PLCs or the automation of mechanical and electrical systems are used in almost every structure and facility. In fact, PLCs are employed in a wide range of industries and have innumerable uses in labs, plants, and factories.
Their use will only grow when more intricate facilities are built and factory floors are expanded.
Given that PLCs have been in use for almost 50 years, you may assume that they are an outdated technology, yet advancements are imminent.
This article by CM Industry Supply Automation - Lenze VFD, KEB VFD, Servo Drive supplier and repair service provider will discuss the future of PLCs in industrial automation and advancements in the industry.
A new generation of PLCs
In all industries, processors, circuit boards, and other components are getting smaller. PLCs are starting to adopt this strategy.
Modern improvements include larger memory capacities, quicker CPUs with improved cycle times, and additional communication functions.
We may anticipate that as higher level PLCs get smaller and more compact, mini PLCs will evolve to include many of their functions.
The fact that solid state memory drives are getting smaller and cheaper is a tremendous benefit to PLCs.
This makes it possible to store data locally and enables the use of a PLC in numerous applications that previously required pricey data collecting devices.
Nonvolatile portable memory devices are another example of a characteristic from the consumer electronics industry that is becoming more widespread.
These provide the PLC customer with significant advantages by housing a sizable quantity of extra memory in a compact chip.
PLCs and PACs Merge
As automation experts pay more attention to the advancement of the performance and functionality of the machines rather than the terminology around these devices, PACs and PLCs will continue to converge over time.
Advanced capabilities like motion control, vision system integration, and simultaneous support for various communication protocols will become more widespread thanks to faster CPUs and greater memory.
However, the machines will continue to have the ease of use that makes the PLC so appealing to many users.
The increasing need for these systems has made it difficult for designers to create systems that are durable and able to survive an industrial setting.
Future problems could include maintaining a degree of quality while keeping costs down (connectivity, memory expansion, and processor power upgrades needed to run ever more complex applications).
As a result, PLC prices could rise in the future.
A high-end PLC currently has numerous communication ports to accommodate various protocols.
Future consumers' demands for more standardized solutions, maybe limited to Ethernet and wireless with industrial Bluetooth as a potential option, will cause a shift in this.
Before we see a significant convergence of commercial and industrial wireless communication protocols, the industry does need a more reliable wireless technology with increased range and the preservation of data integrity.
Wi-Fi, ZigBee, and the rise of Bluetooth have all contributed to advancements in this area, but none of them have provided a solution for applications on factory floors.
The use of wireless will become more widespread in the future because it is effective in many less important monitoring applications where real-time control is not necessary, such as remote terminal units (RTUs) where line-of-sight is accessible.
The integration of enterprise resource planning (ERP) and other higher level computing systems to the manufacturing floor will be the most daring shift in the future of the PLC.
Manufacturers of controllers must take into account the requirements of the user and offer a solution where the PLC not only manages the application but also offers the means to easily manipulate and present process data to the users who require it.
ERPs play a role in that.
PLCs are unable to turn data into reports, which has a negative impact on management's capacity for planning and decision-making.
A PLC, for instance, can determine when a piece of machinery or equipment needs to be repaired.
However, it doesn't keep vital data regarding particular pieces of equipment, which is required for workers to decide what to do next.
If an ERP is involved, staff will then have access to this data, enabling a more effective reaction.
Employees are able to make more informed and effective decisions on the factor floor thanks to the mix of historical data and real-time data.
Additionally, this entails a decrease in operational expenses and an overall improvement in performance.
PLCs' Future Is Promising
PLCs will continue to advance, making newer models of these controllers worthwhile to consider as the technology gets more streamlined and efficient and continues to be the ideal choice for a range of industrial automation applications. Its longevity will be determined by evolving characteristics including wireless capability, smaller sizes, and flexibility.
The technical expertise and understanding required to work with programmable logic control systems are provided through our Programmable Logic Controller Technician Program.
Servo drives occur in a variety of sizes and shapes, selecting the right form factor is frequently a crucial step in determining which servo drive to utilize for your application.
A form factor is defined precisely. An electronics device's size, shape, and other physical characteristics are referred to as its form factor.
Form factors are one of the most typical ways servo drives are characterised in the field of motion control.
Why do servo drives come in so many distinct form factors?
You might expect it to be rather uniform by this point given that technology has been around for decades.
However, certain applications frequently benefit more from different form factors.
Engineers frequently must decide which servo drive style to use based on criteria other than power capacity, including space limitations, accessibility, exposure to the elements, and even personal preference.
Let's explore the different types of servo drive form factors and where it might be best to use a certain one.
Servo Panel Mount Drive
An external connector, bracket baseplate, and cover are included in this digital panel mount servo drive.
The conventional servo drive form factor is panel mount.
They have existed for many years.
They have a very plain appearance—they seem like boxes with connectors on them.
The majority of the circuit board is covered by a plastic or metal cover that is secured to a metallic base plate.
The baseplate usually has an L-shaped cross-section, which allows it to completely enclose the servo drive on two sides.
The baseplate has a number of uses.
PCB mount servo drives
Several examples of PCB mount servo drives.
PCB mount drives forego wire connections and connect directly to another printed circuit board solely using pins, offering tight integration.
Unlike panel mount servo drives, PCB mount servo drives have an open structure. There's no protective cover, so the printed circuit board is largely exposed. Some PCB mount servo drives, however, do feature a baseplate that acts as a heat sink.
The pin-based connection of PCB mount servo drives lends itself best to compact servo drive designs. For many years, the PCB mount form factor has been associated with lower power servo drives because of their small size.
A few illustrations of servo drives mounted on PCBs.
In order to provide tight integration, PCB mount drives forgo wire connections and connect directly to another printed circuit board using only pins.
PCB mount servo drives feature an open structure as opposed to panel mount servo drives.
The printed circuit board is largely exposed because there is no protective cover.
Nevertheless, some PCB mount servo drives do have a baseplate that serves as a heat sink.
Compact servo drive designs work best with the pin-based connection of PCB mount servo drives.
Because of its tiny size, the PCB mount form factor has long been linked to lower power servo drives.
However, improvements in power density have made PCB mount servo drives competitive with earlier, bigger panel mount servo drives, as seen in the Matrix drive family from Darwin Motion, which is avaiable at CM Industry Supply Automation.
Embedded servo drives with mounting cards for machines
Servo drives incorporated in machines with flying leads and connectors.
Our machine integrated drivers combine the openness, compactness, and connection style of panel mount servo drives with PCB mount servo drives.
It is, in essence, a PCB mount servo drive with an integrated mounting card.
Machine integrated servo drives are ideal for machine applications where space may be at a premium, as the name suggests.
They work well for mobile applications in the field where modest size is required yet immediate maintenance and replacement are required.
A servo drive mounted on a fully enclosed vehicle.
Heavy duty amplifiers with tough exteriors and large current outputs are vehicle mount servo drivers.
The core electronics of vehicle mount servo drives are well-protected by a strong plastic shell with an ip65 rating that surrounds the drive and a substantial baseplate.
Five screw terminals are used to connect the supply power to the motor, and a sealable connector is used for all communication.
Vehicle mount servo drives, as their name suggests, are designed to move big electric vehicles by producing a lot of current to provide them the traction they need.
A strong heat sink is provided by the extra-thick baseplate, which helps control the high current output.
All terrain mobile robots are well suited to the robustness of vehicle mount servo drives.
There are some flexible guidelines for choosing a servo drive like Lenze Drive form factor. The servo drive's mounting method or size may not always matter for a given application.
Small PCB mount servo drives are available that can perform on par with certain bigger panel mount servo drivers.
For an entirely static application, a vehicle mount servo drive is occasionally the best option.
Other times, selecting a servo drive with the appropriate form factor will determine whether an application is successful or not.
There are various types of variable frequency drives (VFDs) available in the market. Each one is designed for a unique application. This article by CM Industry Supply Automation will review the main factors that will help you make an informed decision.
There are various factors you have to consider while choosing a variable frequency drive for any type of drive system. These factors include:
1. The incoming power supply
The drive system incoming power supply is the biggest definer of volume in your system. VFDs should be chosen based on their compatibility with the power supply. According to voltage and frequency, recent capacity, and available KVA, you need to make the right selection.
2. The type of motor
Usually, several induction motors can advantage of having a Variable Frequency Drive including higher efficiency. Permanent magnet synchronous motors are not usually self-starting and require a Variable Frequency Drive for working. Some VFDs are available with permanent magnet motor control choices as a usual feature, permitting users for controlling the permanent magnet motor to drive the machine proficiently.
3. The rated current, frequency, and voltage of the motor
The rated current, frequency, and voltage of the motor are crucial factors to make a choice. A VFD must not be chosen based on the motor power rating alone. It is highly crucial to find the VFD that can offer the motor’s rated nameplate current uninterruptedly.
4. The application type
Many Variable Frequency Drives are only made to be utilized on normal duty or light duty loads such as pumps or centrifugal fans and will only stand lighter overloads for a short time frame. Some Variable Frequency Drives Are Dual Rated and can be utilized on HD or ND/LD loads both.
5. The installation setting
Choose the right IP rating for the Variable Frequency Drive identified by if it will be installed in inclusion or straight onto a wall, machine leg, or pump skid.
Understand condensation that takes place if the Variable Frequency Drives are exposed to high-temperature changes for instance daytime sun to night-time frost.
When connecting Variable Frequency Drive or other non-linear loads you must consider the effect on the power supply. Non-linear loads including diode rectifier input designed to ‘bite’ current from the chunks mains and at particular multiples of the base supply frequency instead of sinusoidal as with linear loads which in turn results in misrepresentation to the supply voltage waveform.
Harmonic currents can put an adversarial effect on transformers, cables, and delicate electronic devices, so certain harmonic limits are applied before linking VFD loads onto a new or current network.
Looking for Lenze VFD, Variable Frequency Drive, Inverter Drive, Variable Speed Drive, or Servo Drive? Speak to CM Industry Supply Automation specialists at +91 8956113099 or +61 3 9013 5882
CM Industry Supply Automation specialist offers great support to different industries regarding industrial automation products. Our specialist offers advice on the drive system and helps in choosing the best variable frequency drive for the essential application. From fan or pump, or a heavy-duty application, we can provide VFD from dimensioning to installation services at the best price.
Get all industrial automation products sales & repair services. Call us for Lenze Drive, Keb Drive, Siemens, Allen-Bradley equipment sales and repair services.
CM Industry Supply Automation are supplier and repair services provider of drives, VFD drive (variable frequency drive), VSD (variable speed drive), inverter, frequency converter, ac drive, servo drive, servo motor, industrial drives, industrial drives and controls, industrial drives and applications, high-power servomotor, high torque DC servo motor, high-power servo drives, high frequency drives, of some well-known brands that include:
Siemens Drive, Rexroth Drive, Elau Drive, Vacon Drive, Baumuller drive, Danfoss drive, Parker drive, Mitsubishi VFD drive, Sprint drive device, Allen Bradley drive, ABB drive, Rockwell VFD Drives, AB Powerflex drive, Kendrion, Intorque, Ntorq company Yaskawa drive, Fanuc drive, Weg drive, Toshiba drive, Hitachi drive, Gefran servo drive, INVT servo drive, INVT drive, INVT Servo Drive, Inovance drive & more.
Lenze, KEB, Siemens, Rexroth, Schneider Electric - Elau, Vacon, Baumuller, Danfoss, Parker, Mitsubishi, Sprint, Allen Bradley, ABB, Rockwell, Powerflex, Kendrion, Intorque, Ntorq, Yaskawa, Fanuc, Weg, Toshiba, Hitachi, Gerfan, INVT, Innovance, Bharat bijlee ,Balluf, Baumer, Bonfigilio, Contrinex, Panasonic, Heidehain, Hengsteler, Moxa, Motovario, Proface, Pilz, Pizzato, Rosemount, Helmholtz, Delta, Altivar, NIDEC, Control Technic, VLT FC, Kollmorgen, Innovance, Jetter, Crompton,HPB Motion, Techmation, Emotron,Beckhoff, Stober.
Textile control panel, Stenter Machine, Dying Machine, Merchinzer Machine, Sizing Machine, Flat Belt Machine, Rotary Printing Machine, Singing Machine, Ball Warping Machine, Indigo dyeing Machine, Rope Dyeing Machine, Weaving Sheet Dyeing Machine, Weaving sizing cooker system, Processing shrinking range machine, processing drying range machine, processing desize and mercerizing range, processing cold pad batch.
Printing machine and packaging machine control panel, rotary printing machine, flat belt printing machine, NC cutter, Corrugation Sheet Cutter, Steel Sheet cutter, Die Cutting Systems, Winders/Re-winders
Steel Control Panel, Bar Rolling Mills, Automatic Cooling Bed, Sponge Iron & Casting Applications, Flat Rolling Mill Applications, Paper & Plastic Applications, Flat Rolling Mill Applications, Flat Rolling Mill Applications, Pilger mill:
Machine tools control panel, CNC Machine, VMC Machine, Hydralic press Machine, Servo Press Machine, Automotive Machine CONTROL PANEL, Injection Molding Machine, Pipe Extrusion Machine, Wire Extrusion Machine, Wire Drawing Machine, Blow Molding Machine
Pharma machine control panel, filling machine, Blister packaging machine, Bottle labeling machine, Tablet press machine
Vision Camera, Absence/presence detection, Automated vision testing and measurement, Bar code reading, Color verification, Defect detection, Optical character recognition and verification, Part verification, Pattern matching, Sorting, Traceability, Vision guided robots
VFD Control Panel, PLC Control Panel, SCADA Control Panel, Electric Control Panel, Retrofiting solution, PCC Control, MCC Control Panel, Vision Camera, Laser Sensor, Electrolux washing machine