Wie kann man SPS-Systemabstürze verhindern?

All mentioned is fine, also consider correct amount of memory (RAM). PLC will hang or freeze running out of working memory…….

To prevent PLC system crashes, you can follow some preventive measures, such as: Use a backup power source or an uninterrupted power supply to ensure a constant flow of power to the PLC and avoid power surges or interruptions12. Use proper grounding and shielding techniques to protect the PLC from electrical noise and interference that can affect the signals and data transmission12. Use compatible and reliable I/O modules and field devices that match the PLC configuration and specifications. Check the wiring, connections, and terminal blocks for any damage or looseness. Replace any faulty or worn-out components123. Use the latest version of the PLC software and update it regularly. Make sure the PLC program is backed up and stored safely.

Here's the brief answer, prevent PLC system crashes by regularly updating firmware, implementing proper backups, conducting routine maintenance, and ensuring compatibility with other systems. Learn from past incidents to fine-tune your preventive measures and keep the PLC running smoothly.

Preventing a PLC (Programmable Logic Controller) system crash involves several measures. Ensure proper programming practices, implement error-handling routines, regularly update firmware, use stable power sources, and conduct periodic system testing to identify and address potential issues before they lead to a crash.

Step 1 is a quality install. Best practices regarding wiring, wire routing, termination techniques, shielding and grounding. UPS and power quality. Step 2 is resource management. Processor loads, network management and using integration to offload resources correctly. VFD control and management. Data management Step 3 ongoing maintenance, keeping panels clean and dry, corrosion protection. Like a hi end car or a data center a PLC is a high performance industrial computer. The processor is the brain and the power is its food. The devices connected are its appendages & all the interconnected wiring is blood vessels, nerves, arteries & muscles. If you don't eat good food, have proper hygiene and get your exercise you won't live long

To prevent PLC system crashes, you can follow some preventive measures, such as: Use a backup power source or an uninterrupted power supply to ensure a constant flow of power to the PLC and avoid power surges or interruptions. Use proper grounding and shielding techniques to protect the PLC from electrical noise and interference that can affect the signals and data transmission. Use compatible and reliable I/O modules and field devices that match the PLC configuration and specifications. Check the wiring, connections, and terminal blocks for any damage or looseness. Replace any faulty or worn-out components.

Stored potential energy sources needs to be identified as well that is connected to or controlled by PLC system and will require safe isolation or the release of its stored energy first as needed. It can be as simple as releasing any pressure, relaxing charged spring, discharging capacitors, putting mechanical components in a safe position that will not unintentionally move, etc.

In my view , while conducting any hot work like welding on the machine where PLC is connected should be power shut off and welding maching part should thrpugly earthed . Secondly earthing conductors n its earth pits be separately taken n not connected to electrical earthing system.

Some of the possible methods are: Practicing and applying what you learn on real or simulated PLC systems. For example, you can use software such as PLC Simulator, PLC Fiddle, or PLC Lab to create and test your own PLC programs and troubleshoot common errors and faults. These tools can help you gain hands-on experience and confidence in PLC system maintenance and repair.

Based on my experience, I encountered a PLC code wherein division by zero causes the data block variable to freeze indefinitely. The frozen value will never changed even if the result of a mathematical operation (formula) is assigned to it cyclically in rhe program. This happened when the human operator unintentionally entered (copied) a value from the existing values on the HMI. Restarting the PLC will not fix it. The DB has to be re-initialized so the memory area will be useful again and values changing.