred in different parts of the world. Originally designed to replace hardwired systems composed of relays, cam timers, drum sequencers, and dedicated closed-loop controllers.

Q: How is PLC useful?

A: PLC is an industrial computer that monitors inputs and outputs to make decisions based on the program stored in the PLC's memory. The use of PLCs helps to reduce human decision-making efforts to gain higher efficiency.

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