Programmable Logic Controllers: An Integral Cog in the Automated Machine

Modern day PLCs have continued to become smaller and yet they are filled to the brim with power with increasingly agile capabilities. These advancements are a driving force behind operational efficiency across a vast array of applications. Let’s take a look at the advantages of PLCs over relay systems. 

Simplified Wiring and Rugged Design

Back in the day when relays were a necessity, a system fault meant the relay wiring had to be switched out which often led to long periods of unplanned downtime. Having a PLC in the automated process means less wiring and therefore simplified maintenance requirements.

In comparison with relay control systems, PLCs are far more compact and easier to integrate into operations. Their rugged design makes them the perfect solution for industrial manufacturing environments with additional tiers of protection from varied temperatures and sound levels.

Real Time Fault Finding 

We touched on this in the above section but the technology behind fault finding goes deeper. A PLC has a built-in diagnostic tool meaning the operator can identify an issue and pinpoint the hardware or software as the root cause in real time. Usually monitored through a human machine interface(HMI), the PLC will highlight the error and communicate this with the HMI for the operator to take prompt action. Even as products on a production line fly past the sensors at rapid speed, the PLC has the capacity to capture this information.

Reliability and Flexibility

Having identified project requirements, a program must be written to provide instructions via the PLC. The program does not need to be wired into the device, simply downloaded to its memory and the risk of making a wiring error is minimised. This greatly simplifies the programming process, nullifying the need to rewire the system or change the connectors between input and output elements. Instead, the program carries the torch and holds the power to modify processes when required. Let’s say an OEM informs you of an update required to optimise your PLC. Before programs, you would more than likely receive an IKEA- like rewiring manual but now it is a simple case of downloading a shiny new program to the device or customising the current one in action. 

Minimising Costs and Energy Usage

PLCs are more cost effective. The significant savings on offer mean that many relay based control systems are falling victim to obsolescence.  Aside from the initial outlay, the running costs are also considerably less, approximately 90% less in fact. This is highly dependent on the size of your operation and the number of relays which would be otherwise required, however as PLCs are easier to maintain there are plenty of ways in which you can give your wallet a little TLC. The software most commonly comes with a test feature which allows the operator to test the functionality of a program before going into mass production, similar to a prototyping process. This means the process can be refined and optimised, saving manufacturing costs further down the line as faults can be fixed during the early stages of planning. 

Clear Lines of Communication

Whether it be professionally or personally, we can all agree that communication is key between us humans. The same can be said for your automated manufacturing process. A PLC communicates with every stage of your process, instructing each piece of integrated equipment of their next step. From collating data to monitoring a specific element, these devices may communicate with another controller or something like a HMI to produce the desired outcome as outlined in the program.