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Meeting the Integration Challenge in Programmable Logic Controllers By: Suhel Dhanani Principal Strategic Marketing Manager Maxim Integrated

Meeting the Integration Challenge in Programmable Logic

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Page 1: Meeting the Integration Challenge in Programmable Logic

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Meeting the Integration Challenge in Programmable Logic Controllers By: Suhel Dhanani Principal Strategic Marketing Manager Maxim Integrated

Page 2: Meeting the Integration Challenge in Programmable Logic

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Executive Summary In today’s highly competitive global economy, small improvements in manufacturing processes can yield huge competitive advantages.

This mindset is driving fundamental transformations across the factory floor. Manufacturers are deploying the latest sensor technologies, adopting new control architectures, and starting to discover the potential of “big data” and analytics. Often called Industry 4.0, what’s happening in manufacturing is nothing short of a revolution.

For equipment OEMs, this represents a massive opportunity. The number of sensors used to track environmental and process variables continues to increase. This is accelerating the transition to a distributed control architecture, as plant operators seek to reduce bottlenecks and shorten control loops by moving PLCs closer to the processes they control. Ultimately, the promise of improved operational efficiencies and yields will lead to the largest overhaul of plant operations since the invention of the PLC.

This poses a considerable challenge for PLC engineers. To win in this market, system designers will need to pack more I/O and more functionality into enclosures that keep getting smaller. The problem is that there’s relatively little space to be gained from digital scaling of the microprocessor. In today’s advanced PLC modules, analog and discrete components consume approximately 85% of board space.

Engineers can no longer afford to ignore the obvious problem on their boards. Many of the analog and discrete components that have worked so well in previous systems are simply too big for Micro PLCs and embedded controllers. The promise of Industry 4.0 will only be realized through greater levels of integration, across the PLC system design.

Page 3: Meeting the Integration Challenge in Programmable Logic

Table of Contents Executive Summary 1

The Next Industrial Revolution Has Arrived 2

Addressing the New Integration Problem 3

Increasing I/O Density in Micro PLCs 4

Lowering Heat Dissipation in Power Designs 6

Reducing the Complexity of Power Subsystems 7

Integrating Safeguards Against New Security Threats 7

Seizing the Integration Advantage 8

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