Setting up a properly functioning control system can sometimes be expensive and time-consuming. Even small projects, such as computer-aided design (CAD), have different skill requirements for wiring, design, and programming. The following six tips can make designing and building systems simpler.
1. Specifying components
Express this item in words in as much detail as possible. First, determine the requirements in the document—potential or expanded requirements. This should provide enough information to determine whether a programmable logic controller (PLC) and individual control components, such as temperature controllers, timers, counters, and human-machine interfaces (HMIs), are needed.
2. System Design
This step requires some knowledge of electrical and mechanical design. For a small control project, the project can be drawn up by hand to determine the dimensions; a single-line diagram can be created for the electrical requirements.
When designing and building a small control project, issues such as component selection, system construction, and programming software should be considered.
3. Ordering parts
Ordering components involves several procurement details. Price is important, of course, but don't spend too much time trying to save a few percentage points. Delivery time also needs to be considered. Keep all documentation regarding the components. Some may end up in the project binder; packing lists can be used for purchasing list references and future returns.
4. Establish the system
Wiring, panel fabrication, and bracketing also require specific skills and tools. These include panel layout (drilling, punching holes, and "inspection" drilling), panel preparation (cutting DIN rails, wire channels, and component notches), wiring (crimping, stripping, and labeling), and sometimes some carpentry and hand-drawing work. For external wiring, grounding, and cable/conduit (field wiring), legal requirements must also be met.
5. Programming and Software Design
For systems involving PLCs or HMIs, it's necessary to understand the relevant software platform. Such software is often expensive, so this should be considered during the design phase: Does the customer own this software? Are there licensing fees involved? Is there local support for troubleshooting or modifications, or can the customer perform these tasks themselves?
6. Startup and Debugging
Most experienced programmers know that minor errors are not a major concern during the programming and software development phases, as they are easily identified and fixed once the system is up and running. This is why systems require comprehensive testing before being deployed to production. Larger systems may require Factory Acceptance Testing (FAT) and Field Acceptance Testing (SAT) to ensure smooth operation.
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