Allen Bradley MicroLogix 1200 PLC PLCs are programmable controllers that are specially designed for applications in the industry. Before the advent of PLC, the industrial control system was a relay contractor system. However, these relay systems had many disadvantages, such as complicated wiring, longer durations for designing and production, problematic maintenance, fewer functionalities, and a variety of adaptations difficulties. PLCs use programmable storage for storing the instruction set of logic, timings, counting, and mathematical operations. They act as a controller in the industrial PC, adapted for control or production operations like assembly lines, fault diagnosis, robotic applications, and the ones which required great precision. There are many industrial component producers who are designing and manufacturing PLCs globally, and because of that, there is intense marketing competition. Two of the big names in this regard are Allen Bradley and Omron. We will be seeing the...
The RX3i CPU series has only one standalone CPU (IC695CPE400 ). It functions independently, unlike other models which are usually plugged into a backplane. Two mounting possibilities are facilitated; mount on a DIN rail or install in a cabinet. The CPE400 is the latest and most advanced CPU with unmatched processing power, performance, and features. It has a quad-core 1.2 GHz AMD G-Series processor. The operating system in this CPU is VxWorks, similar to all other CPU variants. This CPU operates in a temperature range from -40°C to 70°C, unlike all others having a 0°C to 60°C operating temperature range. CPE400 has battery-backed 64 Mbytes of RAM and a similar capacity non-volatile flash memory. CPE400 has built-in non-switched and four switched RJ45 Ethernet ports. Additionally, it has an Embedded Field Agent (EFA) RJ45 Ethernet connector, the specialty of CPE400 alone. In contrast, all other CPU models support high-speed PCI and Serial module backplanes for data transfer. A user can...
The 90-30 series of programmable logic controllers (PLCs) by General Electric (GE) was launched in 1991. This series has been serving automation control requirements of the industry for many years. This series provided flexibility and modularity, making it the primary choice for field professionals. In comparison, the RX3i is a programmable automation controller system, abbreviated as PACSystem, a new and upgraded series of automation controllers that provides a shift towards a more holistic vision of automation. This series is founded on the core abilities of the 90-30 series while providing even further sophisticated capabilities and versatility. Emerson has acquired Intelligent Platforms (Automation Control Systems) from GE which these automation controllers are part. The 90-30 series offers 10 CPU models for standard and high performances applications. The number of discrete I/O ranges from 160 to 4096, the total number of Analog I/O ranges from 62 In/32 Out up to 2048 In/ 512...
Programmable Logic Controllers are ruggedized computers, specially designed and built to operate reliably under harsh industrial environments. A typical PLC system consists of a processor (CPU), programmable memory, power supply, a user-defined program, I/O modules with associated circuitry, and so on. The programmable memory stores a series of instructions that enable the PLC to perform various control functions like arithmetic computation, relay logic, timing, counting, and sequencing. Essentially, these control functions are used to monitor and control either individual machines or complex electro-mechanical processes through the PLC inputs and outputs. As the PLC processor reads the inputs, the PLC processes them through the stored user-defined program and generates outputs that are sent out as control commands to field output devices. The I/O modules in the PLC system provide digital or analog electronic connections to field input and output devices. In this modern era, PLCs are...
In general, the concept of Sourcing and Sinking details a current flow relation between input and output devices of a control system and their power supply. This concept is based on the basic electrical theory, which states that; to complete an electrical circuit, the conventional current should flow from the DC+ terminal through a load to the DC- terminal. In that regard, the two terminologies (Sinking and Sourcing) apply only to DC input and DC output circuits. And not to AC circuits because of the reference to positive (+) and negative (-) polarities. In PLC systems, the Sinking and Sourcing concept may be confusing to most people but it’s fairly a simple one. As Sink and Source logic circuits are mainly associated with digital PLC Input and Output (I/O) signals. A logic circuit is basically an electrical I/O circuit in which its output is a function of the input. Such circuits are defined by the type of components used and the direction of current flow. A simple logic circuit can...
PLCs and CNCs are two major categories of digital controllers employed in different industrial control applications. On a surface level, it’s easy to group them together since they are both run by programs, digital processors, and they both interface with input and output devices. For example, if you ask a systems programmer whether a CNC controller can be used in place of a PLC system, the answer could be a frustrating variation of “Yes or No.” It’s therefore important to identify the differences between the two control systems, as discussed in this article. In electrical terms, PLC stands for Programmable Logic Controller. It is a compact, special-purpose computer designed to perform logic operations to control different electro-mechanical systems. Initially, PLCs were developed to perform the functionalities of hard-wired relays in the automotive industry. Today, Programmable Logic Controllers (PLCs) are widely used to automate manufacturing processes, assembly lines, and different...
In industrial applications, an electrical panel is basically a service box that connects the main power line to an electrical device and distributes electric currents to various other circuits within the system. In an industrial setting, you don’t simply plug a PLC controller into a wall socket, instead, an electrical panel is used. A PLC panel is simply an electrical control panel consisting of electrical components which use electric power to control a variety of mechanical functions of industrial machinery or equipment. In order for industrial machinery and equipment to accomplish their various process goals, they require user-defined functions and well-organized control. Thus, electrical control panels like the PLC panel are used to perform these functions within manufacturing machinery. Any electrical control panel you’ll ever come across will always consist of two main categories: panel structure and electrical components. Similarly, a PLC panel consists of a special stainless...
Recent advancements in industrial automation have led to the development of more powerful and more flexible control systems, which are easier to program, configure and communicate with. Modern industrial controllers are characterized by higher processing power and better interconnectivity in comparison to traditional controllers. Today, many industrial control applications utilize Human Machine Interfaces (HMIs) and Industrial Personal Computers (IPCs) to acquire raw data, process, visualize or store the processed data. You’ll often find both HMI and IPC on the factory floor, and it is almost impossible to distinguish them at first glance; as they resemble each other in physical appearance. Even many plant operators usually call an IPC an HMI, which adds to potential confusion. However, there are technical and functional differences between an IPC and an HMI that go beyond their outward physical design. These differences include processing and connectivity capabilities, feature set...
PowerFlex 755 20G11ND186JN0NNNNN PowerFlex 755 is a variable-frequency AC drive designed by Allen-Bradley/Rockwell Automation, for ease of integration, high motor control performance, advanced safety and application flexibility. This high-power drive (power rating of up to 1500kW) builds on the common user experience and application flexibility of PowerFlex 750-Series, providing heavy industries with an option for state-of -the-art power control. It is well suited for a wide variety of applications ranging from simple variable torque and variable speed control in demanding industrial systems that require constant torque control. Target applications for PowerFlex 755 AC drives include pumps, conveyors, fans, extruders, compressors and mixers control, as well as process control applications in tire and rubber, metals and mining, oil and gas, and refining industries. The PowerFlex 755 drives are configured with instructions embedded in Allen-Bradley CompactLogix Programmable Automation...
Programmable Logic Controllers (PLCs) are rugged and lightweight computers used to automate industrial processes such as wastewater treatment plants, ore processing plants, and manufacturing plants assembly lines. They are designed to perform logical decisions for different electro-mechanical control applications and to operate reliably in harsh industrial environments like in extreme low or high temperatures, and dusty conditions. Also, PLCs are capable of automating an entire production line or a specific machine function, or a given process. All Programmable Logic Controllers consist of four basic components. These components include the Processor section, an Input/Output(I/O) section, a programming section, and the power supply. The power supply provides the appropriate voltages levels required to power on the PLC and its internal components. It accomplishes this by converting a line voltage, mainly 120V or 240V AC (Alternating Current), into the required DC (Direct Current)...
In designing industrial automation systems, half of the challenge is how you wish to control a system, and the other half is in how to connect the system’s components together. Specifying input, output, and communication methods can be a huge undertaking, as all other devices up- and downstream have to be both compatible with, and reliable when using, your selected technologies. To aid in your selection of PLC connectivity modules, we’ll start with this article discussing the differences between discrete output types – namely, the design, functionality, and comparative details between Relay and Solid-State Output modules. PLC CompactLogix Controller We’ll set the stage for our discussion by first outlining a number of key terms involved with discrete PLC output modules. Said in plain English, we have an industrial computer referred to as a PLC, or Process Logic Controller, that uses electrical signals to turn other, separate devices on and off. These separate devices might be pumps...
Generally, a FLEX I/O line is a Distributed Input/Output System that connects to several Networks including EtherNet/IP, ControlNet, and DeviceNet. Being a bus coupler, the Flex I/O allows you to add different modules consisting of bases and I/O cards along the DIN rail. In particular, Flex I/O systems are flexible and modular providing all the functions of vast, rack-based I/O at a low cost and without the space requirements. They are available via a variety of communication modules, depending on the protocol of the lead module. The FLEX 5000™ I/O is the most recent release of Allen-Bradley’s popular Flex I/O line. Its architecture offers a variety of I/O modules to meet a wide range of your operational needs, with its applications spanning from high-speed digital control to process control. These I/O modules are designed for use with the Logix 5000™ controllers. Their architecture uses Consumer/Producer network communication models, an intelligent data exchange technology between...
In 1969, Programmable Logic Controllers (PLCs) were first introduced into manufacturing processes, and today, they are most widely used for automation and industrial process control. In an industrial setup, PLCs are used to control conveyor systems, to sequence automated devices such as robots, and to capture data and communicate information. Almost any machine function, process or production line is greatly enhanced whenever a PLC control system is used. A PLC system is modular, this allows you to mix and match different types of Output and Input devices to best suit your applications. Nevertheless, the greatest benefit of utilizing a PLC is its ability to replicate and change a given process or operation, while collecting and disseminating essential information. Typically, any PLC has a Central Processing Unit, the CPU, which contains an internal program. The program tells the PLC how to perform various functions such as Execute user defined control instructions that are contained...
In any automation system design: cost, functionality, space, and interoperability are always on the mind of the engineer designing the system. This is true of small control builds and complex, factory-wide control environments with numerous machines connected to the system. For many decades, PLCs have been the workhorse of such automation and control systems, providing an effective and reliable way for engineers to get the job done. But within the last decade, microcontrollers have come to the forefront of numerous applications leading many to wonder if they can be considered a more cost-effective and smaller substitute for PLCs. As the “maker” culture arose with small automation applications such as desktop 3D printers, an entire ecosystem of accessories grew with them until many have reached a comparable feature set and list of capabilities of PLCs. Why then can’t they be used in place of traditional PLCs? The answer lies in a few important distinctions between the two. Benefits of...
According to ISA, automation is defined as “the technique of making an apparatus, a process, or a system operate automatically”. In a more practical sense, it is a system that operates with minimum or no human intervention at all. It has been part of the development of mankind all along however, the concept was further realized after the mass production system was finally implemented. With automation in the mass production setup, consistent and uniform outputs may be produced. Absolutely, this cannot be achieved with manual and traditional automation. Fast forward today, a control system – whether commercial or industrial scope, meets the modern automation requirements if it is programmable. With the birth of the 1st programmable controller and the enhancement in the succeeding years, most control systems are now being governed by programmable controllers. Programmable controllers can be used in both home and industrial setup. They are also the core components of automation. They...
