Intoduction to PLC and Industrial Automation
Hello guys👋😎, today I am exciting to share with
you some useful information’s that certainly help you to beginning in the world
of industrial automation, what else if you are a student, technician or
engineer, you should have a minimum knowledge about PLC’s.
PLC or “Programmable
Logic Controller” is one of essentials components that has revolutionized the
landscape of industrial automation and development. PLC is a digital computing device specifically designed to control,
monitor, and automate various processes in industrial applications. It acts as
the brain of industrial systems, allowing for precise control, real-time
monitoring, and seamless coordination of machinery and processes.
PLCs were initially developed in the late
1960s to replace traditional relay-based control systems or also known as classic
control, which come more complex with big application and complex process
that require huge number of electrical components classic control in this case
will be more expensive, and less flexible.
The first
PLC was created by Dick Morley in 1969, revolutionizing the automation
industry. Since then, PLCs have evolved exponentially in terms of capabilities,
processing power, and versatility.
So, what is the main components of PLC?
PLC Compenents:
A typical
PLC compose of three main components:
- Power Supply: PLCs require a stable power supply to
function correctly. The power supply provides the necessary electrical power to
all the components of the PLC, ensuring smooth operation
- CPU: The central processing unit or the processor, his role to executes programs and processes data from various input devices The central processing unit is the brain of the PLC. It executes the control program and performs various calculations and logical operations based on the inputs received from input modules. The CPU also handles communication between different components of the PLC..
- Input Modules: These modules are responsible for acquiring data from sensors and other input devices, converting them into digital signals, and sending them to the processor, and there two types of input modules Digital and Analog.
- Output Modules: These modules receive signals from the
processor and activate various output devices, such as motors, solenoids, and
valves, to control the industrial process. and there two types of input modules Digital and Analog.
- Communication Ports: PLCs often come equipped with communication ports in the CPU (Ethernet, serial, USB) that allow them to communicate with other devices, such as computers, Human Machine Interfaces (HMIs), or other PLCs, for data exchange and system integration.
.png "PLC Control")
And who it operates?
Opreration principle of PLC:
- Input Scan: The PLC starts its operation by performing an input scan. during this phase, the PLC reads the state of various input devices connected to the input modules, such as sensors, switches, and other digital or analog devices.
- Program Execution: After completing the input scan, the PLC's central processing unit (CPU) executes the control program stored in its memory. This control program is a sequence of logical instructions written by the programmer using ladder logic, function block diagrams, or other programming languages.
- Logical Processing: The CPU processes the control program based on the input values obtained during the input scan, logical operations, such as AND, OR, NOT, timers, counters, and comparison functions, are used to determine the appropriate output states based on the current inputs and the logic defined in the program.
- Output Scan: in this phase, the CPU sends output commands to the output modules based on the results of the logical processing, the output modules actuate various devices, such as motors, solenoids, valves, and indicators, to control the industrial process according to the programmed logic.
- Update Output Devices: the output devices are updated to their new states based on the output commands from the PLC,this step completes the control action affecting the connected industrial system
.png "Communication with PLC CPU")
Advantages of PLC in Industrial Automation:
- Flexibility: PLCs allow for easy modification and reprogramming of control logic without significant hardware changes, enabling rapid adaptability to changing production requirements.
- Reliability: PLCs are known for their robustness and reliability, ensuring continuous operation in harsh industrial environments.
- Diagnostics and Monitoring: PLCs facilitate real-time monitoring, diagnostics, and error reporting, which aids in predictive maintenance and reduces downtime.
- Increased Productivity: Automation through PLCs improves efficiency, reduces human error, and enhances overall productivity.
These
advantages allow PLC to be used in a wide range of industrial application like:
- Manufacturing: Automating assembly lines, robotics, and
quality control processes.
- Energy: Monitoring and controlling power
generation and distribution systems.
- Transportation: Managing traffic control systems, railway
signaling, and airport baggage handling.
- Water Treatment: Controlling purification, pumping, and distribution processes.
Conclusion:
In conclusion, Programmable
Logic Controllers, have played a pivotal role in the development of various
industries, bringing automation, efficiency, and reliability to the forefront
of industrial processes. Their evolution from classic control system to
sophisticated digital controllers has transformed the industrial landscape,
driving progress and innovation. As technology continues to evolve, PLCs will
remain at the heart of modern industrial automation, propelling us towards a
more connected, efficient, and sustainable future.
In order to
get a better understanding about PLC their components and how it operates I
will give you an incredible guide lines that introduce to PLC and industrial
automation with professional, simple and amazing way
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