Programmable logic controllers (PLC)
A Programmable Logic Controller (PLC) is a specialized hadware designed to manage control tasks in industrial settings.
A PLC is a special kind of digital computer that plays a crucial role in industrial automation. It has a CPU that runs the control program and manages other components.
Ever peeked inside a control cabinet on a factory floor?
If so, you've likely seen PLCs at work. Often called the brains of a production line, PLCs are vital for industrial automation. Engineers design, program, and set up PLC systems to fit the needs of specific automation tasks. PLCs control and monitor machinery and processes, boosting productivity, reliability, and safety.
If you haven't looked inside a control cabinet yet, keep reading to learn about the amazing technology powering today's industries.
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| CJ2 | CP2E | CP1L | CP1E | CP1H | CS1D | |
|---|---|---|---|---|---|---|
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| Modular | Compact | Compact | Compact | Compact | Rack | |
| 2560 | 180 | 180 | 180 | 320 | 960 to 5120 | |
| 4 axes PTO I/O line driver | Up to 4 axes linear interpolation and PWM | 2 axes PTO I/O and PWM | 2 axes PTO I/O and PWM | 4 axes PTO I/O line driver | - | |
| 5 to 400K steps | 4 to 10K steps | 10K steps | 2 or 8K steps | 20K steps | 10 to 250K Steps | |
| 64 to 832K Words | 4 to 16K words | 32K words | 2 or 8K words | 32K words | 64 to 448K Words | |
| CompoNet Controller Link DeviceNet EtherNet EtherNet/IP ModBus TCP ModBus RTU PROFIBUS-DP PROFINET CAN (freely configurable) | EtherNet ModBus TCP ModBus RTU Serial | EtherNet ModBus TCP ModBus RTU Serial | ModBus RTU Serial | CompoNet Controller Link DeviceNet EtherNet EtherNet/IP ModBus TCP ModBus RTU PROFIBUS-DP PROFINET CAN (freely configurable) | Controller Link (duplex/optical ring) DeviceNet EtherNet EtherNet/IP | |
| Function Block Ladder programming Structured Text programming with structures and arrays | Function Block Ladder programming | Function Block Ladder programming | Ladder programming | Function Block Ladder programming | - | |
| CJ2 | CP2E | CP1L | CP1E | CP1H | CS1D |
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What Is a Programmable Logic Controller (PLC)?
A Programmable Logic Controller (PLC) is a specialized hadware designed to manage control tasks in industrial settings, operating continuously and reliably all year round.
A Programmable Logic Controller (PLC) can be described as a specialized digital computer, and it’s a key component in industrial automation solutions. It consists of a CPU that executes the control program and coordinates other components. Input/Output (I/O) modules facilitate communication between the PLC and external devices, while memory stores program instructions, data values, and system parameters.
Programming devices or software are used to create and modify control programs, and a stable power supply ensures the PLC's continuous operation. Communication ports enable connectivity with other devices and systems. PLCs support specific programming languages such as ladder logic, structured text, function block diagrams, or instruction lists. These components work together to facilitate control and monitoring of industrial processes, allowing for flexibility, scalability, and customization in automation systems.
Explore all Automation Systems of Omron
How does a PLC work?
In industrial automation, a Programmable Logic Controller (PLC) is crucial for managing complex tasks. But how exactly does a PLC function?
How PLCs adapt to industrial needs
PLCs are programmable devices that allow users to define and modify control logic to suit specific application requirements.
Sensor input to machine operation
They receive input signals from sensors, process the information using the programmed logic, and send output signals to actuators to control the operation of machinery.
Equipment Control
PLCs offer real-time control capabilities, enabling fast and precise coordination of equipment, while handling multiple inputs and outputs at the same time.
Connecting Industry Tools
They also support communication and integration with other devices and systems, making data exchange and higher-level control possible.
OMRON's line of PLCs
OMRON offers a comprehensive range of PLC solutions, combining precision, performance, and reliability to meet diverse industrial automation needs.
Explore our range of programmable logic controllers, PLC solutions designed to excel in complex industrial automation settings.
We offer a comprehensive range of PLC solutions, combining precision, performance, and reliability to meet diverse industrial automation needs.
- Compact PLCs offering scalable options
- Modular Controllers for complex, high-performance applications
- Dual-Redundant PLC System ensures never-fail control for critical applications
- Controllers for synchronized device control, IoT connectivity, and advanced motion control
- PLC's with AI for real-time learning and predictive maintenance.
- Sysmac Studio for an all-in-one setup for programming PLCs
- Additional for setup customization
CP Family of compact PLCs
The CP Family of compact PLCs provides scalability, offering products like CP2E, CP1L, and CP1H.
These controllers are perfect for various automation requirements, providing easy I/O expansion, rapid communication, robustness, and ready-to-use Function Blocks for precise positioning.
They share the same instruction set and professional programming software as OMRON's other modular Programmable Controllers, ensuring consistency and ease of use.
CJ2 Modular Controllers
Moving up in complexity, the CJ2 Modular Controllers excel in high-performance applications, with scalability and advanced functionality.
These controllers are the ideal choice for more complex control systems and requirements.
Programmable Logic Controllers (PLCs) have evolved over time into more advanced systems known as Machine Automation Controllers (MACs)
Information & Productivity in a miniaturized size controller
The NX1 series modular machine controllers provide logic sequence, motion and information functionality. NX1 is joining production and IT worlds, minimizing engineering and maintenance while suppressing middleware.
Sysmac Studio for PLC
Our software, Sysmac Studio, offers an integrated development environment for machine automation, combining configuration, programming, simulation, and monitoring within a user-friendly interface. It uncovers valuable data-driven patterns, reducing downtime.
From the simplicity and scalability of the CP family to the high performance of CJ2, and the unmatched reliability of CS1D, and the advanced automation capabilities of the NX/NJ Machine, OMRON offers a complete spectrum of PLC solutions to meet the evolving needs of industrial automation, all while pioneering the transformative potential of AI and IoT.
With expansion units and accessories available, you can customize your setup to fit specific application needs.
Also, take a look at OMRON’s software tools for programming PLCs, such as the CX-One and CX-Programmer.
PLC advantages and disadvantages
What are some of the advantages and disadvantages of PLCs?
Advantages of PLCs include:
- Flexibility in programming and easy adaptability to different control requirements and applications
- Reliable operation even in challenging conditions
- A wide range of PLC options on the market, each tailored to specific needs
- Scalability to meet changing automation needs
- Real-time control for quick response times and precise coordination of machinery and processes
- Built-in diagnostics and monitoring features simplify troubleshooting and maintenance tasks
- Seamless integration with other automation components and systems facilitates data exchange and coordination
- Support for the implementation of safety functions, enhancing workplace safety
- Collecting and logging data for analysis, enabling performance monitoring, predictive maintenance, and process optimization
- Better long-term value due to lower maintenance costs and increased system flexibility, making them a cost-effective choice over time
Disadvantages of PLCs include:
- Specialized knowledge required for programming
- Higher initial cost compared to other traditional control systems
- If the system isn't protected, it becomes more vulnerable to cyber threats
- Different PLC brands may use proprietary programming languages or software
What applications use PLC?
PLCs can be implemented basically in any automation and machine control application. Let’s look at a bottling line in a beverage factory as an example. Here are a few of the tasks a PLC can perform:
Control speed and direction
Control the speed and direction of the conveyor belts, ensuring synchronized movement and proper spacing between the bottles.
Monitoring and Measuring operations
Monitor the filling process by receiving input signals from sensors that detect the presence and position of bottles.
Inspection and Quality Control
Incorporate sensors or vision systems to inspect the bottles for defects, such as cracks or improper labelling. If any defects are detected, the PLC can reject the faulty bottles.
Managing the Packaging Process
Control the packaging process, including sealing, labelling, and sorting. A PLC can for example coordinate the movement of actuators or robotic arms.
Overseeing Production Line Operations
Monitor the operating conditions of the machinery on the production line.
Programmable logic controllers hardware and programming
How do PLC hardware and software work together?
The CPU is the brain of the PLC, it processes input signals from sensors, performs control logic calculations, and sends output signals to actuators. The power supply provides electrical energy to the PLC system, ensuring its operation.
I/O modules on the other hand serve as the interface between the PLC and external devices. They receive input signals from sensors and send output signals to actuators. I/O modules can be digital or analog, allowing communication with various types of devices.
Communication modules enable connectivity and data exchange with other devices or systems. They support different industrial protocols over for example Ethernet, or serial communication. These protocols are used to integrate with HMIs, SCADA (Supervisory Control and Data Acquisition) systems, or other PLCs. Accessories such as expansion racks, cables, and connectors provide flexibility and ease of installation.
What programming language is used to program a PLC?
For programming PLCs, OMRON offers specialized software such as CX-One and CX-Programmer. They provide a user-friendly interface for creating and modifying control programs. In addition to CX-One and CX-Programmer, if you are looking for a complete machine automation platform for Sysmac controllers, the Sysmac Studio would be a your choice.
Sysmac Studio is a powerful software tool that provides a versatile environment for programming and configuring OMRON's Sysmac range of controllers, offering even more flexibility and control options for automation projects compared to the CX-One. OMRON PLCs support various programming languages, including ladder logic, structured text, and function block diagrams. Ladder logic is a graphical language commonly used for simple logic control, while structured text allows for more advanced programming using a text-based syntax.
Function block diagrams enable the creation of reusable function blocks for complex control algorithms. Visit our page to learn more.
PLC Software Integration for All Series with SCADA Systems
PLCs also have integration capabilities with SCADA systems. SCADA systems provide:
- advanced monitoring
- data acquisition
- a user-friendly interface for operators to control machines efficiently, eliminating the need for manual button pressing or switch manipulation.
PLCs can communicate with SCADA systems using protocols like OPC (OLE for Process Control), allowing real-time data exchange, remote monitoring, and centralized control of multiple PLCs within a larger automation infrastructure. This integration enables comprehensive visualization, data logging, and system-wide control for efficient management of industrial processes.
What do I need to consider when choosing a PLC?
There are a number of PLC-powered machines out there right now. Aside from cost, you need to consider what is listed below for a suitable option based upon application criteria.
CPU Speed and Response Rate:
- Assess the system size and the required response rate for your process. Choose a PLC with a CPU speed that matches your application's demands.
Memory Capacity:
- Determine the necessary memory capacity for your program. Consider if an external memory card will be required to accommodate program size.
Redundancy:
- Decide if any level of redundancy is necessary for your application to ensure uninterrupted operation in case of system failure.
I/O Requirements:
- Count the number of devices your PLC needs to control or monitor. Consider if there's a need to work with external or remote I/O interfaces.
Communication Protocols:
- Identify the devices your PLC must communicate with and the communication protocols they use. Ensure compatibility with these protocols.
Compatibility:
- Determine if your system is being built from scratch or if it needs to interface with existing hardware and software. Ensure compatibility with existing components.
Scalability:
- Evaluate whether the system can be easily scaled up or down to accommodate changes in your process or system requirements.
Environmental Conditions:
- Consider the environmental conditions your PLC will be exposed to. Assess if it needs special features such as conformal coated components for harsh environments.
Special Actions:
- Determine if your application requires unique actions, such as motion control, robotics, or safety features. Choose a PLC that supports these functionalities.
Reliability:
- Assess the expected uptime requirements of your system. If it needs to run continuously for extended periods, select a PLC known for its reliability.
Cost and Total Cost of Ownership:
- Define your budget and consider the collective costs, including hardware, software licenses, programming, installation, ease of integration with existing systems, maintenance, and future upgrades.
When selecting a PLC for your project, it's essential to carefully weigh these factors to ensure that the chosen PLC aligns with your specific application requirements and budget constraints. Additionally, consulting with one of our PLC experts and referring to our manufacturring documentation can provide valuable insights into making the best choice for your project.
Key Takeaways about PLC's
- PLCs, or Programmable Logic Controllers, are the cornerstone of industrial automation, and thrive in challenging environments by offering a robust platform for precise control. These systems stand out for their consistent, high-quality performance, durable construction, and flexible functionalities and can be used in a wide range of applications.
- Selecting the right PLC demands a careful analysis of your specific automation needs, taking into account key factors such as the processing speed of the CPU, the storage capacity for program and data handling, and the system's compatibility with existing machinery and software.
By considering these elements along with the long-term operational costs, you can choose a PLC system that not only fulfills your immediate requirements but also provides sustained advantages in managing and optimizing industrial operations.
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We've got a nearly-infinite combination to fit any production scenes.
Interested?
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