Programmable Logic Controllers (PLCs) are essential for controlling automation systems and production lines in factories and plants.
Experienced control systems engineers work extensively with PLC hardware and software to create customized solutions for manufacturing and industrial clients. One of the most preferred PLC platforms is from Rockwell Automation, a leader in industrial automation.
How do Rockwell Automation PLCs stack up? Let’s break it down.
The Brains Behind the Operation
At the heart of any automated system sits a PLC, the computerized brains directing operations. Rockwell PLCs utilize a proprietary programming language called RSLogix to execute logical and sequential functions that replace electromechanical devices and hardwired relays. Rockwell’s RSLogix platform is extremely versatile yet easy to use compared to alternatives. It provides a robust feature set, allowing us to program complex conditional logic, timers, counters, and math functions.
Rockwell Automation PLCs communicate with sensors, switches, motors, valves, and other devices to control processes. The modular hardware design permits flexible configurations matching each application’s unique I/O requirements. For example, analog modules connect to variable sensors measuring temperature, pressure, or flow. Meanwhile, discrete relay outputs switch pumps, motors, and other loads on and off.
Safety First
Rockwell places a strong emphasis on safety. Their GuardLogix controllers offer safety-rated integrity up to SIL 3 per IEC 61508 standards.
Features like redundant processors, flash memory, and strict programming requirements ensure critical factory operations shut down safely if a fault occurs. Furthermore, applying safe design principles from organizations like NFPA and others greatly reduces risks when working on equipment.
The Power Behind the Controls
When it comes to computing power, Rockwell Automations certainly flexes its muscle for data-intensive or highly complex processes. Even smaller series controllers pack surprising memory capacities. The mid-range CompactLogix 5370 offers even more RAM and storage. For extreme performance demands, the ControlLogix 5580 powers through intricate algorithms and masses of data with multi-core processors and up to 40 MB of user memory.
These PLCs crunch numbers with lightning-fast cycle times measured in milliseconds.
Built-in expansion slots and networking give almost unlimited possibilities for distributed I/O and seamless integration with other systems. Rockwell’s modern architecture even embraces IT programming constructs like object-oriented code reuse.
Long Lifespans for Lasting Value
Companies invest major capital in buying and implementing automation equipment, so longevity and reliability remain top priorities when we advise clients on PLC options. Rockwell’s rigid quality controls and global supply chain deliver consistent products with exceptional lifespans. It’s not uncommon to encounter Rockwell PLCs built in the 1990s still chugging along on older lines. Moreover, upgraded programming software does reach back many hardware generations still in operation.
Rockwell often retains compatible functionality for decades across ever-advancing PLC chipsets. For instance, ControlLogix, CompactLogix, and Micro800 utilize the same RSLogix software environment. This provides a common, comfortable feel for operators, technicians, and engineers as facilities update various lines over the years. During migrations, it’s important to ensure ample testing, training, documentation, and support for smooth transitions before placing upgraded systems into production.
Well-rounded Solutions
PLC hardware represents one key aspect of automation systems. However, Rockwell Automation also provides comprehensive platforms encompassing HMI visualization software, drives, motion control, sensors, and safety technology. The ability to source major components from one automation leader proves extremely advantageous for avoiding integration headaches.
Powerful factory communication buses like Ethernet/IP and DeviceNet simplify sending data across miles of plant floors between distant areas. Everything seamlessly connects both information systems and automation domains into a unified architecture. Rockwell also partners with Cisco Systems, bringing IT expertise into operations technology. This paves the way for concepts like the Connected Enterprise tying business decisions to production metrics.
In Closing
Hopefully, this review provides helpful insight into programmable controllers from Rockwell Automation, one of the most trusted and capable brands in industrial automation. Rockwell’s high-performance PLC hardware, combined with versatile software, delivers solutions suitable for an enormous variety of manufacturing and processing industries.
We encourage those seeking experienced engineering consultation and implementation services to reach out to us at Pacific Blue Engineering. Our extensive Rockwell Automation and PLC software credentials enable custom designs to maximize operational efficiency.
Contact the experienced Rockwell Automation PLC systems integrators at Pacific Blue Engineering today at (657) 201-8603 or request a consultation online.
