According to the Automation World 2024 industry report, 75% of manufacturing companies have problems with over-configuration or insufficient functionality in PLC selection. In this article, Unimat, with 20 years of experience in industrial automation, reveals the scientific methodology for selecting industrial PLC systems to help you save 23% of total cost of ownership (TCO).
1. Accurately diagnose production environment requirements
1.1 Environmental tolerance assessment
. Extreme temperature response: Choose a PLC that supports a working range of -25°C to 70°C (such as Unimat UN smart PLC)
. IP protection level: Food factories require IP67 waterproof level, and automotive workshops recommend IP69K oil mist certification
. Anti-vibration design: Packaging machinery prefers anti-vibration models
1.2 Electromagnetic compatibility (EMC) requirements
. In strong interference environments such as welding workshops, choose PLCs with strong anti-electromagnetic interference
. Use optical fiber communication modules to reduce motor drive interference
2. Core performance parameter matrix analysis
2.1 I/O capacity planning formula
Recommended I/O points = (current number of devices × 1.5) + 20% expansion margin
| Production Type | Digital I/O Base | Analog I/O Requirements |
|---|---|---|
| Discrete Manufacturing | 128-256 Points | 4-8 Channels |
| Process Control | 64-128 Points | 16-32 Channels |
| Mixed Production | 192-384 Points | 12-24 Channels |
2.2 Real-time performance indicators
Scan cycle: High-speed assembly lines require ≤0.1ms
Number of motion control axes: CNC machine tools recommend ≥8-axis synchronous control
Memory capacity: 4MB program memory + 2MB data memory per thousand I/O points
3. In-depth comparison of software ecosystem, programming language support
.Ladder diagram (LD) - suitable for discrete logic
.Structured text (ST) - complex algorithm development
.Function block diagram (FBD) - process control visualization
4. Full life cycle cost model
Industrial PLC total cost breakdown chart
.Initial investment (38%):
1.Hardware procurement (65%)
2.Software licensing (25%)
3.Engineering services (10%)
.Operating costs (62%):
.Maintenance contract (40%)
.Upgrade cost (30%)
.Loss of production suspension (30%)
5. Future expansion architecture design
Communication interface reservation:
.5G module slot (support TSN time-sensitive network)
.OPC UA over TSN protocol support
Computing power redundancy:
.Reserve 30% CPU load margin for AI analysis
.Support containerized application deployment
6. Supplier evaluation golden rule
Technical support: Provide ≤24 hours emergency response
Firmware update: Keep firmware updated
Spare parts commitment: Guarantee spare parts supply
Training resources: Provide remote guidance training
FAQ structured data
Q: How long do Unimat industrial PLCs typically last?
A: The average life of a unimat PLC is 5-10 years, but it is recommended to conduct a technical assessment every 5 years
Q: What's the ROI timeline for PLC automation?
A: According to Unimat case studies, the average payback period is 14 months
