To choose the best programmable logic controller (PLC), consider whether it’s a replacement or new installation, estimate inputs and outputs needed, analyze environmental and communication requirements, and choose a PLC with enough ports and ruggedness for the environment. Choose a PLC with communication and programming capabilities that match the project limitations.
A programmable logic controller (PLC) is a type of device used to control an automated machine, such as an industrial robot or a factory assembly line. There are many different varieties of logic controllers available, each with different features and benefits. To choose the best PLC, you should consider whether an existing unit will be replaced or a completely new installation is required. It’s also important to estimate how many inputs and outputs your device will need, and to analyze any special environmental or communication requirements at your location.
In situations where an existing programmable logic controller is being replaced, the best option is usually to choose a PLC manufactured by the same manufacturer as the old unit. It is usually much easier to transfer a logic program to a replacement controller if the old and new devices are of the same brand. This also helps ensure that connected accessories and sensors will continue to be compatible. Replacing an old PLC with a similar unit should be the first choice, unless other requirements make this option impractical.
Whether you are replacing an existing PLC or installing a completely new device, you need to carefully control the number of inputs and outputs. Create a diagram of each automated process and map out exactly how many devices and sensors need to be controlled. Choose a programmable logic controller that has enough digital and analog ports to cover the intended installation. It is usually a good idea to select a controller with many more inputs and outputs than the minimum required, in case the facility is expanded in the future.
The operating environment is another consideration when selecting a programmable logic controller. Note any potentially dangerous conditions in the installation site, such as extreme temperatures or high humidity. Choose a PLC specifically designed to withstand the environment. Again, it’s usually a good idea to err on the side of caution and select a device that’s built to be rugged. This will help reduce future repair or replacement costs if an unsuitable PLC is damaged.
Select a PLC with communication and programming capabilities that match the project limitations. If you need to interface existing sensors, make sure you choose a controller that uses the same communication protocol. Plan the physical location of the logic controller in the final installation and ensure that the unit you choose can be easily monitored and upgraded. Hard-to-reach locations may require a controller with wireless or remote interface capability.
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