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)
- Functionality and Programming of PLC
- Applications of PLC
- Key providers of PLC and how to integrate Rheonics density meter and viscometers to them.
- Siemens
- Allen Bradley (Rockwell Automation)
- ABB
- B&R Automation
- Mitsubishi Electric
- Omron
- Delta
- Honeywell Process
- Emerson
- Schneider Electric
- Yokogawa
- Bosch Rexroth
- Keyence
- IDEC
- Panasonic
- Fuji Electric
- Toshiba
- Beckhoff
- Wago
- Hitachi
- Phoenix Contact
- Pilz
- Eaton
- Koyo Electronics
- LS Electric (LS Industrial Systems)
- Unitronics
- OPEN PLC
- REFERENCES
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
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
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
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
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
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.
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.
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.
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.
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.
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.
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.
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.
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
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.
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.
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
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.
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.
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.
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
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
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.
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.
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.
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
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/folders/81000298114
AutomationX
AutomationX is a highly scalable and modular DCS (Distributed Control System) specifically designed to support various industrial applications. Its architecture enables seamless adaptation for both small plants and complex distributed control systems, ensuring flexibility and reliability across various industries.
Engineering tool: aXIDE-Engineering
Supported protocols: Modbus RTU and Profibus.
