30 Apr Programmable Logic Controller (PLC) Systems

Programmable Logic Controller (PLC) Systems : Introduction and PLC Architecture

An automated industrial system requires a strong and intelligent controller, and that’s when an industrial PLC controller comes into play. As the name suggests, Programmable Logic Controllers (PLC) are programmed in order to process information by monitoring inputs, processing logic and outputting results, which help in providing real-time control to machines and processes. PLCs are required from small automation cells to large-scale industrial automation systems as they act as a backbone for operational efficiency and effectiveness.

Industrial PLC controllers are of two types depending upon their design structure. Firstly, there are compact PLC controllers that can be used for low I/O systems and secondly, there are modular PLCs that provide scalability through the usage of expansion modules. Furthermore, when dealing with complex systems, a multi-axis PLC controller is employed in order to control multiple machines or motion systems at once. Such a controller provides coordination to several components of the same production line, enabling synchronization within the system as per the new industry 4.0 standards.

Performance and Advanced Motion Capabilities

High-speed processing is one of the main features offered by PLC systems. PLCs have the capacity to process information at a speed of several nanoseconds per instruction, which makes it feasible for performing fast sequence control and other precision operations. In turn, a motion PLC controller is designed for controlling operations that need positioning, speed control, and synchronization.

A motion PLC controller will be useful for complex applications. It has the ability to handle motion and logic operations independently since it utilizes two processors. Moreover, a motion PLC system with EtherCAT communication capability functions as an advanced PLC with EtherCAT and has the potential to perform complicated and fast motion control applications. Such machines can implement motion algorithms such as circular interpolation, 3D helical interpolation, electronic cam (E-CAM), and electronic gearing. Such capabilities are useful for robotic applications, CNC machinery, packaging lines, semiconductors, and fast assembly lines. Control of multi-axis motion ensures the coordination of multiple axes in order to improve accuracy, decrease cycle time, and ensure better quality of products manufactured.

Flexibility, Programming, and Communication

Programmable controller’s greatest strength lies in its ability to be configured based on the needs of an organization. It is possible to enhance a programmable controller with various other components including digital and analog input/output devices, positioning device, temperature control unit, load cells, communication module, etc. Hence, it becomes possible to configure a programmable controller as per need.

PLCs can be programmed using the IEC 61131-3 standard. Such standards ensure compatibility of controllers all over the world and make them more user-friendly. PLC programming supports several languages such as Ladder Diagram (LD), Function Block Diagram (FBD), Sequential Function Chart (SFC), Structured Text (ST), and Instruction List (IL).

Communication is another significant feature of PLC systems. Nowadays, most PLCs use various communication technologies such as Ethernet/IP (EIP), EtherCAT, and MODBUS. When using a PLC with EtherCAT, users will benefit from a fast and real-time data exchange between the devices. This way, PLCs become more compatible with other devices that could be used by enterprises including other PLCs, sensors, actuators, and SCADA or MES.

Our PLC Solutions and Services

Automation Strategy provides a variety of PLC systems, which meet today’s demands. Some of the products and services provided by Strategi Automation include reliable, efficient, and heavy duty Panasonic PLC and Fatek PLC. Apart from this, Strategi Automation provides a wide array of solutions such as controller systems, motion PLC, and multi-axis controller systems. When working on a project, we start with choosing the appropriate PLC system and its configurations depending on your requirements. Selection of an effective controller is essential for providing maximum productivity. Therefore, we take into account parameters like the level of complexity, the speed needed, scalability, and communication capabilities when choosing the right PLC system.

Moreover, we are experienced in developing control logic and designing an architecture for the PLC system. Our experts create programs following IEC 61131-3 standards in order to provide maximum reliability for our customers. Apart from design and programming, we can offer you the supply of high-quality PLC hardware and modules. Installation and system integration are also included in our services, making sure that everything works as a whole system. Our team has great experience in PLC applications using EtherCAT.

Process optimization is one of the most important directions we are focusing on. Analyzing the system performance, we can determine where there are bottlenecks and help optimize them in order to increase efficiency and productivity. Also, we can consult you on maintenance and technical support in case you need it. Choosing the right technologies and solutions with Strategi Automation, you can make your industrial process better and faster. No matter if you need a simple PLC controller application or a multi-axis system, we can offer you an excellent solution.