The Future of Ladder Logic

Ladder Logic diagram example by “The Engineering Projects”

What is Ladder Logic?

Ladder Logic is a programming language used in industrial automation and control systems. They specifically are used in Programmable Logic Controllers (PLCs). These specialized computers control industrial machinery and processes.

The History

Richard E. Morley is credited for being the inventor of ladder logic. Morely invented the first Programmable Logic Controller in 1968. Morley’s invention was a significant innovation in industrial control systems, and it paved the way for the development of ladder logic. In the early days of ladder logic, programming involved hand-drawn diagrams on paper. These papers got fed into machines that converted the diagrams into machine code. Over time, ladder logic evolved to include more advanced programming functions.

As a Language

The fundamental building blocks of Ladder Logic are inputs, outputs, and logic gates. Inputs refer to the signals received from sensors or other devices. Outputs refer to the signals sent to actuators or other devices. Logic gates are the basic building blocks of digital circuits and perform logical operations on the inputs to produce the desired output.

Examples of “coils” and “gates”

The diagrams in Ladder Logic consist of horizontal “rungs” that represent the logical operations performed on the inputs, and vertical “rails” that represent the power supply and ground. The rungs stay connected by “contacts” and “coils”. Contacts represent the inputs while coils represent the outputs. Various symbols represent the logic gates. Some examples of these symbols are AND gates, OR gates, and NOT gates. These gates perform logical operations on the inputs.

Ladder Logic’s Advantage

One of the advantages of Ladder Logic is its simplicity and ease of use. The graphical representation of the program makes it easy to understand and maintain. Those with little or no programming experience can quickly learn it. This leads to significant time and cost savings for industrial automation and control systems. Additionally, the standardized symbols and syntax make it easy to share programs between different PLCs and programming software, further reducing development time and costs.

Another advantage of Ladder Logic is its ability to handle complex control functions. Ladder Logic includes advanced programming functions such as timers, counters, and math functions, allowing it to handle complex control functions in industrial processes. This flexibility makes it a powerful programming language for industrial automation and control systems. This is due to customizability to suit specific control requirements.

The Future of Ladder Logic

Ladder Logic is in the development of smarter and more sophisticated industrial control systems. The Internet of Things (IoT) and Industry 4.0 are driving the development of intelligent factories and industrial processes. Ladder Logic can handle the advanced programming functions required for these systems. For example, Ladder Logic can be implemented into program predictive maintenance systems. This system uses sensors and data analysis to predict when equipment will fail and schedule maintenance accordingly.

Another potential future use of Ladder Logic is in the development of more energy-efficient industrial control systems. As sustainability and energy efficiency become increasingly important, Ladder Logic can be used in program systems that optimize energy usage and reduce waste. It can control HVAC systems, lighting systems, and other building automation systems to reduce energy usage and improve efficiency.

The future of ladder logic has been a topic of debate for quite some time. While some are optimistic about it still having a place in the industry, there are others who think that it will eventually go in the way of languages already forgotten. Ladder logic’s story is one that started a long time ago and is continuing to unfold.

Common UNI1405 Fault Codes

Below is a table of common Unidrive faults found within the Control Techniques Unidrive series, more specifically, the UNI1405. MRO Electric offers core credit on exchanges for new and refurbished units, and have a wide selection of option cards such as the UD51, UD73, and UD77. We also repair Unidrives in-house. Contact us if you are interested in finding a new machine so we can keep your downtime to a minimum!

HF81Software Error (odd address word)
HF82Large option module removed
HF83Power Board Code Failure
HF84Current Offset Trim Failure
HF85A to D failure (ES-CC step)
HF86Interrupt Watchdog failure
HF87Internal ROM check error
HF88Watchdog Failure
HF89Unused Interrupts (nmi as source)
HF90Stack Overflow
HF91Stack Underflow
HF92Software Error (undefined op code)
HF93Software Error (protection fault)
HF94Software Error (odd address word)
HF95Software Error (odd address inst.)
HF96Software Error (illegal ext bus)
HF97Level 1 Noise
HF98Interrupt Crash
HF99Level 1 Crash

Virtual Reality: A Game-Changer in Industrial Automation

Virtual reality (VR) technology is revolutionizing the way industrial automation operates. Transforming the manufacturing sector, VR enables companies to create immersive training environments and digital prototypes that simulate real-world conditions. The benefits of VR in industrial automation are numerous, making it an increasingly popular tool in the industry.

The Brief History of VR

Virtual reality (VR) technology has a history that dates back to the mid-20th century. According to a report by the History of Human-Computer Interaction (HCI) research group. In the 1960s, computer scientist, Ivan Sutherland created the first device, the”The Sword of Damocles”. It was a crude prototype that consisted of a head-mounted display and a tracking system. The device enabled users in experiencing computer-generated environments in a way that felt more immersive than any previous computer interface.

In the following decades, VR technology advanced rapidly, especially in the field of military simulation and training. The 1990s saw the commercial sector showing interest in VR technology. This led to the development of more advanced VR systems for use in video games, medicine, and other fields. Today, VR technology is more sophisticated and is used in various applications. This ranges from gaming and entertainment to education and training. Over the years VR technology has become more affordable and there has been wider development in VR software. This makes the technology more accessible to a much broader audience as it rapidly evolves.

VR’s Effect on the Industry

There are different significant uses of VR in industrial automation. One is the creation of virtual simulations of production lines, assembly processes, and operating procedures. This enables engineers and operators to experience the manufacturing process from start to finish in a virtual environment. This improves their understanding of the process and reduces the risk of errors. One report by ResearchAndMarkets, estimates the market to grow from $4.08 billion in 2020 to $9.51 billion by 2025.

Another way VR is advancing industrial automation is through the use of digital twin technology. A digital twin is a virtual model of a physical system. It provides real-time data and insights into the system’s performance. This allows manufacturers to monitor and optimize the performance of their machines in real time, reducing downtime and improving efficiency. MarketsandMarkets, predicts, the digital twin market to grow from $5.72 billion in 2018 to $35.8 billion by 2023.

Furthermore, VR is also being used in training and education in the industrial automation sector. Companies can create immersive training environments for employees. This allows them to experience realistic scenarios without putting themselves or others at risk. Additionally, this not only improves employee safety but also helps employees acquire new skills faster and more effectively.

Virtual reality is advancing industrial automation by providing a safer, more efficient, and more effective way to train employees. It simulates production processes and optimizes machine performance. VR’s versatility and ability to provide real-time data and insights make it a vital tool in the industrial automation industry.

Company Spotlight: FANUC

FANUC, (aka FANUC Corporation), is a Japanese multinational corporation. They specialize in the manufacturing and sale of robotics, automation, and CNC (computer numerical control) systems. Founded in 1956, the company has a long history of becoming one of the manufacturing industry’s leading players.

The Beginning

Like any good industry story, FANUC began with three engineers. Seiuemon Inaba, Ichiro Kigawa, and Takeshi Nakamura worked at the Fujitsu Fanuc factory in Japan before establishing FANUC in 1956. The company’s first product, a computerized numerical control (CNC) system, automated turning raw materials into finished products. This revolutionary system significantly increased the efficiency and precision of manufacturing processes. According to the company’s website, Fanuc produced the first CNC system in 1958.

Throughout the 1960s and 70s, FANUC continued expanding its product line, developing new CNC systems and other automation technologies. Specifically, the 1970s saw FANUC focus on establishing itself as a leading manufacturer of numerical control (NC) systems. The company’s sales during this decade were modest, as it was still building its brand and reputation in the market. According to the company’s official website, FANUC’s focus on innovation and customer satisfaction helped it establish a strong foundation in the NC systems market. The company also began to establish a global presence. They opened subsidiaries in Europe and the United States. According to MarketsandMarkets FANUC had established itself as a major player in the global CNC market by the 1970s.

Ending the Century Strong

The 1980s saw FANUC entering the robotics market with the launch of its first industrial robot, the FANUC Robot M-1. The M-1’s success established FANUC as a leading player in the robotics industry. In a report from Technavio, by the early 1980s, FANUC had become one of the leading suppliers of industrial robots in Japan. The company continued expanding its robotics product line throughout the 1980s and 1990s, developing new robots for a variety of industrial applications.

The New Millenium

In the early 2000s, FANUC continued to innovate and grow, expanding into new markets and developing new technologies. The company launched a series of collaborative robots, designed to work alongside human operators. It also began developing AI-powered systems. By the early 2000s FANUC had become one of the leading suppliers of collaborative robots in the world.

Today, FANUC stands as a global leader in the manufacturing industry. They provide products and services used in a wide range of industries. This includes automotive, aerospace, electronics, and medical devices. The company has a strong reputation for innovation and quality, and it continues to invest in R&D to develop new technologies that can improve the efficiency and productivity of manufacturing processes. According to a report from Frost & Sullivan, FANUC is the world’s largest supplier of industrial robots, holding a market share of over 30%.

The company has a long and storied history that has seen it become one of the leading players in the global manufacturing industry. FANUC has established itself as a company dedicated to innovation, quality, and efficiency. They continue to invest in R&D, developing new technologies that can improve the efficiency and productivity of manufacturing processes.

Industrial Automation: Job Growth

The industrial automation sector has seen significant job growth in the past decade. A report by MarketsandMarkets, estimates the global industrial automation market to reach $296 billion by 2023. From 2018 to 2023 the CAGR saw a growth of 6.6%. The adoption of Industry 4.0 and Internet of Things (IoT) technologies, rising labor costs, and a growing need for improved efficiency and productivity have been contributing factors.

This growth in the industrial automation market has also led to an increase in job opportunities in the sector. The International Federation of Robotics (IFR) found industrial automation jobs increased by 2.6 million worldwide between 2010 and 2016. The study also predicted continued job growth in the sector reaching 2.8 million by 2019.

Manufacturing roles aren’t the only jobs increasing in the industrial automation sector. Additionally, industrial automation technologies have led to a growing need for skilled professionals in other areas. These include engineering, programming, and data analysis, according to a report by the Bureau of Labor Statistics. Employment of industrial engineers, for example, projected 8% growth from 2016 to 2026, faster than the average for all occupations.

In addition, the industrial automation sector is also a significant contributor to the growth of the economy. The IFR estimates that every robot installed in the manufacturing industry creates an average of 1.6 jobs. Furthermore, the increasing adoption of industrial automation technologies is also expected to lead to new jobs. These areas can include the installation, maintenance, and repair of automation systems.

In conclusion, the industrial automation sector has seen significant job growth in the past decade, driven by the increasing adoption of Industry 4.0 and IoT technologies, rising labor costs, and a growing need for improved efficiency and productivity. Experts continue to expect this growth in the coming years, leading to an increase in job opportunities not just in manufacturing roles but also in areas such as engineering, programming, and data analysis.

The History of “The New Year”

For thousands of years, New Year celebrations have changed and evolved. Some of the oldest celebrations evidently located in ancient civilizations such as Mesopotamia and Egypt.

In Ancient Times

Ancient Mesopotamia celebrated the new year around the time of the vernal equinox, around March 21st. The Akkadian people, who lived in ancient Mesopotamia, celebrated the new year with a festival called Akitu. This festival included crowing a king and honoring the gods.

Egypt

Ancient Egypt celebrated the new year around the time of the inundation of the Nile, which typically occurred in the month of September.

One of the most important of these was the festival of Wepet Renpet, which honored the god, Ra. During this festival, the Pharaoh would lead a procession to the temple of Ra and offer sacrifices to the god.

Other rituals and ceremonies associated with the Egyptian new year included the reading of the “Book of the Dead.” These were a collection of spells and incantations used to protect the deceased in the afterlife. There also existed an “Opening of the Mouth” ceremony. This gave the deceased the power to speak and eat in the afterlife.

The Egyptians also celebrated the new year with feasts and celebrations. They would decorate their homes and temples with flowers and other decorations. They also held large banquets in honor of the gods.

Rome

The Roman calendar, which was based on the movements of the moon, originally had only ten months. They celebrated the new year on March 1st, calling it the “New Year’s Day of the Consuls.” Later, the Romans reformulated the calendar and the new year moved to January 1st.

A variety of traditions and customs marked the Roman new year. One important tradition, the exchange of gifts, brought good luck for the coming year. The Romans would also decorate their homes with greenery and other decoration. Like the Egyptians, they also held feasts and parties to celebrate the new year.

The Roman Empire also marked the new year by performing religious rituals. The Romans believed that the gods had a special role to play in the new year. They offered sacrifices and perform other rituals to honor them.

Medieval Europe

The celebration of the New Year in Medieval Europe landed on different dates depending on the region. The British Isles celebrated the new year on March 25th, the feast of the Annunciation. For the Catholic Church, December 25th was the feast of the Nativity. They celebrated by singing Christmas carols and exchanging gifts.

Overall, the celebration of the new year in medieval Europe was a time of renewal and a time to look forward to the future. It was a time to come together with family and friends and celebrate the blessings of the past year.

Africa

In Africa, the celebration of the new year varies among different tribes and cultures. Some African tribes mark the new year as a time of renewal and celebrate with rituals, ceremonies, and feasts.

For example, the Ashanti people of Ghana celebrate the new year with the festival of Homowo, which is a time to honor their ancestors and give thanks for the blessings of the past year. During this festival, the Ashanti people hold traditional dances, perform rituals, and prepare special foods.

Other African tribes celebrate the new year with different traditions and customs. The Zulu people of South Africa mark the new year with the Umkhosi woMhlanga, or Reed Dance, which is a celebration of womanhood and fertility. The Maasai people of Kenya and Tanzania celebrate the new year with the Eunoto, a rite of passage for young warriors.

Overall, the celebration of the new year in Africa is a time of renewal and a time to honor the past and look forward to the future. It is a time for families and communities to come together and celebrate the blessings of the past year.

The Modern Celebration

The modern celebration of New Year’s Day on January 1st traces back to the adoption of the Gregorian calendar in the 16th century. In 1582, Pope Gregory XIII implemented the calendar as a way to reform the Julian calendar which had become inaccurate over time. Presently, the Gregorian calendar is the uniform system for determining the dates of holidays and other important events.

Today, countries all over the world celebrate New Year with a variety of traditions and customs. Many countries mark New Year’s Eve with parties, fireworks, and the ringing of church bells at midnight. In other countries, New Year’s Day is a time for family gatherings and the exchange of gifts.

The Best U.S. States for Storm Chasers

Title image of the best U.S. States for Storm Chasers.

If “fear” is not in your vocabulary and “danger” is your middle name, storm chasing may be right up your alley. For individuals who are fearless enough to add “Storm Chaser” to their resume, MRO Electric determined the best states to keep a pulse on hurricanes, tornadoes, and tropical storms in the country. 

In this study, we ranked the top 50 states across the country to chase cyclones based on several factors, including the number of tropical storms, hurricanes, and tornadoes within the past 5 years, average nightly price of temporary accommodations, average travel expenses, and more. Read on to find out if you’re in a hotspot for hurricanes or if you’ll have to venture a little further out to enter the eye of the storm.

Taking the Nation by Storm: The 10 Most Turbulent States

Map depicting the top 10 U.S. states for storm chasing.

Storm chasers looking for a chance to be in the middle of the action should plan a trip to the southern and southeastern regions of the U.S. Our friends down south made up 8 of the top 10 states, making it the place to be for storm chasers all over the nation.

Florida is undoubtedly the place to be for any aspiring storm chaser. The Sunshine State comes in first on our list with a storm chaser score of 80.23. Florida reports more days of tropical storms than any other state in the country and frequently faces other natural disasters, like hurricanes and tornadoes. Average airfare to Florida is also cheaper than any other U.S. state, making it accessible to storm chasers who plan on trekking from parts unknown to catch a glimpse of the carnage.

If you feel tempted to chase after terrible tornadoes, your best bet might be to travel to Illinois or Kansas. These two states are the only states in our top 10 not located in the southern or southeast part of the country. Interestingly, they are also the only states in our shortlist to have reported impacts by only one of the storm types. Their impact from tornadoes being so exceptionally high was enough to put the pair in the top 10.

The Danger Zone: States That Get Hit the Most

Map depicting the U.S. states that get hit the most by storms.

Texas had the highest number of storms at nearly 200 impacts in the past five years alone. When it comes to the sheer number of natural disasters, no one else comes close to touching the Lonestar State. In five years, Texans have had to grapple with 158 days of tornadoes, 7 days of hurricanes, and 12 days of tropical storms. If you’re a veteran storm chaser looking for a challenge, remember everything’s bigger in Texas.

Even though Illinois doesn’t even receive a gold, silver, or bronze medal for states most frequently hit by storms, it definitely deserves an honorable mention. With only reporting impacts from one of the three storm types, it is the 4th state overall to get banged up regularly by storms. In just five years, it has reported nearly 20 tornadoes on average a year.

Though Texas was the state to experience storms the most frequently beyond any doubt, Georgia takes a surprising second for most areas hit by storms. Geographically, Georgia shares borders with four states on our top 10 states with the most areas hit by storms list. Residents in Georgia have to deal with disasters coming from every direction since Alabama, Florida, North Carolina, and South Carolina are more than happy to share some of the action with them.

Closing Thoughts

If you’re no stranger to danger and love the thrill of hunting down disaster, storm chasing might be the perfect hobby for you. Storm chasers who are up for a challenge and a little traveling should head down south if they really want to test their mettle against some of the country’s most terrifying storms and natural disasters. Just remember to keep safety and the cost of accommodation in mind.

Storms pop up in various regions and cause disruptions to our natural way of living. Storm chasers are crucial in tracking the patterns and reporting the conditions of these storms. More often than not, one common occurrence with these harsh weather conditions is power outages across hundreds of neighborhoods. That’s why MRO Electric is committed to ensuring people across the country have access to trustworthy electric and power systems they can depend on during an emergency.

Full Data

That wraps up our state ranking for The Best States for Storm Chasers. Interested in diving deeper into the numbers for all of the states, or wanting to see how your state stacks up if it’s not listed within the above map? 

We’ve compiled our full data study for all 50 U.S. states and the District of Columbia analyzed into the interactive data table below. Search for the state you call home or click on the heading of each column to sort by that category!

Methodology 

To find out the best states for storm chasers, we began with a list of all 50 of the U.S. states and the District of Columbia. We collected data on 10 factors that pertain to or impact storm chasers. We assigned states with a score of 0-5 for each factor, with a score of 5 representing the most favorable conditions. We determined each state’s total score from the total of its individual factor scores, which were weighted according to their impact on storm chasers. Individual factor scores were then added together to give each state a final score from 0-100. Higher scores indicated states that are better for storm chasers. Details on our ranking factors can be found below.

Ranking FactorWeightSource
Number of Days with Hurricanes Reported (in last 5 yrs)1.75NCEI
Number of Days with Tornadoes Reported (in last 5 yrs)2.75NCEI
Number of Days with Tropical Storms Reported (in last 5 yrs)2.75NCEI
Number of County/Zone Areas Affected by Hurricanes1.75NCEI
Number of County/Zone Areas Affected by Tornadoes2.75NCEI
Number of County/Zone Areas Affected by Tropical Storms2.75NCEI
Average Price of Airbnb/Hotels1.50Airbnb
Average Gas Costs by State1.50AAA
Average Airfare Into a State1.00BTS
Average Car Rental Fees1.50Kayak