Address industrial automation challenges with a new generation of PLC hardware
Environments (IDEs) such as Eclipse or Microsoft Visual Studio. The software can then be imported into PLCnext Engineer as a library for use with any compatible PLC (Figure 5). A key advantage of PLCnext technology is that it allows several developers to work independently and in parallel on a single PLC program, even if they are using different programming languages. This enables fast development of complex applications and allows developers with legacy language skills and those with higher-level language skills to combine their talents.
The IIoT promises to transform the factory. However, while engineers are installing Industrial Ethernet, the full potential of factory automation is being held back by traditional PLCs that offer limited connectivity and dated software.
Improving decision making in the factory Optimization of factory production is essential because manufacturing demands precision and repeatability. The key to ensuring high levels of precision and repeatability is process control. In the modern factory, IIoT sensors and cameras can monitor machines and measure finished components to pick up any minor deviations in the product and correct the process accordingly. Other sensors keep track of the health of machines to predict maintenance requirements before a worn machine starts to fail. Even more sensors keep track of the factory’s temperature, humidity, and air quality. A key feature of PLCnext Control is that, unlike traditional PLCs, it can tap into this factory data. According to Phoenix Contact, it is sufficient to connect the PLC to just 3 to 5% of the system’s analog and digital inputs and outputs (I/Os) for it to be able to map the manufacturing
at 1.3 gigahertz (GHz). The PLC features 1 gigabyte (Gbyte) of flash memory and 2,048 megabytes (Mbytes) of RAM. The IEC 61131 runtime system has 12 Mbytes of program memory and 32 Mbytes of program data storage. The unit can support up to 63 local bus devices and requires a 24 volt supply with a maximum current draw of 504 milliamps (mA) (Figure 4). Phoenix Contact’s PLCnext range includes PLCs and other critical elements of an industrial automation system, such as communications modules and managed switches. Specific examples are the 2403115 communications module and
the 2702981 managed network address translation (NAT) switch. The communications module adds an extra gigabit-capable Industrial Ethernet interface to the PLC. The module has an independent MAC address, offers PROFINET support, and includes electrical isolation between the Ethernet interface and the logic. The managed switch is used for storing and forwarding Ethernet- transported information and features four Ethernet RJ45 ports, two small form-factor pluggable (SFP) ports, and two combination ports (RJ45/SFP). The switch is a PROFINET Conformance Class B product.
processes comprehensively and without significant intervention. PLCnext Control can then connect to any Cloud service, including Phoenix Contact’s Proficloud. io, Amazon’s AWS, or Microsoft’s Azure. As a result, the factory system gains access to powerful computing resources to ensure that the operations management and maintenance processes run as efficiently as possible. The result is higher productivity, better product quality, and lower costs.
To use the starter kit, the PLC and analog/digital module units must first be connected to the 24 volt DC (VDC) supply. Next, an Ethernet cable is connected between the PLC and PC and the PC’s IP address is set. Then, the IP address of the PLC is typed into a browser window on the PC. The PLC becomes operational after users log in with their username and password. Further instructions are supplied from the web-based management system. Programming of the PLC is done using the PLCnext Engineer software. The software allows an engineer to configure, diagnose, and visualize an entire automation solution. PLCnext Engineer enables programming and configuration using the legacy languages defined under IEC 61131-3. It is also simple to program in higher- level languages such as C++ and C#. In addition to PLCnext Engineer, code can be built in other popular Integrated Development
Conclusion
The IIoT promises to transform the factory. However, while engineers are installing Industrial Ethernet, the full potential of factory automation is being held back by traditional PLCs that offer limited connectivity and dated software. PLCnext technology from Phoenix Contact is based on open systems, collaborative platforms, and accessible software. It can combine routines coded in legacy languages with those written in higher-level languages to open industrial automation to future- proof solutions with enhanced productivity, higher yields, better product quality, and lower costs.
Getting started with PLCnext
Working with PLCnext controllers and related units is relatively straightforward. To assist in starting a PLC programming project, Phoenix Contact has introduced the 1188165 PLCnext Technology Starter Kit. The kit comprises a 2404267 PLCnext control module (PLC), a module carrier, and a choice of analog or digital modules.
Figure 5: PLCnext PLCs can be programmed using legacy languages from PLCnext Engineer, higher- level languages from IDEs, or from model-based design systems. Image source: Phoenix Contact
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