Articles

PLCs, or programmable logic controllers, are essential parts of contemporary industrial automation systems and are responsible for managing and keeping an eye on a variety of operations. PLC reliability is critical to maintaining industrial systems' continuous and secure operation. A wide range of reliability strategies were used to improve the reliability of Programmable Logic Controllers, and this article methodically looks at them all. The evaluation classified PLC reliability techniques into Root Cause Analysis (RCA), Reliability Centered Maintenance (RCM), Hazard analysis (HA), Reliability block diagram (RBD), Fault tree analysis (FTA), Physics of failure (PoF) and FMEA/FMECA, after thoroughly reviewing the body of literature. The proportion of reviewed papers using either RCA, RCM, FMEA/FMECA, FTA, RBD, RCM, PoF, or Hazard analysis to increase the reliability of PLCs showed that RCA, which makes up 20% of the publications reviewed, has been used the most to increase the reliability of the PLC, followed by HA, RCM, RBD, FTA, and PoF, which account for 17%, 16%, 16%,13%, 10%, and 8% of the articles reviewed, respectively. The paper discusses new developments and trends in PLC reliability, such as the application of machine learning (ML) and artificial intelligence (AI) to fault detection and predictive maintenance.

The control of processes is made smooth and effective by Programmable Logic Controllers (PLCs), which are essential to industrial automation. The assessment of PLCs' reliability is crucial since more and more sectors depend on them for crucial tasks. In-depth reviews of the components necessary to evaluate PLC system reliability are presented in this study. To ensure a robust review, the review first clarifies the basic concepts of reliability, highlighting the significance of system uptime and the ramifications of failures in industrial settings. Next, it examined the different elements that go into a PLC's overall reliability, such as availability, testability, and (maintenance and maintainability). The percentage of the reviewed papers that employed (maintenance and maintainability), testability, or availability to improve the reliability of PLC systems showed that, availability and (maintenance and maintainability) has been employed the most for enhancing system reliability, accounting for 32% each of publications analyzed, followed by testability, accounting for 28% respectively. The scatter chart that depicts the progression of reliability components from 2010 to 2023 also explained that the use of availability and (maintenance and maintainability) was increasing. This upward trend can be explained by the fact that repairable systems are heavily reliant on availability, whereas (maintenance and maintainability) tend to avoid unnecessary equipment breakdown and testability, which ensures the ease with which the functionality of any system or component can be ascertained with the required level of precision.