A programmable logic controller (PLC) is the nervous system of an organization’s computer system that allows management and technicians to work better. It continuously makes decisions based on system inputs that increase equipment efficiency, production lines, and manufacturing processes. PLCs collect and share data so that teams have insight into what specific operations need to be adjusted or should remain the same. They are typically used to monitor motors or machines, often acting as the basis of a predictive maintenance approach to avoid unplanned breakdowns.
PLCs are typically compact or modular. Compact PLCs are better suited for small applications because they have a set number of input and output capabilities. However, if your organization is large or growing substantially, modular PLCs allow for customization and easier expansion of an overall system.
Regardless of the type of PLC, they all include common key components, including:
PLCs are critical to the smooth operation of your factory, so it’s important that they remain running at peak efficiency. The best way to keep a PLC system properly functioning is with regular, preventive maintenance. PLC preventative maintenance tasks can save you money in repair bills and downtime. Below are a few suggested tasks you can add to your preventative maintenance checklist:
The manufacturer of your PLC should provide an optimal preventative maintenance schedule for your analog input devices, so be sure to follow the guidelines for keeping your analog inputs clean and accurately calibrated.
There will always be a risk of your PLC being exposed to debris during regular operation. Debris might include corrosive and conductive contaminants that can damage the components of your PLC. Perform regular visual inspections of all input and output devices and look out for signs like black dust. Canned air can be used to blow debris away from the system when necessary.
To prevent build up of debris and dust, change ventilation filters in any PLC enclosures. The frequency should be determined by environmental conditions and specific needs.
The input and output modules of a PLC are susceptible to general wear and tear. Be sure to follow the manufacturer’s instructions for when to repair or replace modules and how to do so properly.
Environmental conditions like humidity levels and temperature can impact the proper functioning of a PLC’s components. Use sensors to help you monitor these conditions around the clock.
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