Industrial control and automation can be complex. At Maple Systems, we want to break the barrier between knowledge and know-how to make sure every engineer and operator is fully prepared for whatever task comes their way.
Industrial control systems have to respond to process changes without continually adjusting their output. Small signal variations can lead to unnecessary switching, actuator movement and equipment wear. Understanding hysteresis and deadband in the context of industrial PID control is key to achieving the right balance…
Read More Understanding Hysteresis and Deadband in PID Control
Imagine a PID temperature loop that once held a steady setpoint now takes longer to recover after each batch. The controller settings have not changed, but the sensor, heater, wiring, or process conditions may have. Effective PID loop maintenance checks these parts together to identify…
Imagine you have a control panel set up just how you need it. Your field sensors are connected and calibrated, your PLC is programmed, and the resulting values and metrics appear on the HMI. However, the entire panel requires clean, regulated 24VDC, while the facility…
Read More Single-Phase vs. Three-Phase DIN-Rail Power Supplies
Imagine you’ve just deployed a full control panel. It’s a prototype for a new machine your company will be manufacturing. You plug in the power supply, and the cabinet jumps to life. Indicator lights flash as the PLC runs through your test program, while the…
Read More DC OK Relay Contacts for Industrial Power Supply Monitoring
Industrial automation systems can use several DC voltage levels. Three common options are 12V, 24V, and 48V DC. Each voltage affects how much current the system requires to deliver a given amount of power. Choosing between a 12V, 24V, and 48V power supply starts with…
Read More 12V vs. 24V vs. 48V Power Supplies for Industrial Automation
DIN-rail power supplies are usually found in crowded industrial enclosures where other components such as PLCs, HMIs, relays, drives, and various heat-generating devices are also located. Even when a power supply has a rated capacity that is sufficient for the load connected to it, temperature…
Read More DIN-Rail Power Supply Derating and Thermal Management
Power supplies provide the DC power required by PLCs, HMIs, sensors, relays, communication devices, and other industrial equipment. When a single power supply cannot meet an application’s requirements, designers may use multiple supplies. Two common approaches are parallel power supplies and redundant power supplies. Although…
Read More Parallel vs. Redundant Power Supplies for Industrial Control Systems
Industrial control systems always rely on stable DC power to keep connected equipment operating efficiently. Wiring faults, excessive loads, equipment failures, or high temperatures can cause abnormal conditions. Industrial power supplies use built-in protection modes to respond to these conditions. The type of protection matters…
Read More Industrial Power Supply Protection Modes Explained
A 24V DC power supply provides operating power for many devices inside an industrial control panel. PLCs, HMIs, sensors, relays, communication devices, and other control components often depend on the same 24VDC power source. Choosing a power supply requires more than adding the wattage printed…
Read More 24V DC Power Supply Sizing for Industrial Control Panels
Imagine managing a heated liquid tank that uses PID control to maintain temperature. Should a dedicated controller handle the temperature locally, or should a PLC execute the PID calculation alongside filling, mixing, and draining logic? PID control in PLC systems combines process regulation with machine…
Read More PLC-Based PID Loops vs. Standalone PID Controllers
A heated tank can follow a preset heating schedule or adjust its heater output based on measured temperature. Both approaches can serve a purpose, but they respond differently when operating conditions change. A timed heating command might work for a repeatable process, while changing material…
Imagine a heating tank that repeatedly rises above and falls below its temperature setpoint (SP). An operator adjusts the PID control loop settings, but the cycling continues. Is the controller responding too aggressively, is the temperature measurement delayed, or is the heating equipment failing to…
Read More Troubleshooting PID Loop Instability, Oscillations, Overshoot & Hunting