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While PLCs were traditionally used for machine control and DCS systems were used for process control, the lines have blurred over time. PLCs are still best for high-speed machine control due to their fast input-output cycle times, while DCS systems are better for complex continuous processes due to their integrated redundancy, diagnostics, and centralized database. When deciding between a PLC or DCS, it is important to consider factors like internal expertise, vendor support availability, long-term maintainability, and lifecycle costs rather than just technical features.
While PLCs were traditionally used for machine control and DCS systems were used for process control, the lines have blurred over time. PLCs are still best for high-speed machine control due to their fast input-output cycle times, while DCS systems are better for complex continuous processes due to their integrated redundancy, diagnostics, and centralized database. When deciding between a PLC or DCS, it is important to consider factors like internal expertise, vendor support availability, long-term maintainability, and lifecycle costs rather than just technical features.
While PLCs were traditionally used for machine control and DCS systems were used for process control, the lines have blurred over time. PLCs are still best for high-speed machine control due to their fast input-output cycle times, while DCS systems are better for complex continuous processes due to their integrated redundancy, diagnostics, and centralized database. When deciding between a PLC or DCS, it is important to consider factors like internal expertise, vendor support availability, long-term maintainability, and lifecycle costs rather than just technical features.
What is the difference? | You must automate a process, but you can't decide between a DCS and a PLC. Are these systems really all that different? he answers depend on a slew of other !uestions. Turn the clock back 10-15 years: The programmable logic controller (PLC) is king o machine control !hile the "istribute" control system (#C$) "ominates process control% & you manuacture plastic !i"gets' you speak PLC% & you pro"uce chemicals' you speak #C$% To"ay' the t!o technologies share king"oms as the unctional lines bet!een them continue to blur% (e no! use each !here the other use" to rule% )o!e*er' PLCs still "ominate high-spee" machine control' an" #C$s pre*ail in comple+ continuous processes% The early #C$ looke" "ramatically "ierent rom the early PLC% &nitially' the #C$ perorme" the control unctions o the analog panel instruments it replace"' an" its interace mimicke" their panel "isplays% #C$s then gaine" se,uence logic capabilities to control batch processes as !ell as continuous ones% #C$s perorme" hun"re"s o analog measurements an" controlle" "o-ens o analog outputs' using multi-*ariable Proportional &ntegral #eri*ati*e (P&#) control% (ith the same .-bit microprocessor technology that ga*e rise to the #C$' PLCs began replacing con*entional relay/soli"-state logic in machine control% PLCs "ealt !ith contact input/output (&/0) an" starte"/stoppe" motors by perorming 1oolean logic calculations% The big change in #C$ o*er the past 20 years is its mo*e rom proprietary har"!are to the personal computer (PC) an" stan"ar" L34 technologies% (ith each a"*ance in PC po!er' #C$s ha*e mo*e" up in po!er% PCs ga*e us spee"y' responsi*e' multi- me"ia' !in"o!e"' operator-process interaces (0P&)% 5elational "atabases an" sprea"sheet sot!are enhance the ability o #C$s to store an" manipulate "ata% 3rtiicial intelligence (3&) technology gi*es us 6smart6 alarming% To"ay7s #C$ architecturally looks much like the #C$ o 20 years ago' but tomorro!7s #C$ may control through net!orke" 6smart6 "e*ices- !ith no &/0 har"!are o its o!n% 8ost #C$s oer re"un"ant controllers' net!orks' an" &/0s% 8ost gi*e you 6built-in6 re"un"ancy an" "iagnostic eatures' !ith no nee" or user-!ritten logic% #C$s allo! centrali-e" coniguration rom the operator or engineering console in the control room% 9ou can change programming oline' an" "o!nloa" !ithout restarting the system or the change to be eecti*e% #C$s allo! inter-controller communications% 9ou can "o "ata e+change in most #C$ systems a" hoc (no nee" or pre"eine" "ata point lists)% 9ou access "ata by tag name' regar"less o har"!are or location% #C$s use multi-tasking operating systems' so you can "o!nloa" an" run applications asi"e rom the real-time control unctions an" still "o ractional-secon" control% #C$s no! come in 6micro6 systems' to price-compete !ith PLCs-but !ith ull #C$ eatures an" capabilities% The typical #C$ has integrate" "iagnostics an" stan"ar" "isplay templates that automatically e+ten"/up"ate !hen your "atabase changes% This "atabase is central to the system-you "on7t ha*e "ierent "atabases sitting in the controllers% #C$s ha*e user-rien"ly coniguration tools' inclu"ing structure" :nglish' control block libraries' $;C (se,uential unction chart)' an" e*en 5LL (relay la""er logic)% 8ost #C$s allo! graphical coniguration' pro*i"e online "iagnostics' an" are sel-"ocumenting% 8ost pro*i"e or user- "eine" control blocks or customi-e" strategies% The controllers e+ecute control strategies as in"epen"ent tasks< thus' making changes to part o the control logic has no impact on the rest% 3n important "ierence bet!een #C$s an" PLCs is ho! *en"ors market them% #C$ *en"ors typically sell a complete' !orking' integrate"' an" teste" system< oering ull application implementation% They oer many ser*ices: training' installation' iel" ser*ice' an" integration !ith your &normation Technology (&T) systems% 3 #C$ *en"or pro*i"es a ser*er !ith a relational "atabase' a L34 !ith PCs or oice automation' net!orking support an" integration o thir"-party applications an" systems% The #C$ *en"or tries to be your 6one-stop shop%6 The PLC is more o a 6"o-it-yoursel6 "e*ice' !hich is sometimes simpler to e+ecute% Programmable Logic Controllers% (hen PLCs !ere solely replacements or har"-!ire" relays' they ha" only "igital &/0' !ith no operator interace or communications% $imple operator interaces appeare"' then e*ol*e" into increasingly comple+ interaces as PLCs !orke" !ith increasingly comple+ automation problems% (e !ent rom a panel o buttons an" &/0-"ri*en lamps to PLC ull-color customi-e" graphic "isplays that run on $C3#3 sot!are o*er a net!ork% PLCs no! ha*e many #C$-like control unctions (e%g%' P&# algorithms) an" analog &/0% They7*e mo*e" past their birthplace: the "igital !orl" (s!itch an" binary sensor inputs an" output contacts to run motors an" trigger solenoi"s)% PLCs are ast: They run an input-compute-output cycle in millisecon"s% 0n the other han"' #C$s oer ractional secon" (1/2 to 1/10) control cycles% )o!e*er' some #C$s pro*i"e interrupt/e*ent-triggere" logic or high-spee" applications% PLCs are simple' rugge" computers !ith minimal peripherals an" simple 0$s% (hile increasing reliability' PLC simplicity is not con"uci*e to re"un"ancy% Thus' ully re"un"ant (6hot'6 automatic' bumpless) *ariations o PLCs' !ith their a""e" har"!are an" sot!are' sometimes suer rom a re"uction in their reliability-a characteristic PLCs are amous or% #ata e+change typically re,uires you to preassign "ata registers an" har" co"e their a""resses into the logic% & you a"" registers or nee" to reassign "ata' you typically ha*e to "eal manually !ith the #omino :ect% Typical PLC 5elay La""er Logic (5LL) languages inclu"e unction blocks that can perorm comple+ control an" math unctions (e%g%' P&# algorithms)% Comple+ multi-loop control unctions (e%g%' casca"e management an" loop initiali-ation) are not typical% ;or unctions too messy to implement in 5LL' most PLCs pro*i"e a unction block that calls a user-!ritten program (usually in 13$&C or C)% PLCs typically operate as 6state6 machines: They rea" all inputs' e+ecute through the logic' an" then "ri*e the outputs% The user- !ritten logic is typically one big 5LL program' !hich means you may ha*e to take the !hole PLC o-line to make a change o any si-e% 9ou also run into "atabase synchroni-ation problems because o the separation o PLCs an" the 8an 8achine &nterace (88&) sot!are packages' as oppose" to the central "atabases o #C$s% 3 PLC !ill run in a stan"-alone coniguration% 3 #C$ controller normally e+pects an operator interace an" communications' so it can sen" alarms' messages' tren" up"ates' an" "isplay up"ates% 8any PLC installations use interace sot!are rom thir"-party *en"ors or impro*e" graphics an" *arious le*els o alarming' tren"ing' an" reporting% The PLC an" 88& sot!are normally interact by sitting on the net!ork an" using the register e+change mechanism to get "ata rom an" to the *arious PLCs% This type o communication presumes you ha*e preassigne" "ata registers an" can etch "ata on an absolute a""ress basis% This can lea" to "ata processing errors (e%g%' rom the !rong input) you !on7t encounter !ith the central "atabase o a #C$% $ome PLCs use proprietary net!orks' an" others can use L34s% :ither !ay' the communication unctions are the same-etch an" put registers% This can result in bottlenecking an" timing problems i too many PCs try communicating !ith too many PLCs o*er a net!ork% 3 PLC may ha*e a thir"-party package or operator interaces' L34 interace to PCs an" peripherals' PLC "ata high!ay or bus' re"un"ant controllers !ith local an" "istribute" &/0' local 88& an" local programming capability% The PLC !oul" ha*e re"un"ant me"ia support' but not the re"un"ant communication har"!are or &/0 bus har"!are you7" in" in a #C$% 3 PLC !oul" ha*e preprogramme" &/0 car"s or speciic signal types an" ranges% To"ay' the "ecision bet!een PLC an" #C$ oten "epen"s on business issues rather than technical eatures% =uestions to consi"er are those in*ol*ing: The internal e+pertise to e+ecute the pro>ect' Le*el o support a*ailable rom a *en"or/integrator' Long-term maintainability' an" Lie-cycle costs% PLCs an" #C$s o*erlap in their eatures' but also ha*e "istinct strengths an" !eaknesses% (hen "eci"ing bet!een the t!o' kno! !ho !ill "eli*er an" support your system' an" ho! they !ill "o it% What is a Control System? What is Industrial Automation? What is Analog I/O?
What is Robotics? What is a Programmable Logic Controller PLC? What is IEC 6!"!? What is Ladder Logic?