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Friday, August 28, 2015

PLC Troubleshooting

PLC Troubleshooting - Failure Probability

PLC MTBF does not apply, so much.

(Right click, "Open Image in New Tab", click on image in new tab to view full size)

Failure probability is categorized like this (in order of most likely to least likely).

  1. Mechanical
  2. Electro-Mechanical
  3. High Current
  4. Low Current
  5. Solid State

Environment can be an exception to the general rule.
(Relay card most likely, and MTBF is useless unless solid state, as frequency PLC program activates, dictates failure rate as well as the environment does.)

The above probability guide translate to troubleshooting PLCs as ...

  1. Output Cards
  2. Input Cards
  3. Power Supply
  4. Backplane
  5. CPU (Processor Card)

Environment can change basic order above. Examples: In a foundry, the metal dust causes backplane to fail more frequently. Machining industry, penetrating fluid getting into sensors causes input cards to fail more than output cards because sinks more current than designed to. Wire manufacturing a lot of high voltage insulation testing is going on, CPUs fail more often because control voltage for PLC does not have line filter in series with it.

(More PLC Troubleshooting)

Don (Follow me on Industrial Skills Training Blog and on Twitter @IndTraining .) Be sure to to stay on top!

Monday, July 13, 2015

PLC Training Video Series

PLC Training Video Series ...

PLC training videos
PLC Training Videos
PLC Training videos come in many flavors. From just an ad, to introductory to full PLC training video series course. The PLC training video series below is 6 samples that are very popular. The samples in this series have been selected as samples of the various PLC training video types mentioned previously. Enjoy and share your favorite one.

  1. PLC training video ad: PLC Training Org
  2. Introductory PLC training video: What is a PLC
  3. Experience transfer: PLC Training
  4. Simplifying complex concept: PLC Training PAC
  5. PLC training video series on a single topic: PLC Training - Networking
  6. PLC training video series course: PLC Training Video Course

Don (Follow me on Industrial Skills Training Blog and on Twitter @IndTraining .) Be sure to to stay on top!

Wednesday, June 17, 2015

Directorate of Industrial Training - FUN

FUN Industrial Maintenance Training

BIN is not the only one who makes training fun ... Industrial Training is not the only ones who make learning fun/ :)
Posted by Business Industrial Network on Wednesday, June 17, 2015

Don (Follow me on Industrial Skills Training Blog and on Twitter @IndTraining .) Be sure to to stay on top!

Wednesday, December 17, 2014

What is a PLC?

What is a PLC?

What is a PLC? (Programmable Logic controller tutorial)

The video below is designed to give the most simple understanding of what is a PLC and and what a PLC does. Great to share with High Schoolers, engineers not in an automation control field, or in management. For those just learning of a PLC, should you want training, come highly recomended. If you or your employees have PLC training needs, see the left hand menu of PLC Training options at the above site.

Also if you have already started the journey to becoming a PLC expert, instrumentation and controls technician or automation controls professional and want to see what courses and in what order you should take to meet your objectives, please see

 Don (Follow me on Industrial Skills Training Blog and on Twitter @IndTraining .)Be sure to to stay on top!

Monday, December 8, 2014

What is Thermography

What is thermography?

Below is one of many infrared thermography videos from the YouTube channel Please subscribe and then share the above channel with others so more will see the many applications of infrared thermography. Example videos from building and home energy surveys, to medical applications to reliability maintenance.

With Infrared Thermography, you can see through things and predict the future! How cool is that?
(Predictive Maintenance, PdM)

Don (Follow me on Industrial Skills Training Blog and on Twitter @IndTraining .) Be sure to to stay on top!

Thursday, September 11, 2014

PLC Programming

PLC Programming:

PLC Structured Text or Ladder Logic?

To answer the common PLC programming question...

Should I use Ladder Logic or Structured Text in my PLC Programming?
PLC Programming
 I like to simplify, so I use a arbitrary percentage. 95% of the world uses ladder logic in PLCs. Out of the 5% left, some use structured text. With introduction of PACs about 10 years ago, the 1-3% who are using structured text, is growing.

Just like PACs have a greater life cycle cost to the end user when compared to PLCs, so does using structured text instead of ladder logic. It like Dick Morley (The Father of PLCs) was telling me one day, the more complicated, the less reliable. This statement is not just in reference to the reliability of design, electronics, or even mechanics, it is in reference to Total Ownership Cost (TOC) over the lifetime of equipment. (Increased training cost due to complicity, increased mistakes due to complicity, greater downtime, more complicated to troubleshoot, more calls and wait time for external support, etc. etc.)

The bottom line is a company should weigh the benefits with the TOC for the system lifecycle. Thus the majority use ladder logic.

It is a Technology lesson society has already learned in the past with computers. Back when computer memory and processing speed were limited, we had to use machine language, then moved on to fortran, basic. Eventually memory and processing speed technology advanced enough, we could use a programming language that was more friendly towards human, easier to learn and work with, visual basics.

The same is true with PLCs. The PLC5 was based on an octal numbering system. But eventual memory and processing speed advanced enough, the more human friendly decimal numbering system could be used. Visual is always better for human interaction than numbers and computer code. So if you know a human will have to understand and work with it at some point in the future, make it simple and more user friendly for the widest audience you can.

When I was in school, because of memory/speed limitations, who ever wrote their code the shortest and the quickest won. Now we teach, who ever writes their code the most simple and user friendly wins. Because PLCs now days and especially PACs have more memory/speed than 95% of all applications need. (The other 5% are exceptions to the rule like two high speed machines needing to communicate and react on each other's live data.) To learn more best practices, see PLC Training at BIN95

Don (Follow me on Industrial Skills Training Blog and on Twitter @IndTraining .) Be sure to to stay on top!

Sunday, August 24, 2014

US Manufacturing Jobs Chart

2014 US Manufacturing

(2nd Quarter)
The BCG report/Manufacturing chart below shows we are a third of the way in recovering US manufacturing jobs lost during the great recession.
"While manufacturing jobs saw significant gains over the past three months, manufacturing has only recovered about 30 percent of the jobs lost during the Great Recession."

US Manufacturing Jobs Chart

The BCG report found by clicking US Manufacturing chart above to its end, goes on to report low US manufacturing jobs wage will slow US manufacturing growth. As it logically states
"...why would workers spend time in training programs for advanced jobs that do not pay adequately"? 
The report also shows that US manufacturing jobs future can be bright if US policy makers invest in in infrastructure and "enforce trade agreements and eliminate currency manipulation, which will give U.S. manufacturers a fair opportunity to compete on the global market."

Don (Follow me on Industrial Skills Training Blog and on Twitter @IndTraining .) Be sure to to stay on top!