Use of PLC Programming in Industrial Automation

A PLC (Programmable Logic Controller) is a computer which is specially designed for industrial conditions and it is essentially built to withstand extreme conditions including dust, wetness or arid. It is used for automating manufacturing processes including oxygen/nitrogen plant, wastewater treatment plant or an iron ore processing plant. PLC comes equipped with industrial control systems which aid in the working of the plant machinery automation. It is solidly built with amazing functionalities easy programming, sequential control and reliable hardware with timers and counters.

Built to function in the rough industrial conditions, it is constructed with high quality materials for long lasting performance with ability to work amidst uneven vibrations so common in industrial conditions, humidity and noise emanating from machinery running on electricity.

Mostly, the purpose of the logic controllers is to monitor and control the functioning of wide array of sensors and actuators. It is to be noted that these computers are different from the regular PCs with the broadness of their operations and I/O (input/out) without traditional keypad. They are not only used for serving specialized requirement but also for numerous other areas such as controlling areas, etc. This is the reason PLC is also called as industrial PCs.

You will find the PLC is used in many applications that come across daily in your notice. It is used in washing machines, elevators and traffic signals. In industrial applications it is applied for monitoring and controlling production system such as oxygen gas plant where it monitors purity level and automates separation of gases.

After completion of its programming, the PLC will perform a sequence of actions based on the input it receives. It gets its triggers for action through stimuli relayed through sensors from delayed actions from repeated events and timers.

Salient Points of PLC Systems –

Programmed to Execute Single Set or Sequence of Tasks

Unlike your PCs, tablets or mobiles a PLC system is designed to perform a single set of tasks or sequence of tasks with efficiency and reliability. Our laptops or mobiles are designed to perform wide array of tasks but it is not the case with PLC systems. PCs and mobiles can do simultaneously numerous tasks through Windows platform or Android platform but PLC remains dedicated to executing single set of tasks over and over again.

Exclusive Features of PLC

The PLC has got amazing features which are not found in PCs or mobiles. It is built in such a way that it is protected from external conditions such as heat, cold, rain, dry weather, sound pollution, etc.

Competitively Priced

Unlike other microcontroller systems available in the market, it is priced very low and is very effective in the automation of manufacturing processes. On the other hand, it can be used in various applications quite effortlessly requiring only the change of software for the application you will apply it for. It is not but the other micro controller applications require. They also need to be accompanied by change of hardware components as well if you switch the system to other applications. Talking of PLC, it is equipped with programmable memory where execution commands are stored based on timing, counting, arithmetic, logic, sequencing, etc.

Working of Programming Logic

Functioning of PLC is accomplished in 3 modes which are known as power supply, CPU and Input/output (I/O). All of these modules serve different purposes and are widely used in the industry. Each of them is designed for meeting specific requirements depending upon the industrial application.  

CPU Module

This module is made up of a central processing unit with memory storage. It is equipped with processor having adequate computational power to execute your commands upon receiving inputs and generating commensurate output.

Power Supply Module

Just as CPU module is designed for meeting the computational requirements, the power module is constructed to run the circuit of PLC which functions on a 5V DC output. This function is done by the power module as this system is responsible for supplying the power to the PLC for its smooth running. The module gets AC power which it changes into DC power so that CPU and I/O modules could receive power for smooth operations.

I/O Modules

It is the smartest module as it gets the data from the sensors and actuators and sends it to the PLC system for real-time monitoring and execution of tasks. It monitors parameters such as pressure, temperature and flow. The I/O can be used either in digital or analogue format.

Applications of PLC in Industry –

PLCs find extensive applications where they are indispensable for achieving efficient productivity. No manufacturing industry can do without the use of PLCs. It is widely used in auto industry, chemical industry, steel industry, energy industry and civil engineering. Moreover, its applications are increasing with the development of newer technologies.

Glass Industry

It is the industry where PLCs have been used for decades. It is specifically used in the industry for determining and controlling material ratio and flat glass processing. With the rapid of technological advancement, the use of program logic controllers is increasing in the glass industry. Making of glass is an intricate process which businesses find can done better with the application of PLCs.

Industrial Gas Industry

In this industry, PLCs are used in the manufacturing and fabrication of oxygen nitrogen plant which are used in the automation of the plant processes. Except the oiling and cleaning of filters, almost all of the processes of the O2/N2 plants are automated with the use of PLCs.

Paper Industry

In the paper making industry, the use of PLCs are used in carrying out various processes that go into making paper. The PLC is very effective in controlling all aspects of papermaking at a very quick pace.  It monitors the quality of production of book pages or newspaper pages.

Manufacturing of Cement

Cement is made by mixture of various raw materials in a kiln. And, the final quality of the product would depend on various factors including the proportion of various raw materials. In order to achieve the desired quality you need to use the right of materials and the precision of data for accomplishing this which is obtained by the use of PLC systems.

We’re also exporter and manufacturer of oxygen nitrogen gas plant, liquid oxygen nitrogen production and oxygen gas plant in India. If anyone is interested, kindly connect with us for setup including installation and commissioning.