predictive maintenance - PLC Programming & Automation

Counting Runtime Hours and Trending Vibration in the PLC

Timing chart of condition monitoring sampling: the machine starts, a warm-up delay blocks sampling, one-second sample pulses run only while warmed up, and the level 1 alert sets after the average crosses the limit

Build PLC predictive maintenance on hardware you own: vibration and motor current inputs, runtime hours, moving averages, baselines and alarm levels.

PLC Sustainable Manufacturing: Measure, Then Shut Off

by PLC

Timing chart of idle shutdown and staggered restart: part flow stops, the idle timer completes five minutes later, the conveyor, vacuum generator and extraction fan switch off in sequence, and when parts return the fan starts first, then the vacuum, then the conveyor

Meter energy, air, water and scrap per part, write idle shutdown in Structured Text, stagger the restart, and report numbers that survive an audit.

Predicting the Demand Peak and Shedding Load from the PLC

by PLC

Ladder rung for load shedding: predicted demand high in parallel with the shed seal-in bit, in series with the shed permit and the chiller alarm contact, driving the shed output for chiller 2

Wire a power meter into Logix or S7, totalize kWh in Structured Text, hold the demand peak with priority load shedding, and check if a VFD retrofit pays.