PLCs - Are They Right for Your Industry?

Programmable logic controllers, or more commonly PLCs, are digital computers used for automating specific tasks or processes for a variety of applications. They can control machinery on assembly lines, roller coasters at amusement parks, or light fixtures. Nowadays, industrial automation is growing in demand for manufacturing facilities globally. Automation is becoming a central aspect in manufacturing as facilities are facing thin profit margins, and still working within just-in-time manufacturing methods. Companies are understanding that in order to deliver for these processes they must meet customer demand while operating at lower costs, mass production, customizable, and flexibility. The main objective of this article is to help facilities understand the benefit of switching from rough manual production lines to automating specific tasks with PLCs.

Programmable Logic Controller Unravelled 

PLCs have become a pinnacle aspect of industrial automation, often serving as a link between machines and humans. As universal controllers, PLCs can be programmed to perform a variety of tasks, from pneumatic operations to mathematical computing. With the processing power, data storage, and communication capabilities of modern computers, PLCs provide a whole other level of application controls. PLCs are designed to deliver reliable operations in some of the most challenging situations, such as in high temperatures, electrical noise, shock, and vibration impact.

PLCs interact through direct connection with input and output equipment. Signals from sensors, switches, and other control devices provide external physical data about the PLC’s ambient operations. PLCs were designed through ladder logic, but modern PLCs are not solely limited to ladder logic, and PLC outputs provide feedback to determine the best possible decision to change the process or environment.

Benefit of PLCs

· Flexibility

o One single PLC can easily run multiple types of machines.

· Correcting Errors:

o Before PLCs, relay panels would need to be physically altered in order to achieve a new circuit design. With PLCs a change in circuit design can easily be modified by simply reprogramming the controller. Correcting errors in controllers is extremely short in duration and cost effective.

· Space Efficiency:

o With PLC memory development growth, the opportunity to utilize contacts, coils, timers, sequencers, and counters on a single controller has greatly increased. Thousands of instruments can be plugged into a single controller. This reduces the need for several different panel boxes for multiple systems.

· Low Cost:

o PLC cost varies from a few hundred to a few thousand. Reducing the number of external components to operate a single system by purchasing a single PLC can save money on direct and installation costs.

· Testing:

o PLCs can be tested and evaluated in a secure lab. The program can be tested, validated and corrected saving very valuable time. 

PLC implementation offers numerous performance benefits, such as reduced hardware requirements, increased efficiencies, and less product waste. Modern PLCs are highly customizable and can be designed to individual control applications while greatly reducing production floor usage.

        With built in controllers, PLCs make installation easier because it needs less space. Also, PLC displays improve operator interaction which leads to increase production efficiency.

        Maintenance and troubleshooting, repairs are reduced due to plug-in components and replacing modules. The chances of PLC faults and the time required to fix errors is significantly reduced, which leads to complete elimination of rewiring of relay panels and accessory components. Additionally, fault detection circuits and diagnostic indicator integration in major components can monitor if components are functioning properly.