PLC

Abstract: Control optimization is often misinterpreted as nothing more than PID tuning and switching control loops from manual to automatic. However, this oversimplification overlooks the broader engineering goal: to enhance automation, reduce manual interventions and process alarms, and ultimately improve plant safety and efficiency. This article outlines five key categories of control optimization and provides […]

For automation engineers, terms like active, passive, powered, and non-powered are commonly encountered. However, many still struggle to clearly differentiate and relate these concepts. This article explains the relationship between transmitter types (active/passive) and DCS I/O card power configurations (powered/non-powered), using a real-world example of the XP351 8-channel AI module. 1. Core Concepts Active vs

Emergency Stop Switches: Core Safety Logic and PLC Integration Guidelines In industrial automation environments, the emergency stop (E-stop) button is a critical last line of defense for personnel and equipment. Standard E-stop designs predominantly adopt normally closed (NC) contacts. Under normal conditions, these contacts remain closed, allowing current to pass through the circuit. When pressed,

UPS stands for Uninterruptible Power Supply. It is an energy conversion system that provides continuous AC power to critical equipment during utility power interruptions by utilizing backup sources such as batteries. While UPS units are often referred to as power supplies, their core function is to enable seamless switching between two power sources to ensure

Short Answer: No – It is not recommended to run DI (Digital Input) and DO (Digital Output) signals through the same multi-core cable in a Safety Instrumented System (SIS). ✅ Key Reasons: Signal Interference Risk DO signals often drive inductive loads such as relays or contactors, which can generate electromagnetic interference (EMI) or back-emf. DI

Introduction The career of a PLC (Programmable Logic Controller) engineer is like a compelling drama played out at the debugging station. Each project delivery is a duel between intelligence and challenge; each debugging session is a thoughtful response to customer needs; every acceptance test marks the realization of engineering value. On this stage, we are

1. Introduction: Simple Yet Powerful Proportional–Integral–Derivative (PID) control is a linear feedback control algorithm that calculates control output based on three terms: present error, accumulated error (integral), and rate of change of error (derivative). Its simple mathematical form has led to widespread adoption across industrial sectors and made it a classic subject for research, comparison,

Alarm management is a critical aspect of ensuring the safe and stable operation of Distributed Control Systems (DCS) in chemical and process industries. This document outlines key principles and best practices for alarm setpoint configuration, grading, and optimization based on industry standards and operational experience. 1. Alarm Setpoint Fundamentals Alarm values must be configured within

Introduction In the field of industrial automation, the choice of communication protocols is a key factor that affects production efficiency, equipment coordination, and system stability. With the continuous advancement of technology, industrial communication protocols have evolved into a variety of standards. Among them, PROFINET, Modbus, and EtherCAT are the most widely used protocols across industries.

Despite significant advancements in PID auto-tuning technology in both academic and commercial domains, its widespread adoption in real-world industrial process control—especially in process industries such as chemical, petrochemical, power, pharmaceuticals, and food—remains far below expectations. The underlying reasons are multifaceted and complex, spanning technical, operational, and cultural dimensions. 1. Process Complexity and Uncertainty ▸ Nonlinearity