Few applications use a standalone PLC and little else. Most control systems combine PLCs, inverters, servo components, network, HMIs, and I/O modules. They work as a system for machine control, process control, positioning, production line automation and even factory-wide coordination. So, is there a role for the PLC in large scale complex automation?

As manufacturing moves towards an Industry 4 model, the importance of communications is growing. This applies to communication between control devices, with the manufacturing unit, and with the outside world. Although they continue to play a vital role, it does mean control devices have become a subset in the business of production. In response, PLC makers are integrating their controls devices to operate as control platforms. This consolidates the position of the PLC in large scale complex automation.

iQ control platform

As an example, Mitsubishi Electric has enabled these benefits through its iQ-Platform. Built on Mitsubishi Electric’s class leading PLCs and dedicated CPUs, the iQ-Platform realises consolidated controllers on a single platform. It uses a common high-speed bus (back-plane) to support a wide range of multi-function automation CPUs to simplify construction. The platform’s large data band-width requires no additional network, so costs are lower.

The iQ provides a powerful PAC (programmable automation controller) platform offering class-leading performance. It features increased security, enhanced safety, reliable operation and reduced downtime. In addition to a logic CPU, the iQ platform will also accommodate CPUs for CNC control for complex machine operations and motion control; a robot CPU, a process CPU, and a C Controller, provides a reliable, open platform for executing C/C++ applications. It uses seamless connectivity provided by open CC-Link and CC-Link IE networks to enable rapid data exchange at up to 1GB/s between remote controllers.

Several edge computing solutions integrate directly with the automation platform to deliver IT information to and from the plant floor, and across the web. So, this improves the opportunities to optimise processes and improvement traceability through direct connection with the enterprise.

Simplifies configuration and reduces costs

The PLC does not handle all data transfer between the plant floor and higher-level systems. As a  result, the automation platform provides seamless connectivity between production management systems and PLCs, and between those systems and other devices. This enables configuring communications without involving network hierarchies and boundaries, hence reducing system configuration costs.

Mitsubishi Electric’s iQ-Platform uses a simple client-server communication protocol called seamless message protocol (SLMP). This enables communication between Ethernet products and CC-Link IE compatible machines. For this reason, it ensures monitoring and collecting of data from SLMP devices (vision sensors and RFID controllers) anywhere on the network.

The advantages of an automation platform go beyond just control. This is because the automation platform is an integrated engineering environment, supported by a complementary software delivery system. Called iQ Works, it specifically provides a single engineering environment provides tools for system design, programming, debugging and maintenance, ensuring consistency of the complete lifecycle of the system. Significantly, iQ Works software suites work with Mitsubishi Electric’s PLCs, servo systems, motion controllers, variable speed drives, HMIs, PC-based controllers, robots and CNC systems.

Supporting the journey to Industry 4.0

The integrated control components within the iQ-Platform offer the system designer the option to implement an optimised control system. As a result, they can integrate different controllers onto the platforms high-speed bus enabling fast data communication between processes. All essential on the journey towards Industry 4.