Solution to Interfacing Problems of Programmable Logic Controller in Hardware Replacement

Upgradation of programmable logic controller in terms of software is easy and economical but when it comes to hardware becomes complex and uneconomical as well. Replacement of any assembly line or carriage unit in PLC automation is time consuming and coast consuming. This paper giving an approach and implemented process chart to reduce time consuming and coast consumption of hardware change and replacement of PLC automation units. Here two conventional studies direct replacement indirect maintenance automation technique (DRIM) are compared with modern approaches of indirect replacement and direct maintenance (IRDM) automation technique. Here assembly sub unit is segmented in order to achieve better replacement taking care of economical aspect of maintenance and unit up gradation. Here direct and indirect methods are compared with their actual cost comparison and presenting a reliable time saving approach. An illustrative study about delaying in response has been given by comparing the process time to set value of the time. suggestive use of analog comparator in the place of digital comparator has been given in order to increase the fault analysis. Temperature based unit automation also presented in terms of temperature sensory unit replacement with normal temperature controller and heat actuators. Paper presents an analytical comparison study of solid iron structure base to the light and hollow allow structure with multiple division and rebated and jointed with nut and bolt system rather than direct welding