PLCs in Manufacturing

With more companies looking to automate their production processes, the rise of data-driven decision-making, and evolving IoT and machine learning applications, the role of PLCs in manufacturing is becoming increasingly prominent.

They often act as the physical interfaces between devices on the plant floor or manufacturing floor, and a SCADA or HMI system in order to monitor and control a variety of automated processes. These devices are growing in popularity because of their simplicity, affordability, and usefulness to so many different sectors and industries.

In this blog, we cover what a PLC is, the role they often play in manufacturing, and the future of PLCs in manufacturing. Keep reading to learn more.

What is a PLC?

A PLC is a kind of industrial automation tool. It stands for Programmable Logic Controller. PLCs are typically hardware-based devices and designed computers that withstand the conditions of an industrial environment.

PLCs can vary in size and form. Some are small enough to fit in your pocket, while others are large enough to require their own heavy-duty racks to mount.

These devices can be used as a standalone unit or in a network of PLCs to automatically control a process, perform a specific function, or even an entire production line. PLCs process electrical signals and use them to carry out preprogrammed commands for almost any application. This means PLCs can be adapted to monitor and control many sensors, and are highly customizable.

The main takeaway here is that PLCs take information from the outside world, such as the temperature of a liquid or the speed of an object, and use different forms of connected sensors to act as the physical interfaces between devices on the plant or manufacturing floor and a SCADA or HMI system in order to provide important information and data.

The Role of PLCs in Manufacturing

PLCs play an important role in manufacturing. The devices communicate, monitor, and control automated processes like assembly lines, machine functions, and robotic devices, and are widely used in various applications and industries, including steel, automobile, chemical, and the energy sector. This is because PLCs are considered fast, easy to operate, and considered easy to program.

They were actually created with the intention of being used by engineers without a programming background, which is why the graphical programming language Ladder Diagram was first developed. Most PLCs today use one of the 5 programming languages: Ladder Diagram, Structured Text, Function Block Diagram, Instruction List, or Sequential Function Charts.

PLC functions are divided into 3 main categories: inputs, outputs, and CPUs — which are used in industrial automation to increase reliability, system stability and performance, and minimize the need for human operations and the chances of human error.

Some more specific examples of how PLCs are used would be:

Transportation systems, like conveyor belts, escalators, and elevators
Packing and labeling systems in the Food & Beverage or Pharmaceutical industries
Industrial crane controls
Productions of pages, books, and newspapers
Mixing the right quality and quantities of raw materials and accuracy and its data.
Temperature or humidity control
Fault detection and protection

Choosing the Right PLC

When turning to programmable logic controllers for production automation and manufacturing, there are some key factors to consider to ensure you choose the right PLC for your needs.

System Compatibility
You should be sure that the PLC you choose is compatible with your current manufacturing systems. Additionally, the PLC should also be compatible with the factory’s power outlet voltage.

Processing Speed
You’ll need a PLC with a CPU processing speed that can handle all the various processes and functions of your facility. A slow PLC means even slower processing and operations.

Number of Ports
It’s important to ensure that the PLC your choose has enough input and output ports to cover your facility’s requirements.

Analog & Digital I/O Capability
Some PLCs can only handle simple on/off processes, and for some small, limited tasks, only one type of I/O may be required (analog or digital only, for instance.) However, if the task or machine is more complex and has both analog and digital I/O, then the PLC should be able to handle both types.

Durability
Most PLCs are positioned near the equipment their monitor or control. Therefore, it’s critical that the device can handle various industrial environmental factors like high temperatures, chemical vapors, etc.

The Future of PLCs

The future of Programmable Logic Controllers in industrial automation has been rising since the late 1940s and as manufacturing organizations move to embrace the modern age, PLCs will need to continue to demonstrate their utility and staying power — but that won’t be difficult.

The ongoing automation of factory-based manufacturing combined with the wide variety of PLCs now available at affordable prices suggests that most other systems used for industrial control applications will continue to be slowly phased out as they become obsolete. More and more, these obsolete technologies are being replaced by modern PLCs, that include faster processors, added memory capacity, and new communication features, as we move toward the new age of automation.

ACI Controls has more than 70 years of experience providing high-quality and reliable control systems. Reach out today to learn more about the innovative process control products we offer all supported by exceptional customer service.