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How can you use PLCs for predictive maintenance?

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Predictive maintenance is a proactive approach to reduce downtime, optimize performance, and extend the lifespan of your equipment. By using sensors, data analysis, and automation, you can monitor the condition of your machines and anticipate failures before they occur. One of the tools you can use for predictive maintenance is a programmable logic controller (PLC), a device that controls and executes logic operations in industrial systems. In this article, you will learn how you can use PLCs for predictive maintenance and what benefits they offer.

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Charles Fagala Jr.

Generator Service Team Chief Engineer at Amazon Web Services (AWS)
Labis Kouzoumpasis

Sr. Control Systems Engineer @ KIREAS | Industry 4.0 Implementation, Smart Factory Integration
Rohit Sinwer

Building Industry Pro for Industrial Automation Solutions, Services, Repairs | Energy Literate

1 What is a PLC?

A PLC is a digital computer that can be programmed to perform specific tasks in real time, such as controlling valves, motors, switches, and sensors. A PLC consists of a central processing unit (CPU), a memory, an input/output (I/O) module, and a power supply. The CPU executes the logic program stored in the memory, which defines the sequence of actions and conditions for the system. The I/O module connects the PLC to the physical devices and signals in the system, such as sensors, actuators, and switches. The power supply provides the necessary voltage and current for the PLC and its components.

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Charles Fagala Jr.

Generator Service Team Chief Engineer at Amazon Web Services (AWS)
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A great use of PLC’s is not only execution of programming but also data collection and analysis. PLC’s can essentially convert otherwise useless data to a wealth of useable information. For example, if a PLC is being used to control a VFD, the PLC can pull an input from the drive that would analyze the torque required to execute the programmed movement. Once that torque reaches a predetermined threshold, it can throw a caution alarm to the operator/maintenance team to indicate that the component needs to be greased or inspected. These thresholds can be set in such a manner as to allow x-number of additional movements prior to maintenance being required. This can also prevent breakdowns by creating an alarm before damage occurs.

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2 How does a PLC work for predictive maintenance?

A PLC can work for predictive maintenance by collecting and processing data from sensors that measure various parameters of the system, such as temperature, pressure, vibration, current, and voltage. The PLC can then compare the data with predefined thresholds and rules, and detect any anomalies or deviations that indicate a potential failure or degradation. The PLC can also communicate with other devices, such as human-machine interfaces (HMI), supervisory control and data acquisition (SCADA) systems, or cloud platforms, to send alerts, reports, or recommendations for preventive actions. The PLC can also execute corrective actions automatically, such as adjusting the speed, torque, or frequency of a motor, or activating a backup system.

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Labis Kouzoumpasis

Sr. Control Systems Engineer @ KIREAS | Industry 4.0 Implementation, Smart Factory Integration
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It doesn't. You can't rely on a PLC for predictive maintenance, except from a few simple cases, because PLCs use real time data (from sensors) and logic. A simple comparison with some indications (like higher than usual temperature) is an alarm or even a call to action anyways. Predictive Maintenance can't rely on last minute calls. Proper Predictive Maintenance requires tools like SCADAs, Historians and even Industrial AI, to collect, compare and predict in a large depth of time using multiple data and parameters.

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3 What are the benefits of using PLCs for predictive maintenance?

Using PLCs for predictive maintenance can offer several benefits, such as reducing downtime and repair costs, improving efficiency and productivity, enhancing safety and reliability, and extending the lifespan of the equipment. This can be achieved by avoiding unexpected breakdowns, minimizing manual inspections and interventions, optimizing system performance and output, reducing energy consumption and waste, preventing accidents and hazards caused by faulty or malfunctioning equipment, and ensuring compliance with standards and regulations. All of these measures together can help maximize the return on investment.

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4 What are the challenges of using PLCs for predictive maintenance?

Using PLCs for predictive maintenance can also pose some challenges, such as selecting the right sensors and PLCs for the system that are compatible and interoperable. Moreover, the logic program and rules and thresholds for the system must be developed and kept accurate and valid. Additionally, data and communication between the PLCs and other devices must be secured to prevent unauthorized access or tampering. Lastly, staff must be trained on how to use and maintain the PLCs and the system, as well as how to interpret and act on the data and alerts.

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5 How can you get started with using PLCs for predictive maintenance?

If you want to get started with using PLCs for predictive maintenance, you can assess the current state and condition of your system to identify the critical components and processes that need monitoring. You should also define the objectives and scope of your project, determine the KPIs and metrics to measure, and choose the sensors and PLCs that suit your system and budget. Additionally, it is important to program the PLCs with logic and rules that define normal and abnormal behavior, as well as test and validate the system. Lastly, you should monitor and analyze data from the PLCs and use them to adjust your maintenance strategy.

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Rohit Sinwer

Building Industry Pro for Industrial Automation Solutions, Services, Repairs | Energy Literate
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The key challenges in doing any of the above two things: 1. Focus on cost rather than value addition. 2. The way execution happens in manufacturing. The bare minimum gets the most attention. Neither the end user not the execution team focus on doing R&D on programming for value addition. 3. Project documentation doesn't cover these requirements. Hence, suppliers don't bother providing them. Any of these would require significant time & resource investment. That can be justified with ROI only if a long-term approach is taken.

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6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Rohit Sinwer

Building Industry Pro for Industrial Automation Solutions, Services, Repairs | Energy Literate
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Summary of the article: Program your PLCs with pre-defined thresholds for predictive maintenance <PM> alerts, E.g., If you have a motor running through some output of the PLC. Monitor the run hour of the motor & set the threshold for PM after specific hours. While this does offer some advantages, a better option would be to focus on collecting data from PLCs & running them through an ML or AI algorithm that can come up with PM schedules based on real-time monitoring. Another option, some devices have internal smart maintenance parameters like VFDs have component life monitoring. We should use PLCs for capturing this data from the VFDs & setting up alerts once the threshold is reached. To be continued...

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How can you use PLCs for predictive maintenance?

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1 What is a PLC?

2 How does a PLC work for predictive maintenance?

3 What are the benefits of using PLCs for predictive maintenance?

4 What are the challenges of using PLCs for predictive maintenance?

5 How can you get started with using PLCs for predictive maintenance?

6 Here’s what else to consider

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