Since the 1960s, PLCs have been the device of choice for automating and controlling machine operation, making them the head of automated processes.
In recent years, engineers have started asking why they need to invest in a PLC. The devices can be expensive, require dedicated software and often mean additional panel and wiring expenses. Is a PLC and its cost really the best option for an application that may only need to control dozens rather than hundreds of I/O points?
With the advent of the field logic controller (FLC), the answer is increasingly no.
FLC is a new category of control that brings logic programming to the device level. It is to PLCs what cellphones were to landlines – a transformation in flexibility, control and potential. FLC empowers engineers, OEMs and system designers to add simple logic to applications via Ethernet I/O blocks with built-in FLC technology. It can be used in conjunction with PLCs or as a standalone solution, which removes PLCs from the equation entirely.
One of the primary FLC advantages for automation experts is saving on the expense of upgrading, buying or replacing a PLC to gain I/O points and connections. It also brings control outside the panel and into challenging field environments, because the blocks carry advanced IP ratings for ingress protection. Additionally, FLC technology makes programming accessible to engineers of all experience levels because of its straightforward and streamlined interface and design.
By reducing the amount of software and hardware required in manufacturing, FLCs enable more flexible and cost-effective programming for engineers and organisations. It is technology that unlocks the potential of I/O blocks for a revolution in logic and control that does not require dedicated software to purchase or license.
The origins of FLC and how it works
Turck developed the FLC as advances in microprocessor technology enabled a better control and programming solution for end-user challenges.
The cost of PLCs and the complex, dedicated software required have been an ongoing concern for engineers. User demand was building for simple logic with a clean, web browser-based interface that anyone could program. It was time to build an industrial automation programming environment that was as easy to use as consumer devices.
At the same time, microprocessors grew more powerful and less expensive, which allowed advanced functionality without increasing end-user cost. These advancements mean I/O blocks can manage both standard I/O functions and the control responsibilities that were formerly only capable through PLCs, and for a fraction of the cost.
To make this control possible, today’s FLC technology uses a flow chart system to custom program local Ethernet I/O blocks via a HTML5-compatible web browser, such as Chrome or Mozilla Firefox. Through a series of drop-down menus, engineers can set up multiple conditions, operations and actions on one block:
• Conditions correspond to input conditions. Examples include a timer expiring, a counter reaching a value, or an input from a sensor becoming true.
• Operations include Boolean operations, such as ‘and’, ‘or’ and ‘not’.
• Actions correspond to output conditions and tell the block the desired action to execute.
When a condition is true, actions run. Where before this functionality was only possible through PLCs, now FLCs can easily manage these communications on their own. They also allow users to write, run, simulate and debug code. Signalling a pump to turn on or off based on liquid level is an example of how this programming might work.
Engineers can choose to access different capabilities of FLC technology based on the application. These capabilities include toggle buttons to signal on/off, arithmetic functions, timers and counters, monitoring via HMI, and defining variables to communicate with PLCs.
New markets and uses on the horizon for FLC
With the introduction of FLC, engineers are able to build more cost-effective control solutions for simple applications. What before involved the investment in a PLC can now be managed through Ethernet I/O blocks with built-in FLC technology.
Whether used as a standalone platform or in conjunction with a PLC, FLC enhances control capabilities that require simple logic in applications.
“FLC will transform how the automation industry thinks about control and control systems,” said Dave Lagerstrom, president and CEO of Turck. “As this technology advances, we can see control capabilities expanding, allowing engineers to create entire standalone control systems using the FLC platform.”
For more information contact Brandon Topham, RET Automation, +27 (0)11 453 2468, [email protected], www.retautomation.com
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