Learn how to improve the user-friendliness of your PLC programs for operators with these six tips, such as using clear comments, modular programming, and user interfaces.

You can use state machines (designed in SFC or otherwise) for top-level supervisory control, for a representative view of the state the system is in. In some cases, standards define what states certain equipment should have (e.g., PackML).

How can you improve the user-friendliness of a PLC program for operators?

PLC programs are essential for controlling and automating various industrial processes, but they can also be complex and confusing for operators who need to monitor and troubleshoot them. If you are a manufacturing engineer who wants to improve the user-friendliness of your PLC programs, here are some tips that can help you achieve that goal.

1 Use consistent naming and formatting

One of the first steps to make your PLC programs more user-friendly is to use consistent naming and formatting conventions for your variables, functions, comments, and documentation. This will make your code easier to read, understand, and maintain, as well as reduce the risk of errors and inconsistencies. You can follow some common standards, such as IEC 61131-3, or create your own style guide that suits your project and organization.

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Levi George

Controls Engineer at Avancez LLC
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Consistent naming is critical for reading and understanding what the logic does. However, there are several other reasons it's important. * It helps you understand how your program works with the process. * It helps you explain the process to other engineers or operators. * It makes retooling systems easier in the future. As PLC Programmers, we don't always get briefed on processes, but the logic we write can help those who come after us.

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2 Use clear and descriptive comments

Another way to improve the user-friendliness of your PLC programs is to use clear and descriptive comments that explain the purpose and logic of your code. Comments can help operators and other engineers to quickly grasp the functionality and behavior of your program, as well as identify any potential problems or issues. You should comment on every important or complex section of your code, as well as any changes or modifications that you make. You should also avoid using too many or too few comments, as this can clutter or obscure your code.

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Levi George

Controls Engineer at Avancez LLC
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Comments should be used carefully, they should not say what you are doing but declare your intent. The logic shows what you are doing, so explaining how it works with the process at hand can eliminate redundant comments. Additionally: -Acronyms, without common documentation on verbiage they make understanding logic much harder. -Utilize built-in tools like variable comments or REGIONS in Tia portal.

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3 Use modular and structured programming

A third tip to make your PLC programs more user-friendly is to use modular and structured programming techniques that divide your code into smaller and simpler units. Modular programming allows you to reuse and modify your code more easily, as well as isolate and test different parts of your program. Structured programming helps you to organize and sequence your code in a logical and hierarchical way, using functions, loops, branches, and blocks. These techniques can enhance the readability, reliability, and efficiency of your PLC programs, as well as make them more scalable and adaptable.

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4 Use graphical and textual languages

A fourth suggestion to improve the user-friendliness of your PLC programs is to use graphical and textual languages that suit your application and audience. Graphical languages, such as ladder logic, function block diagram, and sequential function chart, can provide a visual representation of your program that is easy to follow and interpret. Textual languages, such as structured text, instruction list, and C, can offer more flexibility and precision for your program that is suitable for complex and advanced tasks. You can also combine different languages in your PLC program, depending on the needs and preferences of your operators and engineers.

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Rareș Curatu

Driving the Development of Industry 4.0 and Innovation in the Global Industrial Automation and Machinery Business
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You can use state machines (designed in SFC or otherwise) for top-level supervisory control, for a representative view of the state the system is in. In some cases, standards define what states certain equipment should have (e.g., PackML).

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5 Use user interfaces and feedback

A fifth recommendation to make your PLC programs more user-friendly is to use user interfaces and feedback mechanisms that allow your operators to interact with and control your program. User interfaces can include screens, buttons, switches, keyboards, and touch panels that enable your operators to input commands, parameters, and settings for your program. Feedback can include lights, sounds, alarms, and messages that inform your operators about the status, performance, and errors of your program. You should design your user interfaces and feedback to be simple, intuitive, and consistent, as well as match the expectations and skills of your operators.

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Rareș Curatu

Driving the Development of Industry 4.0 and Innovation in the Global Industrial Automation and Machinery Business
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- Don't overload the displays of HMIs. - If showing alarms, don't show so many that they become irrelevant. - Give clear feedback to the operator's inputs. The system needs to feel responsive. - You can use different user roles. Show the information that is relevant for specific user roles. For example, an operator doesn't need all the information that a maintenance engineer needs. - Use appropriate graphics, colors, and symbols. The HMI needs to be understandable at a glance. - You can find HMI design guides online. You might be surprised by some of the recommendations. Did you know that as people get older, it becomes harder to differentiate between some colors?

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Levi George

Controls Engineer at Avancez LLC
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HMI design is important for safety, quality, and employee retention. Consider your users, their capabilities and inabilities. Some of your operators may be color-blind and using colors that are accessible to them may help all your operators. -Consider how your operators will use it (or observe them using it) this will give you ideas for improving the system. -Document everything, if you use light stacks, have documentation on what each light pattern means.

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6 Use simulation and testing tools

A final tip to improve the user-friendliness of your PLC programs is to use simulation and testing tools that help you to verify and validate your program before and after deployment. Simulation tools can allow you to run and debug your program in a virtual environment that mimics the real conditions and scenarios of your industrial process. Testing tools can enable you to check and measure the functionality and quality of your program in the actual hardware and software of your system. These tools can help you to identify and correct any errors, bugs, or flaws in your PLC program, as well as optimize its performance and user-friendliness.

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Rareș Curatu

Driving the Development of Industry 4.0 and Innovation in the Global Industrial Automation and Machinery Business
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You can also use simulations to train the operators. This creates the opportunity for operators to have a better understanding of the automation system. Operators can see how the PLC program reacts to different scenarios and inputs (that might be unlikely outside of simulation). Simulation is a safe space to learn and make mistakes.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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How can you improve the user-friendliness of a PLC program for operators?

1

2

3

4

5

6

7

1 Use consistent naming and formatting

2 Use clear and descriptive comments

3 Use modular and structured programming

4 Use graphical and textual languages

5 Use user interfaces and feedback

6 Use simulation and testing tools

7 Here’s what else to consider

Manufacturing Engineering

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How can you improve the user-friendliness of a PLC program for operators?

1

2

3

4

5

6

7

1 Use consistent naming and formatting

2 Use clear and descriptive comments

3 Use modular and structured programming

4 Use graphical and textual languages

5 Use user interfaces and feedback

6 Use simulation and testing tools

7 Here’s what else to consider

Manufacturing Engineering

Rate this article

Thanks for your feedback

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