Before programming, we gain a thorough understanding of the industrial process or machinery that the PLC will control. Identify the inputs, outputs, sensors, actuators, and the overall system requirements.
We help our client to choose a suitable PLC model based on the application requirements. PLC programming is done using specific software provided by the PLC manufacturer. Popular PLC brands include Siemens, Allen-Bradley (Rockwell Automation), Omron, and Mitsubishi.
Start a new project in the PLC programming software. This involves configuring the hardware settings, defining I/O points, and setting up communication parameters.
We develop the control logic using ladder logic, function block diagrams, structured text, or other programming languages supported by the PLC. This logic defines how the PLC responds to different input conditions to control the output devices.
Assign addresses to input and output devices connected to the PLC. These addresses are used in the programming logic to read inputs and control outputs.
We use simulation tools provided by the PLC programming software to test the logic before deploying it to the actual PLC. This helps identify and rectify errors without affecting the physical system.
Download the compiled program from the programming software to the PLC. Ensure that the program is properly loaded and verified. Integrate the PLC into the industrial system and perform commissioning. Monitor the system closely to ensure that the PLC operates as intended and meets the process requirements.
Document the PLC program, including the control logic, I/O mapping, and any special considerations. Proper documentation aids in troubleshooting and future maintenance. Train operators and maintenance personnel on the PLC system. Provide them with the necessary knowledge to understand the control logic, diagnose issues, and perform routine maintenance.