Over the past ten years, the manufacturing industry has undergone rapid change. Because most processes are automated, both the quality of the items produced and the effectiveness of the systems that create them are at a previously unheard-of level. Although they were created in the 1960s, programmable logic controllers have continued to be an essential part of these systems despite these modifications.
The following six crucial systems are present in all PLCs, regardless of their size or capabilities:
- Central processing unit
- Rack or mounting
- Input assembly
- Output assembly
- Power supply
- Programming unit
Here is a description of each and what they do.
Processor or Central Processing Unit (CPU)
The processor, also known as the central processing unit, is sometimes referred to as the "brain" of the PLC and is in charge of carrying out orders. The business community has made an attempt to use the following list of programming languages:
- Structured Text
- Ladder Diagram
- Sequential Function Chart
- Instruction List
- Function Block diagram
Despite the fact that the aforementioned list of languages is employed, it's significant to remember that each manufacturer uses a unique technique to implement the code.
Rack or Mounting
The majority of medium to large PLC systems are built so that its separate components—things like the CPU or processor, the I/O, and the power supply—are kept together within a mounting or rack. However, this is not always the case. The components of smaller PLC systems frequently fit into a single, compact enclosure (often referred to as a shoebox, or brick).
Input Assembly
The input assembly's functions total two. Receiving signals from field equipment and control stations is the initial step (switches, sensors). The state of the input point is shown in the second.
Output Assembly
In order to carry out the commands, the PLC uses outputs, which are commonly utilised to direct a manufacturing process (motors, pumps, actuators, lights, etc.).
I/O comes in two flavours: analogue I/O and specialty I/O. The two's distinctions are described below.
- Inputs and outputs with a range of functions are referred to as analogue I/O. (e.g. the running speed of a motor). This form of input relies on the constant shifting of variable ranges to function (temperature, pressure, etc.) In this situation, the output would also involve controlling the motor's speed.
- Specialty I/O controls particular devices, such as high-speed counters, as the name suggests. Digital I/O uses binary changes (yes/no or on/off) to function.
Students in the PLC Technician programme learn about the I/O assembly using the PLCLogix simulation software. Two discrete input modules, two discrete output modules, two TTL modules for BCD control and display, and two analogue modules are shown in the graphic above as an illustration of the software's interface.
Power Supply
If the CPU is the PLC's brain, then the power supply—which typically provides the device with a 24VDC or 120VAC line voltage—is undoubtedly the digestive system. A switch for choosing a certain programming mode may be included in the power supply status monitoring system. The lithium battery included into the power supply ensures that the information recorded in memory will remain unchanged in the case of a power outage.
Programming Unit, Device, or PC/Software
The contemporary PLC is programmed by loading a programmer or piece of software created on a PC or laptop into the PLC. The main benefit of PLC software is that simulations can be done to determine how a PLC system would function in a hypothetical setting. One of the most widely used simulation tools nowadays is RSLogix.
Our students at George Brown College study in similar virtual settings. We utilise PLCLogix software, an RSLogix emulation that enables testing and practising PLC applications. The skills gained from this curriculum may be applied in PLC situations found in the real world.
PLCs Have Never Been More Important
Actually, it's difficult to picture a future without PLCs. Without a doubt, the manufacturing process would be different from what it is now, and it would probably require more human capital to produce at comparable levels. The average PLC's underlying technology is decades old, yet PLCs are still an essential part of manufacturing, robotic, and automated systems.
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