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 A programmable logic controller (PLC) or programmable controller is an industrial computer. Burraq engineering solution provides free plc courses in Lahore. That has been durable and adapted to control production processes such as assembly lines, machines, robotic devices, or any activity that requires high reliability, easy programming, and diagnosis of process errors.

Processor

PLCs can range from small modular devices with dozens of inputs and outputs (I/O), in a case integrated with the processor, to large modular rack-mounted devices with thousands of I/Os, often interconnected with other PLC and SCADA systems. They can be designed for many digital and analog layouts.

Harsh environments

PLCs were first developed in the automotive industry to provide flexible, robust and easily programmable controllers to replace hard-wired relay logic systems. Since then, they have been widely accepted as highly reliable automation controllers suitable for harsh environments.

Designers

The hard-wired nature made it difficult for designers to change the automation process. Changes would require new involvement and careful updating of the documentation. If even one wire was out of place or one relay failed. Technicians often spent hours troubleshooting by examining schematics and comparing them to existing wiring.

General purpose 

When general-purpose computers became available, they were soon used for control logic in industrial processes. These early computers were unreliable[5] and required specialized programmers and strict control of operating conditions such as temperature, cleanliness, and power quality.

Several advantages 

The PLC provided several advantages over earlier automation systems. It tolerated industrial environments better than computers and was more reliable, more compact and required less maintenance than relay systems. It was easily expandable with additional I/O modules, while relay systems required complicated hardware changes in case of reconfiguration.

Manufacturing process

This made it easier to repeat the design of the manufacturing process. With a simple programming language focused on logic and switching operations, it was more user-friendly than computers using general-purpose programming languages. It also enabled monitoring of its operation.

Ladder logic 

 Early PLCs were programmed in ladder logic that strongly resembled the schematic diagram of relay logic. This program enrollment was chosen to reduce training requirements for existing technicians. Other PLCs used a form of instruction list programming based on a stack-based logic solver.

Massachusetts.

In 1968, GM Hydramatic (the automatic transmission division of General Motors) issued a request for proposals for an electronic replacement for hardwired relay systems based on a white paper written by engineer Edward R. Clark. The winning proposal came from Bedford Associates of Bedford, Massachusetts.

Modicon

Bedford Associates formed a company to develop, manufacture, sell and service this new product, which they named Modicon (which stands for Modular Digital Controller). One of the people who worked on this project was Dick Morley, who is considered the "father" of PLC.

Electronics

The Modicon brand was sold in 1977 to Gould Electronics and later to Schneider Electric, the current owner.[11] Around the same time, Modicon created Modbus, the data communication protocol used with its PLCs. Modbus has since become a standard open protocol commonly used to connect many industrial electrical devices.

Electric plant 

One of the first 084s produced is now on display at the Schneider Electric plant in North Andover, Massachusetts. It was introduced to Modicon GM when the unit was retired after nearly twenty years of continuous service. Modicon used the 84 moniker at the end of its product line until the 984 appeared.

Development

In parallel development, Odo Josef Struger is also sometimes referred to as the "father of the programmable logic automaton". He co-invented the Allen-Bradley programmable logic controller and is credited with inventing the initialism PLC. Allen-Bradley (now a brand owned by Rockwell Automation) became the main PLC.

Graphical representation 

Many early PLCs were not capable of graphical representation of logic, so it was instead represented as a series of logical expressions in some type of Boolean format, similar to Boolean algebra. As programming terminals evolved, it became more common to use ladder logic as it was a familiar format used for electromechanical control panels.

Function block

There are newer formats such as state logic and function block (which is similar to how logic is represented when using digital ICs), but they are still not as popular as ladder logic. The primary reason is that the PLC solves logic in a predictable and repetitive sequence.

Programming panels 

Until the mid-1990s, PLCs were programmed using proprietary programming panels or special programming terminals, which often had dedicated function keys representing the various logic elements of the PLC programs. Some proprietary programming terminals displayed elements of PLC programs as graphic symbols.