Intel Casestudy Omron PLC EN Intel Corporation

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Specifications	Intel Casestudy Omron PLC EN Intel Corporation
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Case Study - OMRON* s Integrated Machine Controller Equipment Manufacturer Changes Platform Architecture to Deliver a High-Pe

Specifications	Intel Casestudy Omron PLC EN Intel Corporation
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Content	Case Study - OMRON* s Integrated Machine Controller Equipment Manufacturer Changes Platform Architecture to Deliver a High-Performance Controller Adopting Intel® Architecture to Resolve Problems in Previous Models Previously, PLCs were designed with proprietary ASICs (application-speciﬁc integrated circuits) and general-purpose embedded processors used to control and monitor the system. The ASIC running the user program determined the core processing performance and functionality of the PLC. A drawback to this approach is custom ASICs are expensive to develop and manufacture, particularly with the higher costs associated with the latest semiconductor process technologies. The production of ASICs requires unique and costly photomasks, which are amortized over a relatively small PLC volume, making the cost per chip very high compared to ASICs used in mass-produced household appliances. Another issue is lead-time, since ASIC development can take as long as two years, followed by more time needed to test and qualify the operation of the ASIC as part of the PLC system. In today s competitive environment, conventional ASIC-based architecture poses some major challenges in the areas of cost and development time. Despite these issues, industrial customers continue to demand controllers with higher performance and more sophisticated features. To satisfy the needs of customers, equipment manufacturers are under increased pressure to produce better products at a faster pace. Having recognized the limits of developing controllers based on ASICs, OMRON Corporation responded by switching its entire development process to an entirely new architecture that runs their control software on an Intel® processor-based hardware platform. Programmable logic controllers (PLCs) are used to perform automation for a diverse range of equipment including industrial machines, elevators and automatic doors. PLCs process input from a variety of sensors together with recipe data predeﬁned by the user to generate outputs to relays and other actuators. By speeding up the throughput of the input-process-output sequence, PLCs can control machines on the factory ﬂoor at even higher speeds, resulting in increased manufacturing productivity. In recent years, the number of machines that integrate both motion control and relay switches has increased. Motion control enables electric motors to perform position control in machinery, such as machine tools, robot control, semiconductor production equipment and injection molding machines. By increasing I/O (input/output) throughput, a PLC can control motors with greater precision, thereby enhancing processing quality. Currently, the maximum I/O throughput of conventional PLCs is around one millisecond for simple I/O conﬁgurations. In more complex cases, such as simultaneously controlling the motion of multiple motors, conventional PLC architecture requires signiﬁcant changes in order to handle more I/O with higher throughput – a few hundred microseconds or less. High-performance Intel® processor-based hardware platform SoftwarereusabilityUnderlyingfunctions Shorterdevelopmenttimes Integrated machine controller NJ501-1500
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