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New trends in Programmable Logic Controller

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A programmable logic controller (PLC) is an automated system that collects data from a variety of input devices, including sensors that monitor parameters such as storage tank levels, pressure, and temperature. Using programmed software logic, the PLC then processes the collected data, makes appropriate logic-based decisions, and sends issued instructions and commands to process and machine control. PLCs have been around for nearly 50 years and are still considered the best option for a wide range of industrial automation applications. Despite that era, PLC technology is evolving and PLCs are expected to maintain their dominance in the world of industrial automation for the next few years. Below are some of the 10 latest technological developments that have evolved and adapted PLC technology to the times. – PowerPoint PPT presentation

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Title: New trends in Programmable Logic Controller


1
New trends in Programmable Logic Controller
2
  • A programmable logic controller (PLC) is an
    automated system that collects data from a
    variety of input devices, including sensors that
    monitor parameters such as storage tank levels,
    pressure, and temperature. Using programmed
    software logic, the PLC then processes the
    collected data, makes appropriate logic-based
    decisions, and sends issued instructions and
    commands to process and machine control. PLCs
    have been around for nearly 50 years and are
    still considered the best option for a wide range
    of industrial automation applications.
    Despite that era, PLC technology is evolving and
    PLCs are expected to maintain their dominance in
    the world of industrial automation for the next
    few years. Below are some of the 10 latest
    technological developments that have evolved and
    adapted PLC technology to the times.

3
1) Compact size, faster processing time, cost
optimization
  • Technical improvements such as reduced size
    of processor, circuit board and other components.
    It's changing the electronics industry. In
    addition, these improvements are beginning to affe
    ct PLCs after the introduction of small micro
    and nano-class PLCs. These new PLCs are smaller,
    but with faster cycle times, larger memory
    capacity, new communication improvements, and
    faster processors. Prior to, the above features
    were only high-end and mid-range
    PLC features, but in response to
    market demand, many of the high-end features have
    been moved to low-end PLC systems. As a result,
    we have moved from a large PLC to a small PLC.
    This is because micro and nano classifier PLCs
    can also provide remote connectivity, Ethernet
    communication, onboard PID with auto-tuning, motio
    n control, and other control functions.For
    example, PLC manufacturers are taking advantage
    of the dramatic reduction in size and cost of
    solid-state memory. This allowed for a significant
     increase in local data storage, allowing PLCs to
    be used in many applications that initially
    required expensive data acquisition systems. In
    addition, the reduced memory size allows for many
    other features such as on-board storage
    of product information and faster
    debugging of PLC control systems.In
    addition, current PLCs benefit from USB
    technology, making online programming and monitori
    ng of control systems much easier. In
    addition, as USB technology continues
    to evolve with the availability of micro
    and small mini USB connectors, these
    communication options are expected
    to be incorporated into smaller PLCs.In addition
    to USB readers, the PLC also integrates with SD
    cards, micro SD and mini SD cards, and
    other small connected devices. These portable
    devices provide PLCs with up to 32GB of
    additional non-volatile storage, depending
    on the needs of system integrators, machine builde
    rs, or end users. This is a hallmark of
    the fast-paced consumer electronics industry,
    where integration with PLC is rapidly revolutioniz
    ing industrial control systems.

4
2) Enhanced Communication Networks
  • Over the past few decades, especially in the
    early 1990s, a wide variety of communication
    protocols and networks have been developed for
    use in industrial communications. This trend
    continues to focus on real-time communication
    technologies, raw Ethernet connection speeds, and
    other industrial control networks for
    a variety of applications. In their present form,
    high-end PLCs include multiple ports to support
    several communication protocols. But looking into
    the future, this is likely to change as users
    continue to demand more standardized Ethernet and
    Wireless communication options. Even though its
    a wireless age, industrial processes would
    require more robust wireless technologies with
    enhanced data integrity and improved
    communication range, before we can witness a
    convergence of industrial and commercial wireless
    communication protocols.Though there has been
    great progress in this field, from the latest
    ZigBee (802.15.4) and Wi-Fi (802.11n) protocols
    to the use of mesh and wireless ad hoc networks
    (WANET) as well as the rise of Near Field
    Communication (NFC) and Industrial Bluetooth
    none of these wireless technologies has proven
    capabilities for mission-critical operations
    often encountered plant floors. Therefore, in the
    future, a great deal of less critical PLC
    controlled applications in which real-time
    control isnt essential, are likely to widely
    adopt wireless communication networks
    particularly in RTUs (remote terminal units).

5
3) PAC (Programmable Automation Controller) and PL
C Integration
  • In general, Programmable Automation Controllers
    (PACs) are an enhanced modular industry that uses
    PC-based processors to provide even more
    programming. It is a controller for. Option
    IEC61131-3 programming language. Also called
    an industrial PC or just IPCPACs are considered
    more advanced than PLCs. However, over the years,
    PLCs have evolved to adapt to improvements in
    hardware technology, software, and
    communications. High-end features are
    built into the low-end PLC processor. For
    example, with larger memory capacity and faster
    processors, we have the opportunity to
    integrate advanced features with PLCs such as B.
    Motion control, simultaneous support for multiple
    communication protocols and high resolution image
    processing systems. On the other hand, despite
    its advanced features, the PAC system
    maintains the simplicity of appealing SPS to
    many end users. In addition, the capabilities
    of PAC allow users to push the boundaries of tradi
    tional industrial automation and product
    designers to create custom controllers
    to suit their needs. Throughout this evolution,
    many industrial control manufacturers have
    continued to promote the difference between PAC an
    d PLC. However, at the same time in PLC and PAC,
    the definitions and characteristics of both
    classes changed, and much faster progress was
    seen in both classes. Therefore, as the
    two controllers evolve, the two functions will
    continue to be integrated. In fact, in the
    future, automation engineers may move away from
    nomenclature and focus on the features and
    performance available when specifying control
    systems.

6
4) Open Source PLC
  • When you come across the term "open source",
    you think of an open source hardware design, or
    a standardized, non-exclusive PLC scripting
    language implemented under a public license.
    However, the impact of the open source era on the
    PLC industry is very comprehensive.PLC
    technology completely eliminates the concept of
    PLC by suggesting that it should be based on a
    computer system such as the Raspberry Pi. More
    and more companies are adopting Raspberry Pi
    and incorporating it into systems that are
    robust and can withstand the extreme
    environments of industrial applications. In this
    case, the Raspberry Pi is typically paired with
    one or more boards that provide the digital /
    analog and I / O capabilities that make up
    a traditional PLC.With Raspberry Pi, the
    additional circuit boards are designed with the
    capability to withstand high currents and
    voltages and to provide the isolation required in
    an industrial environment. Therefore, in terms of
    hardware, the Raspberry Pi can at least be
    integrated into industrial automation through
    such extensions.In terms of software,
    single-board computers such as Raspberry Pi are
    not designed to be programmed with IEC 61131-3
    standard languages like Function Block Diagram or
    Ladder Logic used to program PLCs. Instead,
    Raspberry Pi runs on an operating system like
    Linux or a derivative of Linux, and such an O/S
    is best accessed by high-level programming
    languages including Java, C and C, and other
    higher levels of abstraction which purely use
    mathematical expressions. This is quite different
    from the bit-bashing environment of
    Microcontrollers Units (MCUs), that support
    Ladder Diagram and other IEC languages.However,
    some companies like Phoenix Contact are taking
    advantage of the open-source disruptions in the
    PLC market, to create open programming platforms
    like PLCnext. "PLCnext" is an open
    programming environment based on Linux O /
    S, but intended for PLC applications. This is
    achieved by using high-level IT technologies such
    as HTML or by giving system designers the option
    to configure the control system based on the IEC
    61131-3 programming language.

7
5) PLCs Design
  • Designed for Industry 4.0 Many technological
    innovations such as artificial intelligence, cloud
     computing, advanced sensors, and big
    data analytics are having a major impact on the
    manufacturing situation. These advances
    in industrial technology are commonly referred to
    as Industry 4.0. In the reality of this
    new industry, PLCs continue to play an
    important role as main controllers, input hubs, an
    d interfaces for human operators.To continue to
    be the central processing unit for real-time
    manufacturing operations, PLC course in
    trivandrum technology has been further developed
    to enable better communication with multiple
    input sensors over the Industrial Internet of
    Things (IIoT). This makes it much easier for
    SPS to capture large amounts of data and deliver
    it to machine learning programs.For example,
    data from input sensors and other devices can be
    integrated with PLC data to give a big
    picture of the collection of big data.
    Operations managers and data analysts
    use analytics tools to better track big data,
    leverage resources, perform logistics, plan
    orders, plan tasks such as timing suppliers. ,
    You can create a very efficient
    manufacturing process. In addition, "big
    data" can be tracked and analyzed for optimal
    performance and preventative maintenance of
    machines and appliances in manufacturing systems.

8
6) Integrated programming environment
  • We tend to combine human-machine interface (HMI),
    motion control, and PLC into an
    integrated programming environment. This trend
    may continue for the next few years.
    This is followed by integrating the PLC
    with the HMI processor on the same rack and includ
    ing the monitor as part of an external option or
    package. This technology allows the configuration
    of either HMI modules or HMI processors with
    PLC I / O racks.A non-overwhelming
    integrated programming environment is ideal for
    most system designers and control engineers. The
    main benefits of combining these modules include
    an overall reduction in program development time
    and a reduction in the learning
    curve. However, to get the most out
    of such tools, you need to think properly to make
    them easier to navigate.

9
7) More powerful and broader data exchange 
  • The PLC is more powerful and can be equipped
    with features previously reserved exclusively for
    workstations and PCs. This makes exchanging data
    from the PLC on the factory floor to a human
    operator in the control plane faster and cheaper.
    Features that allow current SPS to share
    data widely include internal relational
    databases, FTP servers, web servers, and
    sending email. The web server allows a PLC to
    host a website, for example, on
    the Internet or on the corporate intranet. The
    web server then provides access to real-time data
    logging and acts as a backup HMI for your work
    cell or machine.In addition, the web
    server feature can store documents on some PLCs,
    allowing you to view machine schematics and
    drawings, as well as operation and maintenance
    manuals with short video clips. As a result, PLC
    web capabilities vary from model and manufacturer
    design specifications, from a single "off-the-shel
    f" web page to a full-fledged site that uses JAVA
    and XML-based technologies. PLC web servers are
    probably the most popular of PLC's new data
    sharing technologies.In addition to the PLC web
    server, there is a Send-Email feature
    that simplifies and automates the export of
    critical and production data from the PLC to
    human operators. This allows the PLC control
    program to output production data,
    status changes, material consumption reports,
    alarms, and PLC internal data. Interestingly, the
    PLC's email sending feature allows you to
    quickly send alarm messages to maintenance personn
    el via your mobile phone or alphanum pager.

10
8) Advances in Ladder Logic
  • 50 years ago, Ladder Diagram (LD) replaced
    hardwired relay logic as a PLC programming
    language. The LD language kept things simple for
    system engineers and designers accustomed to passi
    ng logic, but at the time there were some
    limitations, especially when it came to data
    processing and process control. Other PLC
    programming languages ??such as function block
    diagrams (FBD), structured texts (STX),
    sequential function charts (SFC), and instruction
    lists (IL) are introduced in IEC61131 to address
    the challenges of ladder diagrams. It was-3.3.
    However, the developers of ladder diagrams
    have responded to that advance.
    This surprisingly remains relevant and powerful
    in industrial control programming. All IEC
    languages ??have advantages because STX
    is suitable for data manipulation. However,
    ladder logic is still on the rise and continues
    to be the overwhelming leader in PLC
    programming languages. For example, control
    system vendors and end users support large-scale
    base installations of devices, machines, and
    processes controlled by ladder logic PLCs. There
    is also a large group of maintenance personnel,
    electricians, technicians, and engineers who
    prefer the simplicity of ladder logic programming
    technology. In addition, regardless of the
    hardware used, the LD language has come a long
    way in creating industry standards for PLC
    programming. This trend may continue for the next
    few years.

11
9) PLC Designs that Withstand Harsh Conditions
  • PLCs that are currently available in the market
    are rugged and designed to withstand extreme
    climatic events like cold snaps, floods, or heat
    waves conditions that could potentially damage
    electronic devices including PLCs. These robust
    and sturdy PLCs designs are being made with more
    durable materials like fiber signals instead of
    electronic signals, making them well-suited for
    some electronically hostile plant floors. In
    addition, due to the advancements in IIoT
    technology (previously discussed), PLCs can now
    be housed in isolation of harsh environmental
    conditions and operated remotely from regions
    with less or zero electrical noise disruptions.
    This has proven to be of great benefit whenever
    there are sensitive processes and sensors which
    require precise actions and monitoring.

12
10) Higher Security
  • Cybersecurity is becoming increasingly essential
    with the rise of interconnected devices in this
    era of the Internet of Things. For instance,
    interfering with the visibility of sensor systems
    or shutting down sensors, could cause work sites
    and plants to shut down resulting in enormous
    losses. To contain or prevent this from
    happening, industrial control manufacturers are
    responding by incorporating the latest safety
    enhancements into their PLCs. For example,
    Honeywell Process Solutions (HPS) released the
    Control edge programmable logic controller in
    2016. This PLC has a built-in cyber
    security function to prevent cyber attacks. In
    addition, Honeywell's next-generation controller
    leverages the power of the Industrial Internet of
    Things (IIoT).

13
Thank You
  • IPCS GLOBAL
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