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PLC basic principles
1.1 PLC Introduction
Programmable controller is the first in the late 1960s in the United States, then called PLC programmable logic controller (Programmable Logic Controller) is used to replace relays. For the implementation of the logical judgment, timing, sequence number, and other control functions. The concept is presented PLC General Motors Corporation. PLC and the basic design is the computer functional improvements, flexible, generic and other advantages and relay control system simple and easy to operate, such as the advantages of cheap prices combined controller hardware is standard and overall. According to the practical application of target software in order to control the content of the user procedures memory controller, the controller and connecting the accused convenient target.
In the mid-1970s, the PLC has been widely used as a central processing unit microprocessor, import export module and the external circuits are used, large-scale integrated circuits even when the PLC is no longer the only logical (IC) judgment functions also have data processing, PID conditioning and data communications functions. International Electro technical Commission (IEC) standards promulgated programmable controller for programmable controller draft made the following definition : programmable controller is a digital electronic computers operating system, specifically for applications in the industrial design environment. It used programmable memory, used to implement logic in their internal storage operations, sequence control, timing, counting and arithmetic operations, such as operating instructions, and through digital and analog input and output, the control of various types of machinery or production processes. Programmable controller and related peripherals, and industrial control systems easily linked to form a whole, to expand its functional design. Programmable controller for the user, is a non-contact equipment, the procedures can be changed to change production processes. The programmable controller has become a powerful tool for factory automation, widely popular replication. Programmable controller is user-oriented industries dedicated control computer, with many distinctive features.
First, high reliability, anti-interference capability;
Second，programming visual, simple;
Third, adaptability good;
Fourth functional improvements, strong functional interface.
1.2 Motivation
Programmable Logic Controllers (PLC), a computing device invented by Richard E. Morley in 1968, have been widely used in industry including manufacturing systems, transportation systems, chemical process facilities, and many others. At that time, the PLC replaced the hardwired logic with soft-wired logic or so-called relay ladder logic (RLL), a programming language visually resembling the hardwired logic, and reduced thereby the configuration time from 6 months down to 6 days [Moody and Morley, 1999].
Although PC based control has started to come into place, PLC based control will remain the technique to which the majority of industrial applications will adhere due to its higher performance, lower price, and superior reliability in harsh environments. Moreover, according to a study on the PLC market of Frost and Sullivan [1995], an increase of the annual sales volume to 15 million PLC per year with the hardware value of more than 8 billion US dollars has been predicted, though the prices of computing hardware is steadily dropping. The inventor of the PLC, Richard E Morley, fairly considers the PLC market as a 5-billion industry at the present time.
Though PLC are widely used in industrial practice, the programming of PLC based control systems is still very much relying on trial-and-error. Alike software engineering, PLC software design is facing the software dilemma or crisis in a similar way. Morley himself emphasized this aspect most forcefully by indicating [Moody and Morley, 1999, p. 110]:
`If houses were built like software projects, a single woodpecker could destroy civilization.”
Particularly, practical problems in PLC programming are to eliminate software bugs and to reduce the maintenance costs of old ladder logic programs. Though the hardware costs of PLC are dropping continuously, reducing the scan time of the ladder logic is still an issue in industry so that low-cost PLC can be used.
In general, the productivity in generating PLC is far behind compared to other domains, for instance, VLSI design, where efficient computer aided design tools are in practice. Existent software engineering methodologies are not necessarily applicable to the PLC based software design because PLC-programming requires a simultaneous consideration of hardware and software. The software design becomes, thereby, more and more the major cost driver. In many industrial design projects, more than SO0/a of the manpower allocated for the control system design and installation is scheduled for testing and debugging PLC programs [Rockwell, 1999].
In addition, current PLC based control systems are not properly designed to support the growing demand for flexibility and recon of manufacturing systems. A further problem, impelling the need for a systematic design methodology, is the increasing software complexity in large-scale projects.
1.3 Objective and Significance of the Thesis
The objective of this thesis is to develop a systematic software design methodology for PLC operated automation systems. The design methodology involves high-level description based on state transition models that treat automation control systems as discrete event systems, a stepwise design process, and set of design rules providing guidance and measurements to achieve a successful design. The tangible outcome of this research is to find a way to reduce the uncertainty in managing the control software development process, that is, reducing programming and debugging time and their variation, increasing flexibility of the automation systems, and enabling software reusability through modularity. The goal is to overcome shortcomings of current programming strategies that are based on the experience of the individual software developer.
A systematic approach to designing PLC software can overcome deficiencies in the traditional way of programming manufacturing control systems, and can have wide ramifications in several industrial applications. Automation control systems are modeled by formal languages or, equivalently, by state machines. Formal representations provide a high-level description of the behavior of the system to be controlled. State machines can be analytically evaluated as to whether or not they meet the desired goals. Secondly, a state machine description provides a structured representation to convey the logical requirements and constraints such as detailed safety rules. Thirdly, well-defined control systems design outcomes are conducive to automatic code generation- An ability to produce control software executable on commercial distinct logic controllers can reduce programming lead-time and labor cost. In particular, the thesis is relevant with respect to the following aspects.
1.4 Customer-Driven Manufacturing
In modern manufacturing, systems are characterized by product and process innovation, become customer-driven and thus have to respond quickly to changing system requirements. A major challenge is therefore to provide enabling technologies that can economically reconfigure automation control systems in response to changing needs and new opportunities. Design and operational knowledge can be reused in real-time, therefore, giving a significant competitive edge in industrial practice.
1.5 Higher Degree of Design Automation and Software Quality
Studies have shown that programming methodologies in automation systems have not been able to match rapid increase in use of computing resources. For instance, the programming of PLC still relies on a conventional programming style with ladder logic diagrams. As a result, the delays and resources in programming are a major stumbling stone for the progress of manufacturing industry. Testing and debugging may consume over 50% of the manpower allocated for the PLC program design. Standards [IEC 60848, 1999; IEC-61131-3, 1993; IEC 61499, 1998; ISO 15745-1, 1999] have been formed to fix and disseminate state-of-the-art design methods, but they normally cannot participate in advancing the knowledge of efficient program and system design.
A systematic approach will increase the level of design automation through reusing existing software components, and will provide methods to make large-scale system design manageable. Likewise, it will improve software quality and reliability and will be relevant to systems high security standards, especially those having hazardous impact on the environment such as airport control, and public railroads.
1.6 System Complexity
The software industry is regarded as a performance destructor and complexity generator. Steadily shrinking hardware prices spoils the need for software performance in terms of code optimization and efficiency. The result is that massive and less efficient software code on one hand outpaces the gains in hardware performance on the other hand. Secondly, software proliferates into complexity of unmanageable dimensions; software redesign and maintenance-essential in modern automation systems-becomes nearly impossible. Particularly, PLC programs have evolved from a couple lines of code 25 years ago to thousands of lines of code with a similar number of 1/O points. Increased safety, for instance new policies on fire protection, and the flexibility of modern automation systems add complexity to the program design process. Consequently, the life-cycle cost of software is a permanently growing fraction of the total cost. 80-90% of these costs are going into software maintenance, debugging, adaptation and expansion to meet changing needs [Simmons et al., 1998].
1.7 Design Theory Development
Today, the primary focus of most design research is based on mechanical or electrical products. One of the by-products of this proposed research is to enhance our fundamental understanding of design theory and methodology by extending it to the field of engineering systems design. A system design theory for large-scale and complex system is not yet fully developed. Particularly, the question of how to simplify a complicated or complex design task has not been tackled in a scientific way. Furthermore, building a bridge between design theory and the latest epistemological outcomes of formal representations in computer sciences and operations research, such as discrete event system modeling, can advance future development in engineering design.
1.8 Application in Logical Hardware Design
From a logical perspective, PLC software design is similar to the hardware design of integrated circuits. Modern VLSI designs are extremely complex with several million parts and a product development time of 3 years [Whitney, 1996]. The design process is normally separated into a component design and a system design stage. At component design stage, single functions are designed and verified. At system design stage, components are aggregated and the whole system behavior and functionality is tested through simulation. In general, a complete verification is impossible. Hence, a systematic approach as exemplified for the PLC program design may impact the logical hardware design.
1.9 Programming languages
Higher level PLC programming languages have been around for some time, but lately their popularity has been mushrooming. As Raymond Lavelle, vice president and general manager, Siemens Energy and Automation. Inc, Programmable Controls Division, points out :”As programmable controls are being used for more and more sophisticated operations, languages other than ladder logic become more practical, efficient, and powerful. For example, it's very difficult to write a trigonometric function using ladder logic. ”Languages gaining acceptance include Boolean, control system flowcharting, and such function chart languages as Graph and its variations. And these’s increasing interest in languages like C and BASIC.
2.0 PLC in process control
Thus far, PLC have not been used extensively for continuous process control. Will this continue? ”The feeling that I’gotten,” says Ken Jeannette, manager, product planning, Series One and Series Six products, at GE Frame North America, "is that PLC will be used in the process industry but not necessarily for process control.”
Several vendors-obviously betting that the opposite will happen-have introduced PLC optimized for process applications. Rich Ryan ,manager, commercial marketing, Allen-Bradley Programmable Controls Div, cites PLC’ increasing use in such industries as food, chemicals, and petroleum. Ryan feel there are two types of applications in which they’re appropriate.”One, "he says, "is where the size of the process control system that's being automated does’t justify DCS[distributed control systems].With the starting price tags of those products being relatively high, a programmable controller makes sense for small, low loop count applications. The seconds where you have to integrate the loop closely with the sequential logic. Batch controller sere prime examples, where the sequence and maintaining the process variable are intertwined so closely that the benefits of having a programmable controller to do the sequential logic outweighs some of the disadvantages of not having a distributed control system.”
Bill Bark, president of , predicts that "all future controllers that come out in the process control system business will embrace a lot more PLC technology and a lot more PLC functionality than they ever did before.”
2.1 Communications and MAP
Communications are vital to an individual automation cell and to the automated factory as a whole. We've heard a lot about MAP in the last few years, and a lot of companies have jumped on the band wagon. Many, however were disappointed when a fully-defined and completed MAP specification did’t appear immediately. Says Larry Kumara:”Right now , MAP is still a moving target for the manufacturers specification that is not final. Presently, for example, people are introducing products to meet the MAP 2.1standard.Yet 2.1-based products will be obsolete when the new standard for MAP,3.0is introduced.”
Because of this, many PLC vendors are holding off on full MAP implementations. Omro, for example , has an ongoing MAP-compatibility program, but Frank Newborn, vice president of Omro’s Industrial Division, reports that because of the lack of a firm definition, Omro PLC don't yet talk to MAP.
Since it’s unlikely that an individual PLC would talk to broadband MAP anyway, makers are concentrating n proprietary networks. According to Sal Prov, users fear that if they do get on board and vendors withdraw from MAP, they ‘ll pulse width modulation control system be the ones left holding a communications structure that’s not supported.
2.2 PLC compared with other control systems
PLC are well-adapted to a range of automation tasks. These are typically industrial processes in manufacturing where the cost of developing and maintaining the automation system is high relative to the total cost of the automation, and where changes to the system would be expected during its operational life. PLC contain input and output devices compatible with industrial pilot devices and controls; little electrical design is required, and the design problem centers on expressing the desired sequence of operations. PLC applications are typically highly customized systems so the cost of a packaged PLC is low compared to the cost of a specific custom-built controller design. On the other hand, in the case of mass-produced goods, customized control systems are economic due to the lower cost of the components, which can be optimally chosen instead of a "generic" solution, and where the non-recurring engineering charges are spread over thousands or millions of units.
For high volume or very simple fixed automation tasks, different techniques are used. For example, a consumer dishwasher would be controlled by an electromechanical cam timer costing only a few dollars in production quantities.
A micro controller-based design would be appropriate where hundreds or thousands of units will be produced and so the development cost (design of power supplies, input/output hardware and necessary testing and certification) can be spread over many sales, and where the end-user would not need to alter the control. Automotive applications are an example; millions of units are built each year, and very few end-users alter the programming of these controllers. However, some specialty vehicles such as transit bus economically use PLC instead of custom-designed controls, because the volumes are low and the development cost would be uneconomic.
Very complex process control, such as used in the chemical industry, may require algorithms and performance beyond the capability of even high-performance PLC. Very high-speed or precision controls may also require customized solutions; for example, aircraft flight controls.
Programmable controllers are widely used in motion control, positioning control and torque control. Some manufacturers produce motion control units to be integrated with PLC so that G-code (involving a CNC machine) can be used to instruct machine movements.
PLC may include logic for single-variable feedback analog control loop, a "proportional, integral, derivative" or "PID controller". A PID loop could be used to control the temperature of a manufacturing process, for example. Historically PLC were usually configured with only a few analog control loops; where processes required hundreds or thousands of loops, a distributed control system (DCS) would instead be used. As PLC have become more powerful, the boundary between DCS and PLC applications has become less distinct.
PLC have similar functionality as Remote Terminal Units. An RTU, however, usually does not support control algorithms or control loops. As hardware rapidly becomes more powerful and cheaper, RTU, PLC and DCS are incr singly beginning to overlap in responsibilities, and many vendors sell RTU with PLC-like features and vice vers. The industry has standardized on the IEC 61131-3 functional block language for creating programs to run on RTU and PLC, although nearly all vendors also offer proprietary alternatives and associated development environments.
中文翻译：
PLC基础原理
1.1PLC简介
可编程控制器是60年代末在美国首先出现的，当时叫可编程逻辑控制器PLC ，目的是用来取代继电器。以执行逻辑判断、计时、计数等顺序控制功能。提出PLC概念的是美国通用汽车公司。PLC的基本设计思想是把计算机功能完善、灵活、通用等优点和继电器控制系统的简单易懂、操作方便、价格便宜等优点结合起来，控制器的硬件是标准的、通用的。根据实际应用对象，将控制内容编成软件写入控制器的用户程序存储器内,使控制器和被控对象连接方便。
70年代中期以后，PLC已广泛地使用微处理器作为中央处理器，输入输出模块和外围电路也都采用了中、大规模甚至超大规模的集成电路，这时的PLC已不再是仅有逻辑(Logic)判断功能，还同时具有数据处理、PID调节和数据通信功能。国际电工委员会(IEC)颁布的可编程控制器标准草案中对可编程控制器作了如下的定义：可编程控制器是一种数字运算操作的电子系统，专为在工业环境下应用而设计。它采用了可编程序的存储器，用来在其内部存储执行逻辑运算，顺序控制、定时、计数和算术运算等操作的指令，并通过数字式和模拟式的输入和输出，控制各种类型的机械或生产过程。可编程控制器及其有关外围设备，易于与工业控制系统联成一个整体，易于扩充其功能的设计。
可编程控制器对用户来说，是一种无触点设备，改变程序即可改变生产工艺。目前，可编程控制器已成为工厂自动化的强有力工具，得到了广泛的普及推广应用。
可编程控制器是面向用户的专用工业控制计算机，具有许多明显的特点
①可靠性高，抗干扰能力强；
②编程直观、简单；
③适应性好；
④功能完善，接口功能强
1.2动力
1968年，Richard E. Morley创造出了新一代工业控制装置可编程逻辑控制器(PLC),现在，PLC已经被广泛应用于工业领域，包括机械制造也、运输系统、化学过程设备、等许多其他领域。初期可编程控制器只是用一种类似于语言的软件逻辑于代替继电器硬件逻辑，并且使开发时间由6个月缩短到6天。
虽然计算机控制技术已经产生，但是PLC控制因为它的高性能、成本低、并且对恶劣的环境有很强的适应能力而在工业控制的广泛应用中保持优势。而且，尽管硬件的价格在逐渐下跌，据估计，根据Frost和Sullivan对PLC市场的调查研究表明，每年销售硬件的价格要比销售PLC的价格（一千五百万）至少多出八十亿美元。PLC的创造者Richard E. Morley十分肯定的认为目前PLC市场是一个价值五十亿的工业
虽然PLC广泛应用于工业控制中，PLC控制系统的程序依然和语法有关。和软件过程一样，PLC的软件设计也以同样的方式会遇到软件错误或危机。Morley在演讲中着重强调了这个方面。
如果房子建造的像软件过程一样，那么仅仅一只啄木鸟就可以摧毁文明。特别的，PLC程序要解决的实际问题是消除软件错误和减少老式梯形逻辑语言的花费。尽管PLC的硬件成本在继续下降，但是在工业控制上减少梯形逻辑的扫描时间仍然是一个问题，以至于可以用到低耗时的PLC。
一般来说，和其他领域相比生产PLC的周期要短很多。例如，在实践中，VISI设计是一种有效的计算机辅助设计。PLC不需要使用目前的以软件设计为基础软件工程方法论，因为PLC程序要求对软件和硬件搜都要考虑到。因此，软件设计越来越成为花费动力。在许多的工业设计工程中，超过 的人力分配给了控制系统设计和安装，并且他们要对。PLC程序测试和排除错误，
再者，PLC控制系统不适合设计对适应性和重构有越来越多要求的生产系统。一个更深入的问题是在大规模的工程中软件越来越复杂，促使要有一个系统化的设计方法论。
1.3主题的客观性和重要性
主题的客观性是为PLC自动控制系统建立一个系统化的软件设计方法论。这个设计方法论包括以状态转换模型为基础的精确的描述，这个转台转换模型是自动控制系统的抽象系统。方法论还包括一个逐步的设计过程，并且要设置一个设计规则，这样才能为一个成功的设计提供导向和方法。这项研究的真正目的是找到一个减少控制软件发展过程的不稳定性的方法，也就是说，减少程序和调试时间以及他们的变化，以增强自动控制系统的适应性，并且通过调整软件使得软件可以再度使用。这样的目的是为了克服目前程序策略的不足之处，而目前的程序策略是以个人软件开发者的经验为基础的。
一个系统化的设计PLC程序的方法可以克服传统程序生产控制系统的缺点，并且在一些工业应用总有很大的不同。自动控制系统是状态模型用公式语言或等价的语言描述的。公式描述对被控制的系统的行为提供一个精确的描述。可以通过分析估计看状态模型是否达到想要的目标，第二，状态模型的描述提供结构描述，这个结构描述可以说明逻辑要求和如细节安全规则的限制。第三，好的控制系统设计是对自动控制代码生成有益的——一种能够产生可执行的控制软件的能力，不同的逻辑控制器可以减少程序扫描时间和执行那个时间。特别的，这个主题与随后的部分的是有关的。
1.4订制生产
在现代制造业中，系统是用过程和结果的革新来描述的，变得Customer-Driven，并且因此不得不改变系统性能以快速做出反应。因此，一个大的挑战是提供技术以限制自动控制系统对变化需要和新机会的反应，所以，设计和操作知识可以实时的被再次利用，在工业实践中提供了一个重要的竞争面。
1.5高水平的自动化设计和软件质量
研究表明，在自动化系统中，程序实现的方法已经与计算机资源应用的急速增长不能匹配。例如，可编程逻辑控制器（PLC）程序仍然依靠一种方便的有逻辑梯形图的程序实现模式。结果，程序上的延迟和资源成了生产工业过程的主要绊脚石。在可编程逻辑控制器程序设计过程中，测试和调试可能会占用超过百分之五十的人力。在发展和传播“STATE-OF-THE-ART”已经形成标准[IEC 60848, 1999; IEC-61131-3, 1993; IEC 61499, 1998; ISO 15745-1, 1999]，但是，基本上这些标准都不能参与有效的程序和系统设计方面知识的革新。
系统的方法通过使用原有的软件模块，有助于增加设计自动化的水平，同时也将提供一种可管理的大规模系统设计的方法。同样的，它也将改善软件的质量的可靠性，以及关系到系统的较高安全标准，尤其是这些对环境有危害影响的，比如：机场控制、公共铁路运输。
1.6系统复杂性
软件工业被认为是系统性能的破坏者和系统复杂性的产生者。逐渐下降的硬件价格，破坏了对通过优化程序获得的软件性能的需要。其结果是，一方面造成了大量而低效率的程序代码，另一方面并没有获得高的硬件性能。其次，软件变得难以掌握其程度的复杂；在现代自动化系统中，软件设计和保持系统本质几乎变得不可能。尤其是，可编程逻辑控制器程序设计从二十五年前的两条主线，发展到现在的成千上万条。现在安全性增加了，例如，关于防火的新措施，以及现代自动化系统的柔韧性增加了程序设计过程的复杂性。因此，软件的使用周期花费是总共花费的一个固定不变的增长部分。百分之八十到九十的花费用于软件维护、调试、优化（改进）、和扩展以满足不断变换的需求。
1.7设计理论发展
目前，大部分设计研究的主要焦点都集中在机械和电子产品上。这种有目的性的研究产生了一个副产品，就是通过推广这中研究到系统工程设计领域，从而加固了我们对设计理论和技巧的基本理解。针对大规模和复杂系统的系统设计理论并没有成熟。尤其是，对如何简化一个繁冗而复杂的设计任务这一问题，仍然没有被科学的处理。而且，正在设计理论和代表计算机科学及运筹学研究的认识论结果之间构建一条桥梁，这样的具体应该是逻辑硬件电路设计。
1.8在逻辑硬件设计方面的应用
从逻辑学的角度来看，可编程逻辑控制器的软件设计类似与集成电路的硬件设计。现代超大规模集成电路设计（Very Large Scale Integration--VLSI）是及其复杂的，一个集成电路一般有几百万个晶体管，而且产品开发周期大都三年左右。设计过程一般都分成局部功能块设计和系统设计两个阶段。在局部功能块设计阶段，单个功能将被设计出来，并予以验证。在系统设计阶段，所有功能块都将被整合起来，整个系统行为特性和功能将会通过仿真形式加以测试。一般来说，所有部分都完全的验证是不可能的。因此，统计学可以作为可编程逻辑控制器设计的一个例子，并有可能影响逻辑硬件设计。
1.9编程语言
高级PLC编程语言已经在有些方面很普及。但是最近高级编程语言已经迅速发展。西门子的总经理兼生产部长指出：“可编程控制在被广泛的应用与于精密操作，除了梯形图逻辑以外的编程语言变得更加使用、有效和强大。例如，用梯形图逻辑写一个三角函数公式是非常困难的。”被接收的语言包括Boolean,控制系统流程图编制，和如公式编制语言Graph和与它类似的语言，并且还有增加的重要语言如C语言和BASIC语言。
2.0过程控制中的PLC
PLC还没有广泛的应用于过程控制中。是否会一直这样下去呢？美国南部Fancy的经理Ken Jeannette说：“我觉得PLC将被用于过程控制但是对于过程控制又不是必须的。”
一些厂家已经将PLC的优化程序应用于过程控制中，他们十分确定PLC不会广泛用于过程控制这样的事情是不会发生的。Rich Ryan经理提到PLC在食品、化学和石油等工业领域越来越多的应用。他认为PLC适合应用于场合有两种，他说：“第一，过程控制系统的型号不适合离散控制系统，刚开始这些产品的价格非常的高。而一个可编程控制器以它的体积小，价格低顺理成章的被应用。第二，你必须把电路和逻辑紧密的结合爱来。例如，一组基本的控制器，连续的过程变量紧密的互相联系在一起，以至于用可编程控制器来完成一系列的逻辑胜过没有离散控制器的系统。”
2.1通信和生产自动化协议（MAP）
通信对于个人自动单元是很重要的。在过去的几年里，我们听到许多关于生产自动化协议的事情，并且许多公司已经加入大有成功希望的事业。然而，当一个完整的生产自动化协议说明书没有及时出现时许多公司都很失望。Larry K说:”现在，生产自动化协议仍然是生产中一个发展的对象，一个说明书并不是最终的结果。例如，虽然当新的生产自动化协议MAP3.0版本使用之时以MAP2.1版本为基础的产品将会被汰，但是现在人们仍然将产品用于MAP2.1版。”
由于这些原因，许多PLC厂家紧盯着MAP的最新结果。如欧姆龙公司正在进行一个有关MAP兼容性的项目。但是欧姆龙生产部门总经理Frank Newborn说由于缺少一个固定的标准，欧姆龙的产品并不涉及到MAP。
由于工业PLC无论何时不可能广泛的涉及到MAP，生产厂家正在考虑专用网络。根据Sal Prob说法，用户担心如果他们广泛的应用生产厂家将会收回MAP，这样将会留下一个不支持通信的交流框架。
2.2 PLC相比其它控制系统
可编程控制器是可适应一系列自动化任务。这些都是自动化的在制造中通常工业过程开发和维护自动化系统的成本在哪里高，相对于总成本和其寿命期间预计将对系统更改。可编程控制器包含输入和输出设备兼容工业试验设备和管制，小电气的设计问题对预期操作是必要的。PLC应用程序通常是高度定制系统，因此成本包装可编程序控制器的费用比一个具体定制设计的小控制器要高。另外一方面在批量生产货物的情况下自定义的控制系统是组成、成本较低的最佳选择，而不是一个非反复出现工程费用“普通”的解决方案。
不同的技术方法有大量的并且很简单的固定自动化任务。例如消费者用的洗碗机的机电凸轮计时器生产数量成本只有几美元。
一种基于微控制器的设计是需要成百上千个单位（设计电源供应器，输入/输出硬件和必要的检测和认证）和开发成本可以分散到很多的销售，最终用户不需要更改该控件。汽车应用程序就是一个例子：数以百万计的内置单位每一年需要建造，很少最终用户更改这些控制器的编程。然而，一些其他车辆如交通公共汽车经常定制设计的控制,而不是用PLC，因为数量很低,发展成本会赚不到钱的。
像使用在化工中的过程控件就非常复杂，可能需要算法和甚至超出高性能可编程控制器。非常高速的能力范围的性能或精度控件也可能需要自定义的解决方案，例如飞机飞行的控件。
可编程序控制器广泛用于运动控制、定位控制和转矩控制。一些制造商生产运动控制单元与PLC集成、G-code（涉及数控机床）可以用于指导机器运作。
可编程控制器可能包括一个“比例，积分，微分”的单变量反馈模拟控制循环的逻辑或“控制器”。以PID回路可用于控制温度为例。历史上PLC通常配置只有少数模拟控制回路，通常配置可编程控制器将使用分布式的控制系统（DCS）的过程成百上千的循环。可编程控制器功能已经很强大了，可编程序控制器与集散控制系统之间的边界应用已经不是很明显了。
可编程控制器具有类似于远程终端设备的功能。RTU，然而通常不支持或控制回路的控制算法。随着硬件迅速变得更强大和更便宜，RTU、PLC和DCS正在越来越多地开始有重叠，职责，并与PLC卖许多供应商的特点类似，RTU反之亦然。业界基于IEC61131-3创建程序上运行的RTU和PLC功能块语言规范，尽管几乎所有供应商还提供专有的替代方案及相关的开发环境。