Remote Monitoring of PLC Control Systems

Remote monitoring of machines is not a new development. It has, however, come a long way in recent years thanks to modern technological advancements. But what exactly is remote monitoring, and how does it apply to PLCs?

To understand how this technology works, and why it is beneficial to your company, keep reading. We answer these questions and more in our handy guide to the remote monitoring of PLC control systems, below.  

What Is A PLC?

Remote monitoring is only possible when the PLCs on site are adapted to be controlled remotely. But first, let’s quickly look at what a PLC is and does, and why you might need to control it remotely.

A PLC, or Programmable Logic Computer, is a computer used to control the machinery in an industrial facility. You can program PLCs to regulate different types of equipment across the manufacturing industry. They are used across industries to streamline and automate operations.

Depending on your specific needs, you can program a PLC to fulfill simple, specific tasks or control an entire assembly line.

As a type of computer, it operates primarily as other computers do. It has a central processing unit, memory, and software, and it can communicate with other computers. But like any other computer, things can and do sometimes go wrong, which can cause unnecessary expense and inconvenience.

Remote monitoring is the solution that will minimize the impact of such issues.

Remote Monitoring Of PLC Control Systems

PLCs and the ability to remotely control them are important factors for many industries. Remote access allows you to access your PLCs, computers, or network from anywhere. This is possible via a network connection.

By connecting to your PLCs, you can monitor them, troubleshoot problems, and fix issues without the need to be physically present on the site.

There are several benefits to remote monitoring of your PLCs:

• It is customizable for specific industrial environments.
• Remote monitoring allows faster and easier diagnostics.
• Enables smoother operation of your PLCs (Therefore, an extended lifespan is possible).
• It prevents downtime and reduces costs associated with it.
• These benefits all lead to a positive return on investment (RPI)

How It Works

PLC data is always recorded. However, how often and to what degree facilities review this data differs. To stay on top of your site’s operations and especially your PLCs performance, you must enable remote monitoring.

Remote monitoring of PLCs essentially means the ability to monitor your machine’s behavior, performance, and status without the need to be physically present on site. It consists of three main functions:

1. Data collection through connectivity
2. Data processing and storage
3. Data presentation and notifications

To achieve this remote access to your PLCs, you need to virtualize your connections. Depending on the age and design of your machines, you may need to add remote monitoring sensors and connectivity to enable remote monitoring. Newer builds generally have this functionality integrated into the design.

An ethernet port will connect the PLC to the network hub. From there, you will access the PLCs via servers controlling and monitoring their processes or other network-connected machines.

PLC data gets relayed to a Cloud Platform, from where it is accessible to technicians in the form of actionable data. This allows them to engage in diagnostics and maintenance.

Industrial connectivity, which is compatible with the Industrial Internet Of Things (IIOT), allows you to collect pertinent data through built-in (or added) sensors. This is the data sent to the Cloud, where it gets processed and stored.

The most important part, delivery of actionable information in real-time, is the last but crucial step. This information can be presented in different forms but it generally will be accessible through a dashboard on computer software or a mobile application.

Why Is Remote Monitoring So Important?

Remote monitoring of your PLCs allows you to engage in predictive maintenance. Unlike regular maintenance and repair, this does not rely on waiting for problems to occur before fixing them. It predicts potential problems and allows preemptive solutions.

Remote access also means you often don’t always need to travel to the site to fix the problem. If it is possible to resolve the issue with a software patch or upgrade, you can do so immediately and remotely. Technical support can also be available remotely and in real-time to your on-site technicians.

Ultimately, remote monitoring of PLC control systems enables you to detect, diagnose and rectify faults more quickly, without unnecessary downtime or traveling back and forth.

Conclusion

There are so many advantages to remote monitoring for PLC control systems. Production will soar, and with the diagnostic capabilities that remote monitoring offers, you’ll have a clearer picture of what’s happening on site.

Remote monitoring keeps your equipment operating smoothly, and as a result, extends its operational lifespan. It means more time for business and fewer costs for repairs. Contact us today with any further queries you have about remote monitoring of your PLC control systems.