10 Latest PLC Technology Trends

IT 21.10.2023 0 Comments Add to Reading List

10 Latest PLC Technology Trends

A programmable logic controller (PLC) is an automated system that collects data from various input devices such as sensors that monitor parameters such as storage level, pressure, temperature, etc. Then, using its own programmed software logic, the PLC processes the collected data, makes appropriate logic-based decisions, and delivers output instructions and commands to control processes and machines. PLCs have been around for over 50 years, and are still considered the best option for a wide range of industrial automation applications. Despite its age, PLC technology has continued to evolve and PLCs are expected to continue to dominate the world of industrial automation for years to come. Here are some of the 10 most recent technological developments through which PLC technology is advancing and adapting with the times.

Alan Bradley PLC-5 1771-A2B

Contents

10 Latest PLC Technology Trends. 1

1) Compact size, faster processing time and cost optimization. 1

2) Improved communication network. 2

3) PACs (Programmable Automation Controllers) and PLCs are. 3

4) Open source PLC. 3

5) PLCs designed for Industry 4.0. 4

6) Unified Programming Environment 5

7) More power, wider data sharing. 5

8) Development in ladder logic. 6

9) PLC designs that withstand harsh conditions. 6

10) High security. 7

What is the future of PLCs? 7

Top 5 Most Popular Types of PLC Programming Languages

Types of PLC Technologies.

1) Compact size, faster processing time, and cost optimization

technological improvements such as the shrinking size of processors, circuit boards and other components; are drastically changing the electronics industry. Moreover, with the introduction of smaller PLCs in the micro and nano classes, these improvements are starting to affect PLCs. Although smaller, these new PLCs are equipped with faster processors with better cycle times, more memory capacity, and new communication enhancements.

Previously, the aforementioned features were only a feature of high-end and mid-range PLC systems, but in response to market demands, many high-end features and functions are migrating to low-end PLCs. This has led to a shift from large PLCs to smaller ones, as in micro and nanoclassers also capable of remote connectivity, Ethernet communication, onboard PID with auto-tune, motion control, and other control functions.

Allen Bradley PLC-5 1771-A2B

For example, PLC manufacturers are taking advantage of the drastic reduction in the size and cost of solid-state memory. This has allowed a great increase in local data storage, enabling the use of PLCs in a number of applications that initially required expensive data acquisition systems. In addition, the reduction in memory size has made way for many other features, such as onboard storage of product information, which speeds up troubleshooting of PLC-controlled systems.

Additionally, current PLCs take great advantage of USB technology, which makes it much easier to program and monitor your control system while online. As USB technology continues to evolve, with the availability of micro and mini-USB connectors, it is expected that these communication options will be integrated into small PLCs.

In addition to USB readers, PLCs are also being integrated with SD cards, micro-SD and mini-SD cards, and other minute connectivity devices. These portable devices provide up to 32 GB of additional non-volatile memory to the PLC, as required by the system integrator, machine builder, or end user. It is a feature of the fast-moving consumer electronics industry that integration with PLCs is rapidly revolutionizing industrial control systems.

2) Improved communication network

Over the past few decades, particularly in the early 1990s, a variety of communication protocols and networks have been developed for use in industrial communications. This trend further focuses on real-time communication technologies, the raw and connection speeds of Ethernet, as well as other industrial control networks for a wide range of applications. In their current form, advanced PLCs include multiple ports to support multiple communication protocols. But looking to the future, this is likely to change as consumers continue to demand more standard Ethernet and wireless communication options. Although this is the wireless era, before we can witness the convergence of industrial and commercial wireless communication protocols, industrial processes will require more robust wireless technologies with better data integrity and communication range.

1771-ARC

The field has evolved greatly from the latest ZigBee (802.15.4) and Wi-Fi (802.11n) protocols to the use of mesh and wireless ad hoc networks (WANET) as well as the rise of near-field communication. NFC) and Industrial Bluetooth; None of these wireless technologies have proven viable for the mission-critical operations often encountered on the plant floor. Therefore, in the future, many important PLC-controlled applications in which real-time control is not necessary are likely to adopt widespread wireless communication networks, especially in RTUs (Remote Terminal Units).

3) PACs (Programmable Automation Controllers) and PLCs are integrated.

Generally, a Programmable Automation Controller (PAC) is a rigid modular industrial controller that uses a PC-based processor and provides various programming options beyond the IEC 61131-3 programming languages. It is also called Industrial PC or just IPC. PACs are considered more advanced than PLCs. However, over the years, PLCs have continued to evolve by adopting improvements in hardware technology, software and communications. are making their way into lower-end PLC processors with advanced features.

For example, large memory capacities and high-speed processors have allowed the integration of advanced features with PLCs, such as motion control, simultaneous support for multiple communication protocols, and high-resolution vision systems. On the other hand, even with advanced features, PAC systems still retain the simplicity that makes PLCs attractive to many end users. Additionally, the capabilities of PACs have allowed customers to stretch the envelope of what is considered traditional industrial automation, encouraging product designers to develop custom controllers to meet their needs.

During this evolution, many industrial controller suppliers have continued to blur the distinction between PACs and PLCs. But in the same era of PLC vs PAC, the definition and characteristics of each have changed and we have noted very rapid growth in both classes. Therefore, as each controller evolves, the functionality of the two will continue to integrate more closely. In fact, in the future, automation engineers will not care about the name, instead, they will focus on the available features and performance as they define their control systems.

4) Open-source PLC

Whenever we see the term "open source," we think of a hardware design that is open source or a standard non-proprietary PLC scripting language that must be implemented under a public license. However, the way the open source era is affecting the PLC industry is quite comprehensive.

It's just killing the idea of a PLC altogether, by suggesting that PLC technology should be based on a computer system like the Raspberry Pi. A growing number of companies have taken the Raspberry Pi and built it into a system that is rugged and can withstand extreme environments for industrial applications. In this case, the Raspberry Pi is usually paired with one or more circuit boards that provide the digital/analog and I/O features that make up a traditional PLC. With the Raspberry Pi, additional circuit boards are designed with the ability to withstand high currents and voltages and provide the isolation required in industrial environments. So, in terms of hardware, the Raspberry Pi can at least be integrated into industrial automation through such extensions.

In terms of software, single-board computers like the Raspberry Pi are not designed to be programmed with IEC 61131-3 standard languages such as function block diagrams or the ladder logic used to program PLCs. Instead, the Raspberry Pi runs on an operating system such as Linux or a Linux derivative, and such an O/S provides access to high-level programming languages including Java, C and C++, and other high levels of abstraction. which use purely mathematical expressions. . This is quite different from the bitbashing environment of Microcontrollers Units (MCUs), which support Ladder Diagram and other IEC languages.

However, some companies such as Phoenix Contact are taking advantage of open source disruptions in the PLC market by creating open programming platforms such as "PLCnext". "PLCnext" is an open programming environment based on Linux O/S but targeting PLC applications. This is achieved by providing system designers with options to configure their control systems, either using high-level IT technologies such as HTML or based on IEC 61131-3 programming languages.

5) PLCs designed for Industry 4.0

Many technological innovations such as artificial intelligence, cloud computing, sophisticated sensors as well as big data analytics have and continue to significantly impact the landscape of manufacturing industries. These industrial technological developments are commonly referred to as Industry 4.0. In this new industrial reality, PLCs continue to play a key role as central controls, input hubs, and interfaces for human operators.

To remain the central processor for real-time manufacturing operations, PLC technology is being further developed to allow better communication with multiple input sensors on the Industrial Internet of Things (IIoT). This has enabled PLCs to accurately collect large amounts of data and feed it easily to machine learning programs. For example, data from input sensors and other devices together with PLC data can be integrated to define the "big picture" resulting from the collection of "big data".

Plant managers and data analysts then use big data to better track, leverage resources, execute logistics, schedule tasks and plan tasks such as supplier timing in an effort to create highly efficient manufacturing processes. Analysis tools can be used for classification. In addition, “big data” can also be tracked and analyzed for optimal performance and prevention of machines and equipment across the manufacturing system.

6) Unified Programming Environment

There has been a trend to integrate human machine interface (HMI), motion control and PLC into a unified programming environment. This trend is likely to continue in the next several years. The following suite will include the integration of a PLC with an HMI processor on a single rack, and a monitor as an external option or as part of a package. This technology allows the configuration of an HMI processor with either an HMI module or a PLC I/O rack.

A unified programming environment is ideal for most system designers and control engineers if it is not overwhelming. Some of the key benefits of combining these modules include an overall reduction in program development time and reduced learning. But to get the most out of such a tool, it should be properly thought out so that it is easy to navigate.

7) More power, wider data sharing

PLCs are becoming more powerful, allowing them to be equipped with capabilities previously reserved only for the workstation and personal computer (PC) domain. This translates into faster and cheaper sharing of data from PLCs on the factory floor to human operators at the control level. Some of the features that enable current PLCs to share data widely include internal relational databases, FTP servers, web servers, and email sending.

Web servers, for example, allow PLCs to host a website on the Internet or company intranet. The web server in turn allows you access to real-time data logging and acts as a backup HMI for the work cell or machine(s). In addition, some PLCs have a web server feature that can store documents that enable you to view machine schematics and drawings, as well as operator and maintenance manuals with short video clips. Therefore, PLC web capabilities vary by model and manufacturer's design specifications, from a single "canned" web page to fully developed sites using JAVA and XML-based technologies. Web servers in PLCs are probably the most widely used of the new data sharing technologies in PLCs.

Second to the PLC web server, is the Send-Email function that simplifies and automates the export of critical and production data from the PLC to the human operator. It enables the PLC control program to issue production data, status changes, material usage reports, alarms, and PLC internal data. Interestingly, you can send short-term alarm messages to maintenance personnel via cell phones or alphanumeric pagers using the PLC Send E-mail feature.

8) Development in ladder logic

Fifty years ago, the ladder diagram (LD) replaced hardwired relay logic as the PLC programming language. The LD language kept things simple for system engineers and designers used to relaying logic, but it had some limitations at the time, particularly in terms of data handling and process control.

To address the challenges of ladder diagrams, IEC 61131-3 introduced other PLC programming languages such as Function Block Diagram (FBD), Structured Text (STX), Sequential Function Chart (SFC) and Instruction List (IL). However, ladder diagram developers responded with developments that have remained surprisingly relevant and powerful in the programming of industrial controllers. We can say that all IEC languages have their strong points, like STX is suitable for data manipulation. But ladder logic is still moving forward, and PLC programming languages have been the leader by a wide margin.

For example, control system suppliers and end users support the installation of a large base of devices, machines and processes controlled by PLCs that are programmed in ladder diagrams. In addition, there is a large group of maintenance personnel, electricians, technicians and engineers who prefer the simplicity of ladder logic programming technology. Furthermore, regardless of the hardware used, the LD language has gone a long way in making the industry standard for programming PLCs and this trend is likely to continue in the coming years.

9) PLC designs that withstand harsh conditions.

PLCs currently available in the market are rugged and designed to withstand extreme weather events such as cold snaps, floods, or heat waves. Conditions that can potentially damage electronic equipment including PLCs. These robust and robust PLCs designs are being built with more durable materials such as fiber signals rather than electronic signals, making them suitable for some electronically hostile plant floors. Also, due to advances in IIoT technology (discussed earlier), PLCs can now be isolated from harsh environmental conditions and operated remotely from areas with low or zero electrical noise impedance. This has proven to be very beneficial whenever there are sensitive processes and sensors that require accurate measures and monitoring.

10) High security

With the rise of interconnected devices in this era of the Internet of Things, cybersecurity is becoming increasingly important. For example, interfering with the visibility of a sensor system or shutting down a sensor can cause the shutdown of workplaces and plants. Which results in a lot of damage. To prevent or prevent such incidents, industrial controller suppliers are responding by providing PLCs with the latest security enhancements built-in. For example, in 2016 Honeywell Process Solutions (HPS) launched the ControlEdge™ programmable logic controller. This PLC is designed with built-in cyber security features to prevent cyber attacks. What's more, it's Honeywell's next-generation controller that leverages the power of the Industrial Internet of Things (IIoT).

What is the future of PLCs?

Since 1947, PLCs have been able to adapt to changing technological times and maintain their popularity in the world of industrial automation. Looking to the future, the potential of PLCs is closely related to the rapid development of Internet technologies, as a new generation of industries will be more concerned about the reliability, flexibility and safety of their control systems.

Industry 4.0 has already set the trend for industrial automation, introducing "smart factory" models that integrate communication, electronics, and power supply elements to provide a multi-faceted solution to any industrial control problem. Combine the This proves that PLCs will continue to be a fundamental function in automated factory settings, as they become smaller, cheaper, faster, and more powerful.

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