32 n CONTROLS November/December 2024 www.drivesncontrols.com Generative AI: what does it mean for PLC coding? The most common programming language for PLCs is ladder logic (LL), which mimics the appearance of electrical relay logic diagrams. Engineers manually design the logic by arranging symbols, such as contacts, coils, timers and counters, in a graphical format that represents the sequence of operations in a control process. Now, with the integration of generative AI, the traditional process of PLC programming is evolving, oering engineers powerful new tools to streamline and enhance their work. At the Hannover Messe earlier this year, Siemens unveiled the rst generative AI product tailored for engineering in an industrial environment. Called the Siemens Industrial Copilot, it integrates with Siemens’ TIA Portal, and could change the way that engineering teams approach PLCs. The Industrial Copilot software – developed in collaboration with Microsoft – allows engineers to locate the right help topics, generate basic visualisations, and expedite the development of PLC code. This marks a signicant leap forward in the application of AI in industrial automation, but what are the benets? The software uses advanced AI algorithms to generate PLC code in Structured Control Language (SCL). This is a key development because it eliminates the need for engineers to manually write and copy-paste code. Additionally, the software oers step-by-step guidance on repairs and will even suggest ideas to improve system performance. The Industrial Copilot also suggests code snippets directly within the TIA Portal, simplifying the coding process and further reducing the probability of human error. As mentioned, the AI can also create visualisations for machines or plants using WinCC Unied, streamlining the creation of intuitive interfaces for monitoring and control. For instance, in food processing plants, operators rely on HMIs to monitor production lines, track ingredient usage and ensure compliance with safety regulations. Customising these HMIs to suit the specic needs of dierent products or production lines can be challenging. The Industrial Copilot can help by generating initial HMI designs based on a line’s requirements, which can then be rened to meet specic operational needs. Beyond code generation, the Copilot software oers valuable assistance by explaining SCL code blocks and guiding engineers through complex tasks. This helps to demystify intricate code and supports engineers in understanding and implementing complex automation logic. The app also oers natural language search through Siemens manuals, allowing users to quickly nd relevant information without wading through extensive documentation. This is particularly important at a time where industries are facing a shortage of skilled labour. The software can act as a digital assistant, guiding less experienced engineers and operators through complicated tasks. Accuracy and efficiency By integrating with Siemens’ Xcelerator digital business platform, the Industrial Copilot allows AI to analyse data from across a factory and suggest optimisations, making processes more ecient. By automating repetitive tasks and providing intelligent code suggestions, it can reduce the engineering workload signicantly. This not only saves time but also makes the process less prone to human error, leading to more reliable automation. The result is shorter development times, a codebase with fewer bugs, and increased productivity. In a wind turbine manufacturing plant, for example, generative AI could analyse vast amounts of production data to uncover patterns. It might recommend adjusting the speed of a particular machine to balance energy eciency with output, leading to signicant cost savings and a more sustainable operation. Most of today’s PLCs execute preprogrammed instructions, often in LL or other structured languages. Usually used in conjunction with SCADA systems, PLCs monitor inputs from sensors, make logical decisions and control outputs to devices such as motors. Choosing the right controller for an application is a fundamental step in ensuring optimal performance and reliability. PLCs revolutionised industrial automation by replacing cumbersome relay-based systems with programmable controllers capable of executing complex control sequences. The integration of generative AI technology marks a new chapter in this evolution, which will be of huge benet to engineers and manufacturers alike. n Generative AI tools are emerging which promise to change the way that controls engineers work. Tom Cash, director of the automation parts supplier Foxmere, explains how the shift to these tools will a ect engineers, making their lives easier and cutting costs. Siemens’ Industrial Copilot can write code for automation engineering
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