Programmable Logic Controllers

A PLC, or Programmable Logic Controller, is a specialized digital computer system used to control and automate various industrial processes and machinery. PLCs are commonly employed in manufacturing, production, and industrial facilities to monitor and control processes such as assembly lines, robotic operations, machinery control, and other automated systems.

Key characteristics of PLCs include:

1. Programming: PLCs are programmed using specialized software that allows engineers and technicians to create sequences of logic and instructions to control specific processes. The programming is typically done in ladder logic, which resembles electrical relay logic diagrams.

2. Input/Output (I/O) Handling: PLCs interact with the physical world through input and output modules. Inputs might include sensors that detect variables like temperature, pressure, or position, while outputs might control actuators such as motors, solenoids, or valves.

3. Real-time Operation: PLCs operate in real-time, meaning they respond to inputs and execute logic quickly and predictably. This is crucial for maintaining control over industrial processes that require precise timing.

4. Reliability: PLCs are designed for rugged industrial environments and are known for their durability and reliability. They are built to withstand harsh conditions such as temperature variations, humidity, and vibrations.

5. Modularity: PLC systems are modular, allowing for easy expansion and customization. Additional I/O modules can be added or modified without requiring a complete overhaul of the system.

6. Scalability: PLCs can be scaled to accommodate a wide range of applications, from simple control tasks to complex processes involving multiple devices and interactions.

7. Safety: Safety PLCs are specialized versions designed to handle critical safety functions in industrial environments. They are programmed to ensure that machinery operates safely and follows specific safety protocols.

8. Network Connectivity: Modern PLCs often include network connectivity options (such as Ethernet) to facilitate communication between multiple PLCs, as well as with supervisory control and data acquisition (SCADA) systems or higher-level enterprise systems.

Overall, PLCs play a crucial role in industrial automation by providing a reliable and efficient means of controlling and managing complex processes, which leads to improved productivity, consistency, and safety in various industries.

PLCs used at DKIST

Allen-Bradley (Rockwell)

There are several different models of Allen-Bradley (AB) or Rockwell PLCs that are used in the Project:

ControlLogix

The Enclosure Motion Control System (EMCS) and Facility Management System (FMS) use the ControlLogix series of PLCs.

GuardLogix

The Global Interlock System (GIS) uses GuardLogix series of PLCs. There are very similar to the ControlLogix series but feature a redundant processor for added safety.

CompactLogix

The GOS and M5 Thermal Controls use CompactLogix controllers.

MicroLogix

The pFlow lift uses a MicroLogix controller.

B&R

The M1 assembly and the various handling equipment components (M1 Cart and M1 Wash Gantry) use B&R controllers.

Beckhoff

The Telescope Mount Assembly (Mount and Coude) use Beckhoff controllers for motion control.