When designing a custom programmable logic controller, or PLC, striking the right balance between customization and simplicity is crucial. After all, every company system is different, and being able to adjust your own machinery to suit your business’s needs can give you a key advantage. We’ll explore the dos and don’ts of designing a custom PLC, as well as the importance of customization in PLC programming. Below, we’ve also listed several ways to streamline future updates on your custom PLC device. By following these guidelines and incorporating best practices, you’ll be able to design a custom PLC that meets your specific needs.
The Importance of Customization in PLC Programming
Did you know that creating a custom PLC can help you maximize performance, enhance scalability, and provide cost-efficient and tailored solutions for your specific application? Here’s why:
- Performance: Customizable PLCs enable you to optimize your system’s functionality according to your specific requirements. With a PLC tailored to your needs, you can achieve a higher level of performance and gain a competitive edge in your industry.
- Scalability: By designing a custom PLC that easily integrates with new technologies, you can better accommodate future expansion or upgrades, thereby increasing the lifetime value of your PLC system.
- Cost efficiency: With a customized PLC, you no longer have to spend money on unnecessary features you don’t need, thereby achieving long-term cost savings.
Customization plays a crucial role in leveraging the power of PLCs for your projects. But before you dive into the customization process, you should consider some essential factors.
Dos for Customizing Your PLC
A PLC is a complex automation solution. Therefore, there’s much more to integrating it than simply purchasing a highly rated product. This is especially true if you’re going to take the hands-on approach to customizing its performance. To ensure the success of your custom PLC, keep the following considerations in mind.
Determine the Objectives
Clearly define the functional requirements of your PLC system and create a detailed list of features you want. This will give you a clear roadmap during the development process and help avoid costly and time-consuming late-stage adjustments.
Choose the Right Hardware
Carefully select PLC hardware that meets your requirements in terms of processing capability, memory capacity, and communication options. Investigate the reliability and reputation of your chosen hardware to ensure long-lasting operation.
Standardize Your Language Usage
Use standard programming languages such as Ladder Logic or Structured Text to ensure interoperability and make it easier for other engineers to understand and work with your custom PLC. This guarantees that everyone on your team can use the system with little confusion, reducing your margin of error in the process.
Prioritize Safety
The safety of your team while using the PLC equipment is also vital. Implement safeguards and protective measures to prevent risks associated with incorrect PLC operation. Also, ensure that your custom PLC conforms to industry safety standards and guidelines.
Don’ts of Programming Your Customizable PLC
Now that we’ve covered some dos for designing the ideal custom PLC for your business, it’s time to discuss some don’ts. While customizing a PLC can lead to numerous benefits, you must avoid certain pitfalls that can negatively impact the performance and maintainability of your PLC system. Below are some key don’ts to consider when programming your customizable PLC.
Don’t Ignore Industry Standards
Though customization allows for flexibility, you shouldn’t deviate too far from established industry standards in programming languages and communication protocols. Adhering to these standards will ensure compatibility with other systems and make it easier for your team to maintain and troubleshoot the PLC.
Don’t Overcomplicate Code
Strive for simplicity and clarity in your PLC programming. Avoid using overly complex logic or structures that are difficult to understand and maintain. Instead, focus on creating modular, self-documenting code that is easy to read, debug, and update.
Don’t Skimp on Testing
Thoroughly test your custom PLC code before deployment to identify any errors, inefficiencies, or other potential issues. Use a combination of simulation tools, bench testing, and field testing to ensure your PLC performs reliably and meets your project requirements.
Don’t Neglect Documentation
Failing to create and maintain comprehensive documentation for your custom PLC can lead to difficulties in troubleshooting and updating the system. Ensure all design specifications, programming guidelines, and maintenance procedures receive detailed notes in your company files and that this paperwork is easily accessible to your team.
Ways To Streamline Future Updates
Even once you understand how to create the perfect PLC for your current operations, the work isn’t over for you and your team. As your business continues to evolve, you’ll need to make key changes to your systems to keep up with your new demands and regulations. To make updating your custom PLC easier and more efficient, consider the following strategies.
Implement Version Control
Use a version control system to track changes in your PLC code and maintain a history of revisions. This will help you quickly identify and revert to previous versions of the code if necessary, ensuring smoother updates and reducing the risk of errors.
Develop a Maintenance Plan
Establish a regular schedule for reviewing and updating your custom PLC system. This will help you proactively identify potential issues, optimize performance, and ensure your PLC remains compatible with any new technologies or requirements.
Train Your Team
Provide training and resources for your engineering team to ensure they have the necessary skills and knowledge to maintain and update your custom PLC. Encourage pursuing ongoing professional development and staying informed about industry trends and best practices.
Create Thorough Documentation
Maintain comprehensive documentation of your custom PLC, including design specifications, programming guidelines, and troubleshooting procedures. This will facilitate smoother updates and make it easier for your team to address any issues that arise.
Designing a custom PLC can offer significant benefits in terms of performance, scalability, and cost efficiency. By following the dos and don’ts outlined here, you can create a tailored PLC solution that meets your specific needs and ensures reliable operation for years to come.
At PLC Direct, we want all our customers to have access to the exact resources necessary to craft their ideal automation system. That’s why in addition to carrying programmable logic controllers from top brands, we also carry select parts, like our selection of specialized Schneider spare parts. With careful planning and execution, your custom PLC will be a valuable asset in driving your business’s success.
