PLCs Control the Process
A programmable logic controller, or PLC, is an industrial computer which controls machinery or processes. A PLC takes input signals, makes calculations using logic, and then activates output devices such as motors, valves and actuators. PLCs are used because they are rugged and designed for the harsh environments of the factory floor.
SCADA Provides Visibility
Supervisory Control and Data Acquisition or SCADA sits up a layer above PLCs. If PLCs are the muscle of industrial automation, a SCADA system acts like the eyes and ears of the machine. It is used for monitoring equipment, seeing process values, alarms and other data. A SCADA system provides visibility into what is happening at a machine, across an entire production line, or inside a factory.
The Two Works Together
A PLC might open or close a pump, but SCADA makes it possible for an operator to see what the pump is doing, how much is flowing through it, and any alarms that might occur. Using these two products together provide both control and visibility. This can be essential for managing complex machines, or for making sure that people are watching the machines at all times.
Upgrades Can Improve Functionality
Older control systems may continue operating for years but become difficult to support as hardware ages, spare parts disappear or software becomes obsolete. Providers such as AKA Electrical & Automation offer PLC and SCADA services including programming, upgrades, modifications, HMI design and commissioning. Modernisation can improve functionality while also making future maintenance more manageable.
Value of Data for Decision-Implementation
The control system can be utilized to capture hard-to-obtain data which would otherwise require a substantial effort to acquire consistently. For instance, alarm tripping statistics, downtime specifics, temperatures, counts, and cycle data can be used to spot trends, which can, in turn, be used by maintenance and production managers to make decisions. The critical factor is ensuring that the data is useful, and the most important consideration is choosing what to measure instead of measuring everything possible.
Security Aspects and Access Control
As control networks are becoming more connected, the aspect of cybersecurity becomes more important. The management of manufacturing facilities should have an adequate understanding of who can change PLC programs, ensuring limited access to these capabilities, and remote access availability. Additionally, control networks should be segmented and isolated when possible, and proper documentation should be available for operators and technicians, describing the exact state of the system.
Simplification and Local Control
The modern manufacturing plant is a complicated system that involves thousands of interconnected devices. PLCs offer a degree of control and local authority, and SCADA systems give an essential level of overview and management to operate the equipment, thereby making large-scale operations possible.
