Hi Everyone,
I need some help and it seems that there is a great collection of people here who understand PLCs and everything about them.
Quick up front disclaimer. I am a tech guy (but am not an engineer) and am new to PLCs. I regularly work with software and IT stuff in an office context.
As I understand, PLCs are used to control machines on a production floor (or to control other electromechanical processes, which are often automated). What I am trying to understand is: how can the data running through the PLCs be used in other ways than just controlling the machines? I know there are some data logging and analysis applications, and I'm really trying to get a grip on what the scope of these systems is.
So I guess my main questions are:
1. What are the different software systems out there to log the data from PLCs and make it more useful?
2. Is there an industry standard? What are the most common software packages? What are the upsides and downsides to each?
3. Do any of them output or interface with things like Minitab?
4. SCADA systems: Do most SCADA systems log this data? What are the best ones that make it most accessible?
5. Does anyone have any good examples of ways logging the data from their PLCs improved processes or produced cost savings?
The more data or leads you can provide me with the better!
Thanks!
A quick story for people interested in why someone might be so desperately trying to learn about PLC data logging and analysis.
Imagine the following scenario:
Company x, who has a complex manufacturing/production system (think refinery, aluminium smelter, or die casting size facility) hires a new plant manager, who has "absolutely crazy" (not his quote) ideas about changing the way everything is done. A number of others are concerned that this guy doesn't know his a** from his elbow, let alone anything about running a plant. New Guy proposes a total change in systems and wants to implement all new different software, which to many others does not seem value adding in any way. Its been a hard couple of years for Company x with the decreasing demand from customers, courtesy of the crisis. If this super expensive system from lets say, a large American conglomerate, doesn't provide absolutely amazing (and it seems unlikely) efficiency improvements in a short period of time to justify its whoppingly large cost, its likely that Company x will go bust and a whole bunch of hard working loyal people will be out of work.
Now imagine that there are a group of people at company x who want to oppose New Guy, go over his head, and try to propose an alternative (and less risky) solution to the most senior management. This group are looking at ways of making the current system better at a much lower total cost and really want to call this guy out on the millions of wasted pounds (or dollars) that are about to be spent.
To be able to do this, they need to quickly understand how they could become more efficient, and getting more data from the production floor, via PLCs has been raised as an idea. The theory goes that if there is much more comprehensive data available, the process techs and industrial engineers will be able to quantify and justify process changes (that seem logical to both the new and older engineers who have been there for years) that will generate cost savings. And they choose a random, helpful and somewhat clueless IT guy to find out what software could provide this additional data.
So... if someone was in a situation like that, and wanted to learn everything they could about all the possible alternatives for collecting, capturing, and acquiring and analysing data from PLCS (and any other data sources on the floor), what direction would you steer them in?
Thank you all in advance for your help
Mr. Blah
I need some help and it seems that there is a great collection of people here who understand PLCs and everything about them.
Quick up front disclaimer. I am a tech guy (but am not an engineer) and am new to PLCs. I regularly work with software and IT stuff in an office context.
As I understand, PLCs are used to control machines on a production floor (or to control other electromechanical processes, which are often automated). What I am trying to understand is: how can the data running through the PLCs be used in other ways than just controlling the machines? I know there are some data logging and analysis applications, and I'm really trying to get a grip on what the scope of these systems is.
So I guess my main questions are:
1. What are the different software systems out there to log the data from PLCs and make it more useful?
2. Is there an industry standard? What are the most common software packages? What are the upsides and downsides to each?
3. Do any of them output or interface with things like Minitab?
4. SCADA systems: Do most SCADA systems log this data? What are the best ones that make it most accessible?
5. Does anyone have any good examples of ways logging the data from their PLCs improved processes or produced cost savings?
The more data or leads you can provide me with the better!
Thanks!
A quick story for people interested in why someone might be so desperately trying to learn about PLC data logging and analysis.
Imagine the following scenario:
Company x, who has a complex manufacturing/production system (think refinery, aluminium smelter, or die casting size facility) hires a new plant manager, who has "absolutely crazy" (not his quote) ideas about changing the way everything is done. A number of others are concerned that this guy doesn't know his a** from his elbow, let alone anything about running a plant. New Guy proposes a total change in systems and wants to implement all new different software, which to many others does not seem value adding in any way. Its been a hard couple of years for Company x with the decreasing demand from customers, courtesy of the crisis. If this super expensive system from lets say, a large American conglomerate, doesn't provide absolutely amazing (and it seems unlikely) efficiency improvements in a short period of time to justify its whoppingly large cost, its likely that Company x will go bust and a whole bunch of hard working loyal people will be out of work.
Now imagine that there are a group of people at company x who want to oppose New Guy, go over his head, and try to propose an alternative (and less risky) solution to the most senior management. This group are looking at ways of making the current system better at a much lower total cost and really want to call this guy out on the millions of wasted pounds (or dollars) that are about to be spent.
To be able to do this, they need to quickly understand how they could become more efficient, and getting more data from the production floor, via PLCs has been raised as an idea. The theory goes that if there is much more comprehensive data available, the process techs and industrial engineers will be able to quantify and justify process changes (that seem logical to both the new and older engineers who have been there for years) that will generate cost savings. And they choose a random, helpful and somewhat clueless IT guy to find out what software could provide this additional data.
So... if someone was in a situation like that, and wanted to learn everything they could about all the possible alternatives for collecting, capturing, and acquiring and analysing data from PLCS (and any other data sources on the floor), what direction would you steer them in?
Thank you all in advance for your help
Mr. Blah