New trends in Programmable Logic Controller

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New trends in Programmable Logic Controller
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• A programmable logic controller (PLC) is an
  automated system that collects data from a
  variety of input devices, including sensors that
  monitor parameters such as storage tank levels,
  pressure, and temperature. Using programmed
  software logic, the PLC then processes the
  collected data, makes appropriate logic-based
  decisions, and sends issued instructions and
  commands to process and machine control. PLCs
  have been around for nearly 50 years and are
  still considered the best option for a wide range
  of industrial automation applications.
  Despite that era, PLC technology is evolving and
  PLCs are expected to maintain their dominance in
  the world of industrial automation for the next
  few years. Below are some of the 10 latest
  technological developments that have evolved and
  adapted PLC technology to the times.

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1) Compact size, faster processing time, cost
optimization

• Technical improvements such as reduced size
  of processor, circuit board and other components.
  It's changing the electronics industry. In
  addition, these improvements are beginning to affe
  ct PLCs after the introduction of small micro
  and nano-class PLCs. These new PLCs are smaller,
  but with faster cycle times, larger memory
  capacity, new communication improvements, and
  faster processors. Prior to, the above features
  were only high-end and mid-range
  PLC features, but in response to
  market demand, many of the high-end features have
  been moved to low-end PLC systems. As a result,
  we have moved from a large PLC to a small PLC.
  This is because micro and nano classifier PLCs
  can also provide remote connectivity, Ethernet
  communication, onboard PID with auto-tuning, motio
  n control, and other control functions.For
  example, PLC manufacturers are taking advantage
  of the dramatic reduction in size and cost of
  solid-state memory. This allowed for a significant
   increase in local data storage, allowing PLCs to
  be used in many applications that initially
  required expensive data acquisition systems. In
  addition, the reduced memory size allows for many
  other features such as on-board storage
  of product information and faster
  debugging of PLC control systems.In
  addition, current PLCs benefit from USB
  technology, making online programming and monitori
  ng of control systems much easier. In
  addition, as USB technology continues
  to evolve with the availability of micro
  and small mini USB connectors, these
  communication options are expected
  to be incorporated into smaller PLCs.In addition
  to USB readers, the PLC also integrates with SD
  cards, micro SD and mini SD cards, and
  other small connected devices. These portable
  devices provide PLCs with up to 32GB of
  additional non-volatile storage, depending
  on the needs of system integrators, machine builde
  rs, or end users. This is a hallmark of
  the fast-paced consumer electronics industry,
  where integration with PLC is rapidly revolutioniz
  ing industrial control systems.

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2) Enhanced Communication Networks

• Over the past few decades, especially in the
  early 1990s, a wide variety of communication
  protocols and networks have been developed for
  use in industrial communications. This trend
  continues to focus on real-time communication
  technologies, raw Ethernet connection speeds, and
  other industrial control networks for
  a variety of applications. In their present form,
  high-end PLCs include multiple ports to support
  several communication protocols. But looking into
  the future, this is likely to change as users
  continue to demand more standardized Ethernet and
  Wireless communication options. Even though its
  a wireless age, industrial processes would
  require more robust wireless technologies with
  enhanced data integrity and improved
  communication range, before we can witness a
  convergence of industrial and commercial wireless
  communication protocols.Though there has been
  great progress in this field, 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 has proven
  capabilities for mission-critical operations
  often encountered plant floors. Therefore, in the
  future, a great deal of less critical PLC
  controlled applications in which real-time
  control isnt essential, are likely to widely
  adopt wireless communication networks
  particularly in RTUs (remote terminal units).

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3) PAC (Programmable Automation Controller) and PL
C Integration

• In general, Programmable Automation Controllers
  (PACs) are an enhanced modular industry that uses
  PC-based processors to provide even more
  programming. It is a controller for. Option
  IEC61131-3 programming language. Also called
  an industrial PC or just IPCPACs are considered
  more advanced than PLCs. However, over the years,
  PLCs have evolved to adapt to improvements in
  hardware technology, software, and
  communications. High-end features are
  built into the low-end PLC processor. For
  example, with larger memory capacity and faster
  processors, we have the opportunity to
  integrate advanced features with PLCs such as B.
  Motion control, simultaneous support for multiple
  communication protocols and high resolution image
  processing systems. On the other hand, despite
  its advanced features, the PAC system
  maintains the simplicity of appealing SPS to
  many end users. In addition, the capabilities
  of PAC allow users to push the boundaries of tradi
  tional industrial automation and product
  designers to create custom controllers
  to suit their needs. Throughout this evolution,
  many industrial control manufacturers have
  continued to promote the difference between PAC an
  d PLC. However, at the same time in PLC and PAC,
  the definitions and characteristics of both
  classes changed, and much faster progress was
  seen in both classes. Therefore, as the
  two controllers evolve, the two functions will
  continue to be integrated. In fact, in the
  future, automation engineers may move away from
  nomenclature and focus on the features and
  performance available when specifying control
  systems.

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4) Open Source PLC

• When you come across the term "open source",
  you think of an open source hardware design, or
  a standardized, non-exclusive PLC scripting
  language implemented under a public license.
  However, the impact of the open source era on the
  PLC industry is very comprehensive.PLC
  technology completely eliminates the concept of
  PLC by suggesting that it should be based on a
  computer system such as the Raspberry Pi. More
  and more companies are adopting Raspberry Pi
  and incorporating it into systems that are
  robust and can withstand the extreme
  environments of industrial applications. In this
  case, the Raspberry Pi is typically paired with
  one or more boards that provide the digital /
  analog and I / O capabilities that make up
  a traditional PLC.With Raspberry Pi, the
  additional circuit boards are designed with the
  capability to withstand high currents and
  voltages and to provide the isolation required in
  an industrial environment. Therefore, 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 such as Raspberry Pi are
  not designed to be programmed with IEC 61131-3
  standard languages like Function Block Diagram or
  Ladder Logic used to program PLCs. Instead,
  Raspberry Pi runs on an operating system like
  Linux or a derivative of Linux, and such an O/S
  is best accessed by high-level programming
  languages including Java, C and C, and other
  higher levels of abstraction which purely use
  mathematical expressions. This is quite different
  from the bit-bashing environment of
  Microcontrollers Units (MCUs), that support
  Ladder Diagram and other IEC languages.However,
  some companies like Phoenix Contact are taking
  advantage of the open-source disruptions in the
  PLC market, to create open programming platforms
  like PLCnext. "PLCnext" is an open
  programming environment based on Linux O /
  S, but intended for PLC applications. This is
  achieved by using high-level IT technologies such
  as HTML or by giving system designers the option
  to configure the control system based on the IEC
  61131-3 programming language.

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5) PLCs Design

• Designed for Industry 4.0 Many technological
  innovations such as artificial intelligence, cloud
   computing, advanced sensors, and big
  data analytics are having a major impact on the
  manufacturing situation. These advances
  in industrial technology are commonly referred to
  as Industry 4.0. In the reality of this
  new industry, PLCs continue to play an
  important role as main controllers, input hubs, an
  d interfaces for human operators.To continue to
  be the central processing unit for real-time
  manufacturing operations, PLC course in
  trivandrum technology has been further developed
  to enable better communication with multiple
  input sensors over the Industrial Internet of
  Things (IIoT). This makes it much easier for
  SPS to capture large amounts of data and deliver
  it to machine learning programs.For example,
  data from input sensors and other devices can be
  integrated with PLC data to give a big
  picture of the collection of big data.
  Operations managers and data analysts
  use analytics tools to better track big data,
  leverage resources, perform logistics, plan
  orders, plan tasks such as timing suppliers. ,
  You can create a very efficient
  manufacturing process. In addition, "big
  data" can be tracked and analyzed for optimal
  performance and preventative maintenance of
  machines and appliances in manufacturing systems.

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6) Integrated programming environment

• We tend to combine human-machine interface (HMI),
  motion control, and PLC into an
  integrated programming environment. This trend
  may continue for the next few years.
  This is followed by integrating the PLC
  with the HMI processor on the same rack and includ
  ing the monitor as part of an external option or
  package. This technology allows the configuration
  of either HMI modules or HMI processors with
  PLC I / O racks.A non-overwhelming
  integrated programming environment is ideal for
  most system designers and control engineers. The
  main benefits of combining these modules include
  an overall reduction in program development time
  and a reduction in the learning
  curve. However, to get the most out
  of such tools, you need to think properly to make
  them easier to navigate.

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7) More powerful and broader data exchange 

• The PLC is more powerful and can be equipped
  with features previously reserved exclusively for
  workstations and PCs. This makes exchanging data
  from the PLC on the factory floor to a human
  operator in the control plane faster and cheaper.
  Features that allow current SPS to share
  data widely include internal relational
  databases, FTP servers, web servers, and
  sending email. The web server allows a PLC to
  host a website, for example, on
  the Internet or on the corporate intranet. The
  web server then provides access to real-time data
  logging and acts as a backup HMI for your work
  cell or machine.In addition, the web
  server feature can store documents on some PLCs,
  allowing you to view machine schematics and
  drawings, as well as operation and maintenance
  manuals with short video clips. As a result, PLC
  web capabilities vary from model and manufacturer
  design specifications, from a single "off-the-shel
  f" web page to a full-fledged site that uses JAVA
  and XML-based technologies. PLC web servers are
  probably the most popular of PLC's new data
  sharing technologies.In addition to the PLC web
  server, there is a Send-Email feature
  that simplifies and automates the export of
  critical and production data from the PLC to
  human operators. This allows the PLC control
  program to output production data,
  status changes, material consumption reports,
  alarms, and PLC internal data. Interestingly, the
  PLC's email sending feature allows you to
  quickly send alarm messages to maintenance personn
  el via your mobile phone or alphanum pager.

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8) Advances in Ladder Logic

• 50 years ago, Ladder Diagram (LD) replaced
  hardwired relay logic as a PLC programming
  language. The LD language kept things simple for
  system engineers and designers accustomed to passi
  ng logic, but at the time there were some
  limitations, especially when it came to data
  processing and process control. Other PLC
  programming languages ??such as function block
  diagrams (FBD), structured texts (STX),
  sequential function charts (SFC), and instruction
  lists (IL) are introduced in IEC61131 to address
  the challenges of ladder diagrams. It was-3.3.
  However, the developers of ladder diagrams
  have responded to that advance.
  This surprisingly remains relevant and powerful
  in industrial control programming. All IEC
  languages ??have advantages because STX
  is suitable for data manipulation. However,
  ladder logic is still on the rise and continues
  to be the overwhelming leader in PLC
  programming languages. For example, control
  system vendors and end users support large-scale
  base installations of devices, machines, and
  processes controlled by ladder logic PLCs. There
  is also a large group of maintenance personnel,
  electricians, technicians, and engineers who
  prefer the simplicity of ladder logic programming
  technology. In addition, regardless of the
  hardware used, the LD language has come a long
  way in creating industry standards for PLC
  programming. This trend may continue for the next
  few years.

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9) PLC Designs that Withstand Harsh Conditions

• PLCs that are currently available in the market
  are rugged and designed to withstand extreme
  climatic events like cold snaps, floods, or heat
  waves conditions that could potentially damage
  electronic devices including PLCs. These robust
  and sturdy PLCs designs are being made with more
  durable materials like fiber signals instead of
  electronic signals, making them well-suited for
  some electronically hostile plant floors. In
  addition, due to the advancements in IIoT
  technology (previously discussed), PLCs can now
  be housed in isolation of harsh environmental
  conditions and operated remotely from regions
  with less or zero electrical noise disruptions.
  This has proven to be of great benefit whenever
  there are sensitive processes and sensors which
  require precise actions and monitoring.

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10) Higher Security

• Cybersecurity is becoming increasingly essential
  with the rise of interconnected devices in this
  era of the Internet of Things. For instance,
  interfering with the visibility of sensor systems
  or shutting down sensors, could cause work sites
  and plants to shut down resulting in enormous
  losses. To contain or prevent this from
  happening, industrial control manufacturers are
  responding by incorporating the latest safety
  enhancements into their PLCs. For example,
  Honeywell Process Solutions (HPS) released the
  Control edge programmable logic controller in
  2016. This PLC has a built-in cyber
  security function to prevent cyber attacks. In
  addition, Honeywell's next-generation controller
  leverages the power of the Industrial Internet of
  Things (IIoT).

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Thank You

• IPCS GLOBAL