Major Uses of PLCs in Manufacturing Industries

Major Uses of PLCs in Manufacturing Industries

Programmable logic controller is referred to as PLC. It is a specialised computer programme designed to automate and manage business operations. PLCs are frequently used to monitor and control machinery, equipment, and processes in manufacturing and industrial operations. The manufacturing sector uses PLCs (Programmable Logic Controllers) extensively for a variety of purposes.

1. Process Control:

PLCs are widely utilised in manufacturing operations for process control. They continuously monitor and regulate many factors, including temperature, pressure, flow rate, and level. PLCs gather data from sensors, analyse it, and then decide how to control actuators and other devices. They make sure that production operations are precisely and accurately controlled, increasing productivity and quality while lowering errors.

  • Sensor Integration: Sensors that measure several process parameters, including temperature, pressure, level, flow rate, pH, and others, provide input signals to PLCs. These sensors give the PLC real-time data, enabling it to track and assess the process’s present state.
  • Control Algorithms: PLCs process sensor data using control algorithms to arrive at decisions based on predetermined logic and instructions. Different control strategies, such as proportional-integral-derivative (PID) control, on-off control, cascade control, or other specially designed control schemes, can be implemented using the algorithms.
Read: Rockwell Automation MicroLogix 1400 PLC

2. Machine Automation:

  • PLCs are essential for automating shop floor machinery and equipment. They manage how conveyors, robots, drives, motors, and other manufacturing-related equipment operate. PLCs can manage time and synchronisation, carry out complex sequences of processes, and offer dependable control for routine tasks. They facilitate effective and reliable production, minimise manual intervention, and boost output.
  • Sequential Control: PLCs are perfect for automating machines with specified sequences of actions since they perform sequential control tasks exceptionally well. The setup, operation, and shutdown processes of machines can be managed by PLC programmes in a predetermined sequence. They can manage timing, interlocks, and sensor feedback to guarantee optimal machine action coordination and sequencing.

3. Safety Systems:

Safety is of utmost importance in manufacturing settings. PLCs are used to put in place safety measures that safeguard people, property, and the environment. Emergency stop buttons, safety interlocks, light curtains, and other safety equipment can all be monitored by PLC-based safety systems. They offer quick response times and can swiftly turn off or isolate particular devices or locations in the event of a dangerous condition, averting mishaps and lowering hazards.

  • Emergency Stop (E-stop) Control: PLCs are linked to emergency stop buttons placed around a building at various locations. The PLC gets a signal when an emergency stop button is pressed, and a safety sequence is started to immediately cease or isolate particular equipment, processes, or locations. PLCs guarantee an immediate response to emergencies, reducing possible dangers to people and equipment.

4. Quality Control:

Rockwell Automation 1766-L32BXBA MicroLogix 1400 PLC play a crucial role in manufacturing’s quality control procedures. To ensure product quality, they can track and examine data from numerous sensors and devices. PLCs are capable of carrying out activities like trending analysis, data logging, and statistical process control (SPC). They make it possible to monitor quality metrics in real-time, setting off alarms or adjusting when discrepancies take place. PLCs support efforts to continuously improve, decrease defects, and maintain high quality standards.

  • Data Acquisition: Sensors and equipment that track numerous process parameters and quality attributes send real-time data to PLCs. Temperature, pressure, humidity, weight, size, and other factors are examples of these parameters. PLCs collect information from these sources continuously, giving them a complete picture of the production process.
  • Statistical Process Control (SPC): PLCs can use statistical analysis to find patterns, variances, and anomalies in the collected data. PLCs can be used to monitor process stability, spot possible problems, and make data-driven decisions for process improvement utilising SPC techniques including control charts, histograms, and Pareto analysis.

5. Inventory Management:

PLCs are used in production to track and manage inventory effectively. They can automate the ordering process, keep an eye on stock levels, and manage the flow of materials. To precisely identify and record inventory movements, PLCs can be integrated with barcode scanners, RFID systems, and other identifying technologies. They promote just-in-time (JIT) manufacturing, optimise stock levels, and boost supply chain effectiveness by giving real-time visibility into inventory status.

  • Material Flow Control: To regulate the movement of materials inside the manufacturing facility, PLCs can be coupled with conveyor systems, automated guided vehicles (AGVs), and other material handling equipment. They keep an eye on inventory levels and start moving goods from one place to another to provide a seamless and effective material flow.
  • Stock Level Monitoring: Real-time inventory tracking and monitoring is possible with PLCs. They can be wired up to sensors, barcode readers, or RFID systems to gather information on how much material is being used, replenished, and available. These data are analysed by the PLCs, which then provide accurate stock level information and enhanced decision-making for inventory management.

PLCs may be scaled up or down to meet a variety of automation and control needs in production. They also offer flexibility. Their uses range from managing equipment and processes to assuring safety, increasing productivity, and using data to gain an advantage over competitors.

Asteam Techno Solutions Pvt. Ltd. has boasts over 10 years of experience in the industrial sector, founded in India and then became one of the best industrial automation parts supplier in India as well as globally. We provide automation solutions with reputed brands including Allen Bradley, Mitsubishi, Phoenix Contact, Siemens, Schneider, Moxa, VIPA and more.