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What are the top applications for PLC programming in manufacturing?

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PLC programming is a skill that can help you automate and optimize various processes in manufacturing. PLC stands for programmable logic controller, which is a device that can control and monitor inputs and outputs of machines, sensors, and actuators. PLC programming is the process of creating and modifying the logic that runs on the PLC, using languages such as ladder logic, structured text, or function block diagram. In this article, you will learn about some of the top applications for PLC programming in manufacturing, and how they can benefit your projects.

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Ravi Gupta

Industry 4.0 Solutions | Battery Technology | Design and innovation| IT-OT integration | Digital Strategy | MES |…

1 Process Control

One of the most common applications for PLC programming is process control, which involves regulating and adjusting the parameters of a physical or chemical process, such as temperature, pressure, flow, level, or pH. PLC programming can help you design and implement feedback loops, PID controllers, alarms, interlocks, and safety features for your process control systems. For example, you can use PLC programming to control the temperature and pressure of a steam boiler, or the flow and level of a liquid tank.

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Ravi Gupta

Industry 4.0 Solutions | Battery Technology | Design and innovation| IT-OT integration | Digital Strategy | MES | GenAI | Data space
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In process control, PLCs must undergo hardware and firmware modification (by PLC maker company) to function as a DCS (Distributed Control System) controller. Various libraries are developed within PLCs for process control applications to easy and reduce the engineering life cycle. Among these, I particularly enjoy developing libraries for typical PID control, Route Control, and ISA 88-based batch control for Honeywell and Siemens-based process control applications

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2 Machine Automation

Another popular application for PLC programming is machine automation, which involves automating and coordinating the movements and actions of different machines, such as robots, conveyors, pumps, valves, or motors. PLC programming can help you create and modify sequences, timers, counters, and logic for your machine automation systems. For example, you can use PLC programming to automate the loading and unloading of a palletizer, or the cutting and welding of a CNC machine.

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Ravi Gupta

Industry 4.0 Solutions | Battery Technology | Design and innovation| IT-OT integration | Digital Strategy | MES | GenAI | Data space
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In my view, machine automation programming can be categorized into two main parts: discrete automation (such as automotive and semiconductor industries) and motion control (found in aerospace, 3D printing, etc.). Discrete automation often involves typical clients like automotive manufacturers, where standard libraries can be developed. However, motion control demands high precision and nanosecond-level synchronization. Typical applications include printing, wood cutting, CNC (computer numerical control) operations, and the development of kinematic libraries for industrial robot controllers.

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Umair Ahsan

Electrical/Electronics/Instrumentation & control
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PLC has a key position in industrial automation it has a variety of interfaces according to the process. Such as positioning control with RTUs interface and fast data exchange with profit bus and Ethernet rj45 protocol.

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Raphael Baptista da Silva Fontenelle

Software Engineering Manager | MSc Student AI | Sr. Data Scientist
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O PLC pode ser utilizado para aquisi??o de dados, ele é utilizado por exemplo na indústria de rastreamento e seguran?a para imprimir um datamatriz e no final do processo ter uma camera, por exemplo, Cognex lendo o dado e enviando por comunica??o de rede para o PLC que se comunica com um PC industrial cliente que faz a agrega??o do produto em pacotes e depois esse dado, após a agrega??o é encaminhado ao um PC master que faz o rastreamento do produto.

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3 Data Acquisition

A third application for PLC programming is data acquisition, which involves collecting and storing data from various sources, such as sensors, meters, or cameras. PLC programming can help you configure and communicate with your data acquisition devices, and perform calculations, analysis, and visualization on your data. For example, you can use PLC programming to collect and display the energy consumption and efficiency of your production line, or the quality and defects of your products.

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Raphael Baptista da Silva Fontenelle

Software Engineering Manager | MSc Student AI | Sr. Data Scientist
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O PLC pode ser utilizado para controle de seguran?a e rastreamento de produtos. Ele é utilizado, por exemplo, na indústria de bebidas e cigarro para controle de produ??o para ser aplicado o imposto sobre a produ??o. O PLC controla o processo recebendo do PC industrial cliente um código criptografado para ser impresso no produto, datatrix, que será lido ao final do processo utilizando, por exemplo, uma camera Cognex. O dado é enviado ao PLC e dep?s através de protocolo de rede ele é enviado ao PC industrial que se comunica com o PC servidor master que faz o controle e rastreamento do produto.

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4 Human-Machine Interface

A fourth application for PLC programming is human-machine interface, which involves creating and managing the interface between the human operators and the PLC systems. PLC programming can help you design and program graphical user interfaces, touchscreens, buttons, switches, and indicators for your human-machine interface systems. For example, you can use PLC programming to create and update the menus, screens, and commands for your operator panel, or the status and alerts for your dashboard.

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5 Network Communication

A fifth application for PLC programming is network communication, which involves connecting and exchanging data between different PLC systems, or between PLC systems and other devices, such as computers, servers, or mobile phones. PLC programming can help you establish and maintain network protocols, standards, and security for your network communication systems. For example, you can use PLC programming to send and receive data via Ethernet, Modbus, or MQTT, or to access and control your PLC systems remotely via web or mobile apps.

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Ravi Gupta

Industry 4.0 Solutions | Battery Technology | Design and innovation| IT-OT integration | Digital Strategy | MES | GenAI | Data space
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Various industrial legacy buses necessitate communication with third-party PLCs. For instance, a Siemens PLC might communicate with Bosch Rexroth servo drives in real-time, operating at the microsecond level. Such real-time communication is often facilitated through protocols like Sercos 3 or Profinet. While some may question why not OPC UA? Because OPC UA has limitations in achieving microsecond-level communication. Therefore, function blocks, similar to classes in the world of object-oriented programming, are developed on PLCs or servo drives to enable precise communication. This programming demands advanced PLC programming skills and a high level of proficiency in embedded systems and real-time operating systems.

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6 Simulation and Testing

A sixth application for PLC programming is simulation and testing, which involves creating and running virtual models of your PLC systems, or testing and debugging your PLC programs. PLC programming can help you use and develop simulation and testing tools, such as emulators, simulators, or debuggers, for your PLC systems. For example, you can use PLC programming to simulate the behavior and performance of your PLC systems before deploying them, or to troubleshoot and fix any errors or faults in your PLC programs.

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7 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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What are the top applications for PLC programming in manufacturing?

1

2

3

4

5

6

7

1 Process Control

2 Machine Automation

3 Data Acquisition

4 Human-Machine Interface

5 Network Communication

6 Simulation and Testing

7 Here’s what else to consider

Programming

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What are the top applications for PLC programming in manufacturing?

1

2

3

4

5

6

7

1 Process Control

2 Machine Automation

3 Data Acquisition

4 Human-Machine Interface

5 Network Communication

6 Simulation and Testing

7 Here’s what else to consider

Programming

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