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Unit1 PLC Discussion

A PLC and PC have several key differences: - PLCs have higher upfront and programming costs than PCs due to customized ladder logic programming. PCs have lower lifecycle costs. - PLC operation requires extensive training while PCs only require minor training. - PLCs use ladder logic programming while PCs use graphical interfaces like Windows. PLCs also have limited math and communication capabilities requiring additional hardware. - PLC performance declines as PID loops and I/O points increase due to cyclic scanning in the CPU. PCs distribute processing to I/O units to maintain performance. - Expanding PLC capabilities can be difficult if system requirements outgrow the PLC. PC software

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56 views

Unit1 PLC Discussion

A PLC and PC have several key differences: - PLCs have higher upfront and programming costs than PCs due to customized ladder logic programming. PCs have lower lifecycle costs. - PLC operation requires extensive training while PCs only require minor training. - PLCs use ladder logic programming while PCs use graphical interfaces like Windows. PLCs also have limited math and communication capabilities requiring additional hardware. - PLC performance declines as PID loops and I/O points increase due to cyclic scanning in the CPU. PCs distribute processing to I/O units to maintain performance. - Expanding PLC capabilities can be difficult if system requirements outgrow the PLC. PC software

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svss0813
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© Attribution Non-Commercial (BY-NC)
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Discuss the similarities as well as the differences between a PLC and a general purpose computer.

COST
PC - Low cost of the life cycle of the system; purchasing, installing, setup, maintaining and
upgrading. Operating software is preprogrammed.
PLC – Much higher cost per point. Programming is customized in Ladder Logic computer language
requiring services of costly programmers.
OPERATIONS AND TRAINING
PC - System setup and operation requires only minor training for personnel (included with
purchase of PCprocess, PCflow , PCbrew.
PLC - Systems operations can be complicated requiring extensive training. Proprietary network,
communication and programming.
Programming
PC - programming is accomplished in the graphical interface provided by Microsoft Windows 32-bit
platform to present a clear, concise representation of your entire control solution within a single
well-documented setting. No Ladder Logic programming required. Foundation of logic: exception
based, distributed.
PLC - To add features like ASCII communications capability, or complex math functions to Ladder
Logic, completely different hardware and programming environments have to be implemented and
integrated to support functions that Ladder Logic cannot perform. Program source code required.
Continuous scanning.
I/O Checking
PC - The I/O units themselves monitor the I/O points and report changes to the controller. Diverse
protocols and open standards.
PLC - Every I/O point is scanned cyclically and thus the speed depends on scanning power of PLC.
Function and Programming are modeled after relay circuits.
Math Functions
PC - Uses 32 bit architecture that easily handles the execution of both integer and floating point
math using a library of math functions. Multitasking.
PLC - Math functions done by function blocks. (integer only). Expensive add-on cards that require
programming in different language and environments if floating point math is needed.
P.I.D. FUNCTIONS (PROPORTIONAL–INTEGRAL–DERIVATIVE CONTROLLER)
PC - P.I.D. functions are processed by the I/O units, not by the controller. This provides for
painlessly expanding P.I.D. loops.  There is NO decline in performance as the number of P.I.D. loops
increase. Common tag database..
 PLC - P.I.D. functions are mostly calculated in the CPU of the PLC.  Calculations needed for multiple
P.I.D. loops can quickly bog down the CPU. Mandatory duplication of data tags for interoperability.
SCALABILITY
PC - All existing software is compatible. e.g. software on a low-end controller can be loaded and run
flawlessly in high-end controllers.
 PLC - Expanding PLC's may not be an option because the system requirements outgrow the
existing PLC capability.
ANALOG
PC's have an intelligent I/O processor on the I/O units for dealing with analog signals. PC's scale
and linearize all analog signals, so when values are read there is no need for conversion processing.
 PLC's have to execute logic and instructions in the PLC's CPU when dealing with analog signals.
These executions and instructions are required to handle the conversion and scaling it receives
from the physical I/O of analog values from the raw counts into scaled values.
COMMUNICATIONS
PC's work well with serial communications and Ethernet and are designed to communicate with
third party devices and software available "off-the-shelf".
PLC - Serial communications is difficult for PLC's. Multi-function communication PLC's need special
purpose hardware that requires knowledge of higher level language than just Ladder-Logic.

Give examples of when using a PLC would be a better fit than a PC.
PLCs are pretty good at controlling machines with a lot of discrete devices like limit switches, motor
starters, etc., that are often involved in automation such as material handling, sequencing, state
machines. They can also be used used in many factories for assembly line processes. The PLC can
handle multiple input and outputs in order to process a large amount of information flowing
through the system at one time. PLC systems are also designed to handle higher temperature
exposures than a regular computer. The information is processed in real time.

Read more: PLC Programming Tips | eHow.com http://www.ehow.com/list_6910373_plc-programming-


tips.html#ixzz1IcRObV2H

http://www.cemcorp.com/pcbrew/PC-plc.html

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