Safety PLCs

More Information about Safety PLCs

When safety PLCs are compared to traditional safety relays, the advantages become even clearer. While safety relays are effective for individual safety circuits, they might require additional relays and field wiring as the complexity of the safety system increases. Safety PLCs, on the other hand, can manage multiple safety functions and are easily integrated into more complex systems, often resulting in cost savings in the long run.

However, using a safety PLC is not without its challenges. Maintenance technicians might need additional training to understand the nuances of these devices. PLC programming for safety PLCs is different from standard PLCs, requiring a keen eye for data verification and ensuring the correct order of operations. But this learning curve is often justified by the comprehensive information tracking capabilities, enhanced diagnostics, and safety features they bring to a process or equipment.

While the upfront cost of a safety PLC might be higher than a standard PLC or a safety relay, the long-term benefits often justify the initial investment. They eliminate the need for additional relays, reduce the complexity of field wiring, and can be password protected to ensure programming changes are made securely.

FAQs

Can a safety relay be used with a safety plc in a safety circuit?

Yes, using a combination of safety relays and safety PLCs in a safety circuit can provide additional layers of safety and redundancy, making the overall system more reliable and fail-safe.

What are the internal functions of a safety plc compared to standard plcs?

A safety PLC is a specialized type of PLC that is designed to provide enhanced safety functions and meet safety requirements and standards, such as IEC 61508 and ISO 13849. Compared to standard PLCs, safety PLCs have several internal functions that are specifically designed to enhance safety and reliability which include: dual processors, self-checking, safety functions, safety communication protocols, diagnostic coverage and data verification.

What is program flow control?

Program flow control is the process of controlling the sequence of instructions executed in a program. It refers to the way in which a program directs the flow of execution from one instruction to another based on certain conditions or events.

What is software fault injection testing?

Software fault injection testing is a technique used to evaluate the robustness and resilience of software by injecting faults or errors into the software to observe how it behaves under different scenarios.

PLCs

Programming Logic Controllers (PLCs) are industrial computer that are designed to monitor and control a series of inputs and outputs.

The program running the PLC evaluates the inputs, and changes the output signals based on the program response to the input signals. Several programming languages are available to program most PLCs. The most common of these is called ladder logic. Ladder logic is a visual programming language that evolved from relay logic diagrams, which visually look like ladders because they consist of two vertical rails with runs between them that contain programmed logic. While ladder logic is the most common programming language used within PLCs, there are others that are also common, including function block diagrams, structured text and sequential function charts. 

The hardware included in a PLC includes: a CPU, memory, I/O connections, a power supply and a programming device.

The CPU is a microprocessor that acts as the brains of the PLC. It performs logic operations, controls instruction and performs various other tasks that help keep the PLC running effectively. The memory in a PLC allows data to be stored that is needed to run the program, as well as any data that is collected by the inputs. Depending on the the type of PLC, the section for I/O may have a fixed number of points or it may be modular, allowing for additional I/O to be added. Many PLCs require some type of power supply and it is common to see more modular based systems integrate the power supply. Lastly, the PLC provides a programming device that feeds the program into the PLC's memory, so that it can perform the desired operation. This is most commonly some type of computer. 

The PLC is designed to run a program repeatedly over and over again, normally many times a second. Each time a program runs, the PLC goes through some very specific steps.

While the order and the specifics may vary from manufacturer to manufacturer, they all typically follow a pattern similar to the following: 

The PLC performs internal self checks to make sure that it is functioning correctly.

The PLC reads the inputs that are connected to it. It will then store the status of each of those inputs in its memory.

The PLC will execute the program logic.

The PLC will write the new values to the hard wired outputs to match those determined during the program execution. At some point in the cycle, communication requests will also be processed.

Following the execution of the last step, the PLC will then cycle back to the beginning of the process and begin all over again.