Harnessing the power of PLC Data

Harnessing the power of PLC Data

In today’s interconnected world of industrial automation, Programmable Logic Controller (PLC) data is a cornerstone of efficiency and innovation. Leveraging it effectively can transform operations and unlock untapped potential.

Introduction

Software continues to reshape industries, and PLCs are no exception. Introduced in the 1960s, PLCs have evolved from simple controllers into powerful devices capable of executing over 2,000 million instructions per second (MIPS)—a computing capacity 50 times that of the computer used to land humans on the moon.

This leap in PLC performance has driven widespread adoption across industries. The global PLC market, valued at $11 billion in 2020, is projected to grow at a compound annual rate of 5% until 2026, according to Statista. As PLCs proliferate, so does the volume of data they generate—creating both an opportunity and a challenge: how to harness and secure this critical resource effectively.

This guide explores PLC data, from its types and uses to how analysis can elevate industrial operations.

What exactly is PLC Data ?

PLC data refers to the information processed and stored within a PLC to monitor inputs, execute logic, and control outputs. This data is fundamental for industrial processes, ensuring that machines and systems operate as intended.

What is PLC Data inputs and outputs: The Basics

Inputs: These are signals from external devices such as sensors, switches, and instruments. For example, input data might include:

• Temperature readings from an industrial oven.
• Electrical charge on a wire.
• Object presence on a production line.

Outputs: After processing input data, the PLC generates output signals to control devices like actuators and alarms. For example:

• Turning a light on or off.
• Opening or closing a valve.
• Activating an alert system.

The PLC works with a wide range of data types and data sources

PLCs handle a broad spectrum of data types and sources, reflecting the diverse demands of industrial automation. Each piece of equipment provides operational data to the PLC in formats tailored to its specific functions.

By processing this wide variety of data, PLCs can seamlessly manage complex tasks, from fine-tuning precise motion sequences to overseeing intricate manufacturing processes. This adaptability makes PLCs indispensable in modern industry, enabling streamlined control and optimization across a vast range of systems and operations.

Understanding PLC Data Types - Types of PLC Data

PLCs handle a variety of data types to meet diverse industrial needs. Here’s a quick breakdown:

• Boolean: Binary values like ON/OFF or TRUE/FALSE.
• Integer: Whole numbers for tracking quantities, such as production counts.
• Real: Floating-point numbers for precision, like temperature readings.
• Double Word: Larger integer ranges, e.g., total energy consumption.
• Word: 16-bit integers for compact data, such as unit counts.
• Byte: 8-bit values for storing status info from sensors.
• Timer: Tracks time intervals, e.g., duration of mixing processes.
• Counter: Counts discrete events, like items produced.
• String: Stores text data, such as product names or serial numbers.
• Array: Groups similar data types, e.g., daily production stats.
• Structures: Custom data types combining various fields, like employee details.

Why is it important to run PLC data analysis ?

Modern PLCs don’t just control processes; they also generate vast amounts of valuable data. Analyzing this data can revolutionize your operations:

1. Fine-Tuned Optimization
   PLC data analysis helps identify bottlenecks and inefficiencies, allowing precise adjustments that boost productivity, reduce waste, and lower costs.
2. Deeper Machine Insights
   By examining operational data, you can anticipate malfunctions, perform proactive maintenance, and extend equipment lifespan.
3. Operational Excellence and Cybersecurity
   Real-time monitoring of PLC data supports performance optimization, predictive maintenance, and cybersecurity by identifying anomalies and ensuring compliance with standards.

PLC Compliance :

Compliance requirements for Programmable Logic Controller (PLC) systems can vary depending on the specific industry, region, and application. However, there are several common standards and regulations that often apply:

IEC 61131-3 Standard: This is the international standard for PLC programming languages and specifies the syntax, semantics, and display for five languages: Ladder Diagram (LD), Function Block Diagram (FBD), Structured Text (ST), Instruction List (IL), and Sequential Function Chart (SFC).

IEC 61508 Standard: This is the international standard for functional safety of electrical/electronic/programmable electronic safety-related systems. It is applicable to all kinds of industries. The standard covers the complete safety lifecycle and may be used to establish a safety management system.

ISO 13849-1 & -2 Standards: These standards provide safety requirements and guidance on the principles for the design and integration of safety-related parts of control systems, including the design of software.

UL 508 Standard: In the United States, the Underwriters Laboratories (UL) standard 508 is often required. This standard applies to industrial control equipment such as PLCs.

FCC Compliance: In the United States, PLCs must also comply with Federal Communications Commission (FCC) regulations regarding electromagnetic interference.

CE Marking In Europe, PLCs must carry the CE mark to signify compliance with relevant European health, safety, and environmental protection legislation.

RoHS Compliance: The Restriction of Hazardous Substances (RoHS) directive restricts the use of certain hazardous substances in electrical and electronic equipment, including PLCs.

ATEX Directive: For PLCs used in potentially explosive atmospheres in Europe, compliance with the ATEX directive is required.

Cybersecurity Standards: With the rise of Industry 4.0 and the Industrial Internet of Things (IIoT), PLCs are increasingly networked and therefore subject to cybersecurity risks. Standards such as IEC 62443 provide a framework for securing industrial automation and control systems.

It's important to note that this is not an exhaustive list and specific applications may have additional requirements.

Why does PLC data analysis complement your SCADA and MES systems ?

Combining PLC data analysis with Supervisory Control and Data Acquisition (SCADA) or Manufacturing Execution Systems (MES) offers a powerful advantage. While SCADA and MES provide real-time system-wide oversight, PLC data adds granular, machine-level insights. This synergy uncovers hidden patterns and supports predictive maintenance, enabling smarter, data-driven decisions.

Conclusion

In an era where data drives competitiveness, mastering PLC data is no longer optional—it’s essential. Trout Software empowers teams to unlock the full potential of PLC data, enhancing operations, security, and compliance.

👉 Start your journey with Trout today and harness the power of PLC data!