Essential Reading for Engineers: Siemens PLC Innovations in IIoT

Everyone knows that Siemens PLC is the “big brother” of industrial automation. However, things are different now; the era of the Industrial Internet of Things (IIoT) has arrived, and PLCs must keep up with the times. In my more than ten years of engineering experience, I have witnessed these changes firsthand, and today I want to share some insights.

New Features of PLCs in the IIoT Era

The latest Siemens S7-1500 series PLCs now come with built-in OPC UA servers, which is amazing! I remember once on a factory renovation project, the client was thrilled to learn that they could connect directly to the cloud platform without needing to purchase additional gateway devices. This saved them tens of thousands of dollars.

The CPU modules now come with web server functionality, allowing you to view production data on your smartphone without having to go on-site. However, remember to set a strong password when enabling web functionality, or you risk being hacked.

New Approaches to Data Collection

Data collection with PLCs has become interesting. In the past, we would upload each variable one by one, but now we can use the data logging function to directly store production data on an SD card.

One particularly amusing case involved a client in injection molding who insisted on uploading over a hundred parameters from each machine in real-time. I told him that was too cumbersome, so we switched to batch recording, retrieving the data as needed, which made the system much smoother.

Remote Maintenance Insights

Remote maintenance is incredibly useful, but it is also the most prone to issues. I encountered this at a paper mill where the client said the PLC program wouldn’t connect. When I arrived, I found that the firewall settings had blocked the Siemens communication port. This kind of problem is quite common, so I recommend communicating with the IT department in advance.

Now, using TIA Portal to write programs, the remote download feature is very convenient. However, I must remind everyone that you should always back up before remotely modifying programs! I once had a scare when a network issue interrupted a program download halfway.

Cybersecurity Risks

When it comes to the Industrial Internet of Things, cybersecurity must be taken seriously. Over the years, I have seen too many factories expose their PLCs to the public internet, which is extremely dangerous.

Here are some basic security measures that must be implemented:

• PLC access protection should be set up

• Control networks must be properly isolated

• Firmware should be updated promptly

• Remote access should utilize VPN

Future Development Directions

Siemens PLCs are now moving towards Edge computing, with CPUs capable of running AI algorithms. This is impressive! Just the other day, I used it for product quality inspection in a textile factory, and the results were quite good.

However, don’t blindly chase new technology; many times, traditional PLC control is sufficient. The key is to understand your needs and not adopt new technology for the sake of it.

Practical Recommendations

Buy an S7-1200 experimental kit, install TIA Portal V16, and start practicing with the most basic communication configurations. There are online simulators, but hands-on operation is the most intuitive.

If you encounter any problems, feel free to leave a comment and share. By the way, have you faced any pitfalls while connecting PLCs to the Industrial Internet of Things in your factory?