PLC Programming and HMI Software Development a Plus

The Important Role of Industrial Automation in Manufacturing

Automation is the use of machines to automatically perform actions that humans would otherwise have to do manually. We can see the increasingly critical role the automation industry has in manufacturing by exploring its key benefits:

• Increased Efficiency: Automation greatly improves efficiency by reducing the manual labor required to produce goods. Machines can work continuously without the need for rest, leading to faster production times and reduced downtime.
• Improved Quality: Machines are able to perform tasks with a high degree of accuracy and consistency, which can improve product quality and reduce defects. By removing the potential for human error, automation can help ensure that each product is produced to the same high standard.
• Increased Productivity: Without the need for supervision and the ability to work around the clock, automation can increase productivity. This often leads to higher production rates and faster turnaround times, and increased profits.
• Reduced Labor Costs: Automated tasks that would otherwise require human labor reduce the need for manual labor and associated costs. While there may be upfront costs associated with purchasing and setting up automated machines, over time, the savings on labor costs can more than offset these initial investments.
• Increased Safety: Hazardous tasks can put workers in danger. By automating these tasks, workers are able to focus on other tasks that require human knowledge, oversight, and intervention.
• Improved Flexibility: Automation can increase machine operation flexibility by allowing machines to be quickly reprogrammed to produce different products or adjust to changes in demand and industrial workflows. This can help manufacturers quickly respond to changing market conditions and remain competitive

A Breakdown of HMI and PLC

Supervisory Control and Data Acquisition (SCADA) systems are used to monitor and control industrial processes. They consist of hardware and software components that work together for data collection from sensors and other devices and provide a user interface for monitoring and commanding the action. The main components included are HMI and PLC. Let’s take a look at PLC and HMI software, how they work, and how they work together in a SCADA system.

HMI

The human-machine interface (HMI) is the interface that allows human operators to interact with the system. It functions as a display, allowing you to access data, alarms, and events, and allows operators with remote access to monitor and control the process through buttons, touch screens, or other input devices.

It provides a visual representation of the process being controlled and allows users to quickly identify and respond to any issues or changes in the process. Any well-designed, custom HMI software should be easy to navigate, intuitive, and clear in its presentation of messaging. The user experience is key!

PLC

A PLC, or programmable logic controller, is a programmable device that receives input signals from sensors and other devices and uses that information to control output signals to other devices, such as motors, valves, and switches. The PLC systems execute programs that are written in ladder logic or other programming languages to control the process.

How do PLCs Work?

The PLC is the brain of the automation system. It receives inputs from devices in the industrial process, and based on its programming, it makes decisions about what actions to take and controls the output signals to various actuators and devices.

PLC Programming

In addition to providing a way for human-machine interaction with the control system, the HMI software can also be used to configure and program the PLC. The HMI software can be used to create and edit ladder logic diagrams and other PLC programming languages. This allows the operator to make changes to the control system without having to physically access the PLC. It is essential to have custom manufacturing software development in this area. 

Here are the essential steps involved in programming a PLC:

1. Define the process: Identify the input signals that the PLC will receive, the output signals that will be sent to various devices and machines, and the logic that will be used.
2. Develop the program: This involves creating a PLC ladder logic diagram that describes the control logic for the process. This can be done using the supervisory software tools provided by the manufacturer.
3. Test the program: Testing should include simulating the inputs and outputs to verify that the program executes the desired logic.
4. Download the program: Once the program has been tested and verified, it can be downloaded to the PLC. This involves connecting the PLC to an industrial computer and using the software tools provided by the manufacturer to transfer the program to the PLC.
5. Monitor and modify: Once the program has been downloaded to the PLC, the PLC will begin executing the program and can be monitored using manufacturer-provided software tools to ensure that it is working as expected.

How Do HMI and PLC Work Together in Industrial Automation?

In the SCADA system, HMI and PLC work together and communicate information and signals back and forth. The PLC sends information to the HMI solutions about the state of the operation and any alarms or events that have occurred. The HMI screens then display this information to the operator in a comprehensive format.

The operator can then use the HMI system to control the process by sending commands back to the PLC. For example, the operator may use the HMI device to start or stop a motor, adjust the speed of a conveyor belt, or open or close a valve.

How Can Geneca Help?

If you are ready to learn how the implementation of automation can solve your unique manufacturing issues, improve efficiency, and grow your revenue, contact us today! Our team specializes in manufacturing and is ready to support your success by developing your PLC and HMI software.