PLC, or Programmable Logic Controller, is a key component in industrial automation and control systems. It serves as a digital computer that is designed to control and monitor different processes within manufacturing environments. PLCs are widely used across various industries to enhance efficiency, improve productivity, and ensure reliable operation. Here are five paragraphs to provide an overview of PLCs.


This article shows how Rheonics inline process viscometer SRV and inline process density meter SRD support most of the leading PLC in quick integration of viscosity, density and temperature data over various digital and analog protocols.


Rheonics sensors support natively a multitude of analog and digital communication protocols from 4-20mA, HART, Ethernet/IP, Modbus RTU/TCP, Profinet to CAN and soon to be available IO-Link. Check the PLC you pan to use and see examples of how Rheonics sensors have been successfully connected to them.


TABLE OF CONTENTS

Introduction to Programmable Logic Controllers (PLC)


PLCs were initially developed as replacements for relays and timers used in automated control systems. They have evolved into powerful devices capable of executing complex control operations. A typical PLC consists of a central processing unit (CPU), input and output modules, memory, and communication interfaces. These components work together to receive inputs from sensors, process the data, and generate outputs that control actuators and other equipment.


Functionality and Programming of PLC


PLCs are programmable and highly flexible, adapting to various applications in industrial settings. They can be programmed using specialized software, often based on ladder logic diagrams that represent the control logic graphically. The programming language allows users to define the desired behavior of the system, such as sequencing, timing, and logical operations. PLCs can handle multiple inputs and outputs simultaneously, making them suitable for complex control tasks.


Applications of PLC


PLCs find application across a wide range of industries, including manufacturing, automotive, food processing, and energy. In manufacturing, PLCs are used to control assembly lines, robotics, and machine tools. They enable precise coordination, fault detection, and synchronization of equipment, leading to increased productivity and reduced downtime. PLCs are also utilized in process control applications, such as temperature, pressure, and level control, ensuring efficient and safe operation. In addition, process measurements like density, viscosity, flow rate, and similar process fluid and operational parameters are fed to PLC so they can be recorded, analyzed, and decisions made based on them. 


Key providers of PLC and how to integrate Rheonics density meter and viscometers to them.


Siemens

Siemens is a global leader in automation technology, offering a wide range of PLCs. Their SIMATIC S7 series is renowned for its reliability and versatility. For more information check: https://www.siemens.com/global/en.html 

Engineering tool: TIA Portal

Rheonics sensor integration protocol: Profinet, Modbus RTU over RS-485, and Profibus.

Integration page: Siemens PLC integration with Rheonics Sensors

Figure 1. Siemens PLCs.

Allen Bradley (Rockwell Automation)

Allen Bradley, a division of Rockwell Automation, provides robust PLC solutions. Their ControlLogix and CompactLogix series are widely used in industrial automation. For more information check: https://www.rockwellautomation.com/en-us.html 

Engineering tool: Studio5000

Rheonics sensor integration protocol: Ethernet/IP and Modbus RTU over RS-485

Integration page: Allen Bradley and Rockwell PLC integration with Rheonics Sensors

Figure 2. Rockwell Automation PLCs.

ABB

ABB offers programmable logic controllers known for their high performance and scalability. Their AC500 series is popular among various industries. For more information check: https://new.abb.com/plc/programmable-logic-controllers-plcs 

Engineering tool: Automation Builder

Rheonics sensor integration protocol: Profinet and Modbus RTU over RS-485

Figure 3. ABB PLCs.

B&R Automation

B&R Automation offers a comprehensive range of PLC solutions for industrial automation. Their X20 series PLCs provide high-performance control and extensive connectivity options, making them suitable for demanding applications.  For more information check: https://www.br-automation.com/en/ 

Engineering tool: Automation Studio 4

Rheonics sensor integration protocol: Ethernet/IP, Profinet, and Modbus TCP/RTU over RS-485

Integration page: https://support.rheonics.com/en/support/solutions/folders/81000286852 


Figure 4. B&R Automation PLCs.

Mitsubishi Electric

Mitsubishi Electric's MELSEC series PLCs are known for their advanced features and flexibility. They offer a range of models suitable for various automation applications. For more information check: https://www.mitsubishielectric.com/fa/products/cnt/plc/ 

Engineering tool: GX Works3

Rheonics sensor integration protocol:  Ethernet/IP, Profinet, and Modbus TCP/RTU over RS-485

Figure 5. Mitsubishi Electric PLCs.

Omron 

Omron provides reliable and efficient PLC solutions for automation needs. Their CJ series offers excellent performance and connectivity options. For more information check: https://www.ia.omron.com/ 

Engineering tool: Sysmac Studio

Rheonics sensor integration protocol: Modbus RTU over RS-485 and Ethernet/IP.

Figure 6. Omron PLCs.

Delta

Delta offers a diverse range of PLCs, including its DVP series, which is known for its compact size and cost-effectiveness. For more information check: https://www.deltaww.com/en-US/index 

Engineering tool: ISPsoft

Rheonics sensor integration protocol: Modbus RTU over RS-485 and Ethernet/IP.

Figure 7. Delta PLCs.

Honeywell Process

Honeywell's PLCs are designed for process control applications. Their MasterLogic PLC and ControlEdge PLCs provide robust control solutions. For more information check: https://process.honeywell.com/us/en/products/control-and-supervisory-systems/modular-controllers/masterlogic-plc 

Engineering tool: SoftMaster V4.72.99C

Rheonics sensor integration protocol: Modbus TCP/IP.

Figure 8. MasterLogic PLC from Honeywell Process

Emerson

Emerson offers a range of PLCs for industrial automation. Their RX3i and RX7i series provide powerful control capabilities. For more information check: https://www.emerson.com/en-us/catalog/emerson-ic695cpe330-es-mx 

Engineering tool: Proficy Machine Edition.

Rheonics sensor integration protocol: Profinet, HART, and Modbus TCP/IP.

Figure 9. PACSystems RX3i CPE330 Controller-Emerson.

Schneider Electric 

Schneider Electric's Modicon PLCs are widely used in various industries. They offer models such as the Modicon M340 and M580. For more information check: https://www.se.com/us/en/product-range/62098-modicon-m580-pac-controller/ 

Engineering tool: EcoStruxure Machine Expert (SoMachine)

Rheonics sensor integration protocol: Ethernet/IP and Modbus TCP.

Figure 10. M580 PLC controller-Schneider Electric

Yokogawa

Yokogawa provides PLC solutions for process automation. Their FA-M3 controllers are known for their reliability and safety features. For more information check: https://www.yokogawa.com/solutions/products-and-services/control/control-devices/programmable-logic-controllers-plc-pac/fa-m3/#Details 

Engineering tool: FA-M3 Programming Tool WideField3.

Rheonics sensor integration protocol:  Ethernet/IP and Modbus TCP.

Figure 11. FA-M3 Controller-Yokogawa.

Bosch Rexroth

Bosch Rexroth offers PLC solutions for motion control and automation. Their ctrlX CORE series provides precise control in industrial applications. For more information check: https://apps.boschrexroth.com/microsites/ctrlx-automation/en/portfolio/ctrlx-core/  

Engineering tool: ctrlX CORE Automation

Rheonics sensor integration protocol: Ethernet/IP.

Figure 12. ctrlX CORE PLC series-Bosc

Keyence

Keyence offers compact and user-friendly PLCs suitable for small-scale automation. Their KV series is known for its simplicity and ease of use. For more information check:   https://www.keyence.com/products/controls/plc-building-block-type/ 

Engineering tool: KV STUDIO Ver. 11.62

Rheonics sensor integration protocol: Ethernet/IP and Modbus/TCP.

Figure 13. KV-5000 controller-Keyence with in-built ethernet/IP port

IDEC

IDEC provides PLCs with a focus on energy efficiency and reliability. Their FC6A series is designed for small to medium-sized applications. For more information check: https://us.idec.com/Programmable-Logic-Controller/Micro-PLC/FC6A-MicroSmart-PLC/c/MicroSmart_FC6A?page=1 

Engineering tool: Automation Organizer Software

Rheonics sensor integration protocol: Ethernet/IP

Figure 14. FC6A controller-Yokogawa

Panasonic

Panasonic offers PLCs that are compact and cost-effective. Their FP series provides reliable control for various automation needs. For more information check: Panasonic 

Engineering tool: Control FPWIN Pro

Rheonics sensor integration protocol: Ethernet/IP, Modbus TCP and RTU.

Figure 15. FP series controller-Panasonic.

Fuji Electric

Fuji Electric's MICREX PLCs are known for their high-speed processing and advanced features. They offer solutions for diverse industrial applications. For more information check:  https://www.fujielectric.com/products/plc/product_information/computercom/ 

Engineering tool: SX-Programmer Expert

Rheonics sensor integration protocol: Modbus TCP/IP and Profibus.

Figure 16. Milcrex PLC-Fuji Electric.

Toshiba

Toshiba provides PLC solutions for various industries, including manufacturing and infrastructure. Their T3 series offers advanced control capabilities. For more information check: https://www.toshiba.com/tic/other-products/plcs/type1-light 

Engineering tool: nV-Tool

Rheonics sensor integration protocol: Modbus TCP/IP

Figure 17. Type1 PLC-Toshiba.

Beckhoff

Beckhoff offers PC-based PLC solutions known for their scalability and openness. Their TwinCAT system provides a comprehensive automation platform.

Engineering tool: Twincat 3

Rheonics sensor integration protocol: Ethernet/IP,  Profinet, and Modbus TCP/RTU.

Figure 18. CX8093 | Embedded PC with PROFINET device

Wago

Wago's PLCs are known for their modular design and flexibility. Their PFC200 series offers powerful control and communication options. For more information check: https://www.wago.com/global/ 

Engineering tool: CODESYS 

Rheonics sensor integration protocol: Ethernet/IP,  Profinet, and Modbus TCP/RTU.

Figure 19. Ethernet/IP compatible PLC PFC200 Wago

Hitachi

Hitachi provides PLCs for various automation needs. Their HX series offers reliable performance and extensive I/O capabilities. For more information check: https://www.hitachi-ies.co.jp/english/products/plc/eh_150/index.htm 

Engineering tool: Pro-H 

Rheonics sensor integration protocol: Ethernet/IP and Modbus TCP/RTU.

Figure 20. EHV+ Series-Hitachi.

Phoenix Contact

Phoenix Contact offers a wide range of PLC solutions for industrial automation. Their Axioline series provides flexible and reliable control options, enabling seamless integration with other devices in the automation system. For more information check: https://www.phoenixcontact.com/en-gb/products/plcs-controllers-and-i-os/classic-control-technology-in-accordance-with-iec-61131 

Engineering tool: https://www.phoenixcontact.com/en-gb/products/software-plc-pc-worx-srt-2701680 

Rheonics sensor integration protocol:  Profinet and Modbus TCP/IP

Figure 21. ILC 171 ETH 2TX - Controller - Phoenix Contact

Pilz

Pilz is a leading global automation technology company known for its safety PLC solutions. Their PSS series offers programmable safety systems that prioritize safety and compliance with international standards. For more information:  https://www.pilz.com/en-INT/products/controllers/plc-controllers 

Engineering tool: https://www.pilz.com/en-INT/products/controllers/software/pas4000 

Rheonics sensor integration protocol: Modbus TCP/IP

Figure 22. PSS 4000 controller- Pilz

Eaton

Eaton offers a range of PLCs for industrial automation. The XC series provides reliable control and communication options, making it suitable for various applications. For more information: https://www.eaton.com/us/en-us/catalog/machinery-controls/xc-modular-programmable-logic-controllers--plcs-.html

Engineering tool: CODESYS 

Rheonics sensor integration protocol:  Modbus TCP/RTU.

Figure 23. XC module series-EATON

Koyo Electronics

Koyo Electronics offers a range of reliable and cost-effective PLC solutions. Their DL205 series provides flexible control options for a variety of applications. For more information: https://www.electronics.jtekt.co.jp/en/product/plc/directlogic-205/ 

Engineering tool: https://www.electronics.jtekt.co.jp/en/product/plc/directsoft/ 

Rheonics sensor integration protocol: Modbus TCP/RTU.

Figure 24. DirectLogic205-Koyo Electronics.

LS Electric (LS Industrial Systems)

LS Electric is spin-out from South Korean conglomerate LG Electronics. Their XG5000 series PLCs offer advanced control capabilities and seamless integration with other LS products.

Engineering tool: XG5000 programming software 

Rheonics sensor integration protocol:  Modbus TCP/RTU and Ethernet/IP.

Figure 25. XGK CPU Controller-LS Electric

Unitronics

Unitronics is a global provider of integrated PLC and HMI solutions. Their product range includes programmable logic controllers with built-in touchscreens, offering a user-friendly interface for easy programming and monitoring.

Engineering tool: https://www.unitronicsplc.com/software-unilogic-for-programmable-controllers/ 

Rheonics sensor integration protocol:  Ethernet/IP and Modbus TCP/RTU

Figure 26. Unitronics PLC+HMI.

OPEN PLC

OpenPLC is an open-source Programmable Logic Controller that is based on an easy to use software. It is the first fully functional standardized open-source PLC, both in software and hardware. For more information: https://openplcproject.com/ 

Engineering tool: OpenPLC Editor 

Rheonics sensor integration protocol: Modbus TCP

Rheonics also has a few integration projects that we successfully developed in Codesys on Raspberry Pi, find below the support article where we explain how to integrate:

https://support.rheonics.com/en/support/solutions/articles/81000409807-profinet-communication-through-codesys 

https://support.rheonics.com/en/support/solutions/folders/81000298114 

https://www.codesys.com/ 

REFERENCES

  1. https://modbus.org/ 

  2. https://www.odva.org/technology-standards/key-technologies/ethernet-ip/ 

  3. https://www.profibus.com/download/fieldbus-integration-into-profinet-io-guideline 

  4. https://support.fieldcommgroup.org/support/home