What are and what are PLC and PAC controllers used for?

Programmable Logic Controllers

Many of you have probably heard about PLC controllers. It’s a concept very familiar to those involved in automation. However, few people know that recently our offer has expanded to include a wide range of PLC and PAC controllers from the HCFA brand. We invite you to read the article and familiarize yourself with our offer. PLC controllers, or Programmable Logic Controllers, are devices widely used in industries such as manufacturing, energy, building automation, and transportation. Their operation can be compared to the human brain, where the controller—like the human brain—executes a program stored in its memory. Based on the analysis of various input signals (digital and analog), an appropriate control algorithm for the machine/process is executed. This algorithm is written by a programmer in the form of a program. As a result of this process, the PLC controller controls actuators such as valves, motors, actuators, robots, etc., to achieve a specific goal. This goal could be, for example, the production of a specific type of product, maintaining a certain room temperature, dosing and mixing semi-finished products, packaging products, etc. The first PLC controller was developed and introduced by Modicon in 1969. Later, this device revolutionized the control systems market and replaced the previously used relay-contactor systems. One small device replaced the work of hundreds or even thousands of cooperating relays and contactors. The PLC controller was a universal device because the control algorithm could be adapted to different machines by changing the controller’s program without modifying its hardware structure.

What does a PLC controller consist of?

A PLC controller consists of several basic components:

• central processing unit (CPU) – responsible for executing the control algorithm,
• memory – which stores the program,
• inputs/outputs – in the appropriate configuration,
• communication ports – enabling program uploading and communication with other devices.

Over the years and with the development of control systems, it became clear that the existing solutions based on PLC controllers were insufficient. The implementation of Industry 4.0, the digitalization of industrial plants, data acquisition and processing from many machines operating in different standards and communication protocols, and data security required the introduction of new, more efficient, multi-protocol devices. These new devices were termed PAC (Programmable Automation Controller). A PAC controller is a device whose functionality is very similar to traditional PLC controllers, but these controllers offer new possibilities in terms of control and integration with other automation devices. These controllers are characterized by much larger memory, more powerful processors, modularity, and multi-threading, making them suitable for complex and comprehensive automation systems. They allow programming in several different programming languages. A significant difference between a PAC and a PLC is the ability to expand the control system, built-in diagnostics, and the ability to work in continuous systems. Systems based on PAC controllers are also characterized by flexibility and the ability to expand with many communication modules, either local or distributed.

HCFA brand PLC / PAC controllers

One of the flagship products of the HCFA brand are advanced, multi-protocol PLC controllers and PAC controllers with integrated motion control functions (MOTION Control functions). In many cases, these controllers can serve as advanced motion controllers with support for up to 256 real EtherCAT axes. The controller offer includes three product series: – M300 series PLC controllers – M500 series PLC controllers – Q and QP series PAC controllers

M series PLC controllers

M series PLC controllers are economical, yet fast and compact controllers that are perfect for both simpler and advanced drive and process applications.Features of M series PLC controllers:

• Compact and fast – execution time of a single instruction is just 5ns
• Support for multiple programming languages – LD/FBD, ST, and C/C++ (according to IEC61131-3 standard)
• Multi-protocol communication – including Free Protocol, Modbus RTU/TCP, CANopen, EtherNet/IP, EtherCAT
• Support for functional blocks for motion control (Motion functions) according to PLCOpen2.0 – including multi-axis synchronization, electronic cams, axis grouping, functions like flying saw, rotary knife, linear/circular/spherical interpolation
• CNC functions – support for G-code, M-code (selected models)
• Built-in fast 200kHz pulse I/O for encoder handling and axis control (e.g., stepper motors, servo drives, etc.)
• Axis control – from 8 to 64 real EtherCAT axes (up to 128 slave devices) and from 4 to 8 pulse-controlled axes
• I/O expansion capability with HCMX series expansion modules or via HCQX-D4 and HCNXE series signal islands.
• Free and comprehensive programming environment – SysCtrl Studio software

   Fig. 1 M series PLC controllers – communication capabilities.    

Q and QP series PAC controllers

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Features of Q / QP series PAC controllers:

 

• Support for multiple programming languages – IL, LD, FBD, ST, SFC, CFC (according to IEC61131-3 and PLCOpen 2.0 standards);
• Multi-protocol communication – including Free Protocol, Modbus RTU/TCP, CANopen, EtherNet/IP, EtherCAT, OPC UA;
• Controllers equipped with powerful ARM, Intel Celeron, Intel i5, and Intel i7 processors (depending on the controller version);
• Large memory capacity: up to 128MB program memory, up to 128MB Flash, up to 8GB RAM, and support for SSDs up to 64GB;
• Support for functional blocks for motion control (SoftMotion) according to PLCOpen2.0 – including multi-axis synchronization, electronic cams, axis grouping, functions like flying saw, rotary knife, linear/circular/spherical interpolation;
• CNC functions – support for G-code, M-code;
• Support for industrial robot kinematics;
• Built-in fast 200kHz pulse I/O for encoder handling and axis control (e.g., stepper motors, servo drives, etc.);
• Axis control – from 8 to 256 real EtherCAT axes and up to 8 pulse-controlled axes;
• Ability to create very extensive distributed systems – support for up to 65536 EtherCAT SLAVE devices;
• I/O expansion capability with HCQX-D4 series expansion modules or via HCQX-D4 and HCNXE series signal islands;
• Programming environment – CODESYS v.3.5 or HCP WORKS 3 (free) software.

  Fig. 8 Structure of a PAC controller using the HCQ5P-1500-U4 controller as an example.    

Summary

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