Programmable logic controller in the context of Computer systems

A computer is a machine that can be programmed to automatically carry out sequences of arithmetic or logical operations (computation). Modern digital electronic computers can perform generic sets of operations known as programs, which enable computers to perform a wide range of tasks. The term computer system may refer to a nominally complete computer that includes the hardware, operating system, software, and peripheral equipment needed and used for full operation; or to a group of computers that are linked and function together, such as a computer network or computer cluster.

A broad range of industrial and consumer products use computers as control systems, including simple special-purpose devices like microwave ovens and remote controls, and factory devices like industrial robots. Computers are at the core of general-purpose devices such as personal computers and mobile devices such as smartphones. Computers power the Internet, which links billions of computers and users.

Stuxnet is a malicious computer worm first uncovered on 17 June 2010 and thought to have been in development since at least 2005. Stuxnet targets supervisory control and data acquisition (SCADA) systems and is believed to be responsible for causing substantial damage to the Iran nuclear program after it was first installed on a computer at the Natanz Nuclear Facility in 2009. Although neither the United States nor Israel has openly admitted responsibility, multiple independent news organizations claim Stuxnet to be a cyberweapon built jointly by the two countries in a collaborative effort known as Operation Olympic Games. The program, started during the Bush administration, was rapidly expanded within the first months of Barack Obama's presidency.

Stuxnet specifically targets programmable logic controllers (PLCs), which allow the automation of electromechanical processes such as those used to control machinery and industrial processes including gas centrifuges for separating nuclear material. Exploiting four zero-day flaws in the systems, Stuxnet functions by targeting machines using the Microsoft Windows operating system and networks, then seeking out Siemens Step7 software. Stuxnet reportedly compromised Iranian PLCs, collecting information on industrial systems and causing the fast-spinning centrifuges to tear themselves apart. Stuxnet's design and architecture are not domain-specific and it could be tailored as a platform for attacking modern SCADA and PLC systems (e.g., in factory assembly lines or power plants), most of which are in Europe, Japan and the United States. Stuxnet reportedly destroyed almost one-fifth of Iran's nuclear centrifuges. Targeting industrial control systems, the worm infected over 200,000 computers and caused 1,000 machines to physically degrade.

A cam is a rotating or sliding piece in a mechanical linkage used especially in transforming rotary motion into linear motion. It is often a part of a rotating wheel (e.g. an eccentric wheel) or shaft (e.g. a cylinder with an irregular shape) that strikes a lever at one or more points on its circular path. The cam can be a simple tooth, as is used to deliver pulses of power to a steam hammer, for example, or an eccentric disc or other shape that produces a smooth reciprocating (back and forth) motion in the follower, which is a lever making contact with the cam. A cam timer is similar, and these were widely used for electric machine control (an electromechanical timer in a washing machine being a common example) before the advent of inexpensive electronics, microcontrollers, integrated circuits, programmable logic controllers and digital control.

An industrial control system (ICS) is an electronic control system and associated instrumentation used for industrial process control. Control systems can range in size from a few modular panel-mounted controllers to large interconnected and interactive distributed control systems (DCSs) with many thousands of field connections. Control systems receive data from remote sensors measuring process variables (PVs), compare the collected data with desired setpoints (SPs), and derive command functions that are used to control a process through the final control elements (FCEs), such as control valves.

Larger systems are usually implemented by supervisory control and data acquisition (SCADA) systems, or DCSs, and programmable logic controllers (PLCs), though SCADA and PLC systems are scalable down to small systems with few control loops. Such systems are extensively used in industries such as chemical processing, pulp and paper manufacture, power generation, oil and gas processing, and telecommunications.

Supervisory control and data acquisition (SCADA) is a control system architecture comprising computers, networked data communications and graphical user interfaces for high-level supervision of machines and processes. It also covers sensors and other devices, such as programmable logic controllers, also known as a distributed control system (DCS), which interface with process plant or machinery.

The operator interfaces, which enable monitoring and the issuing of process commands, such as controller setpoint changes, are handled through the SCADA computer system. The subordinated operations, e.g. the real-time control logic or controller calculations, are performed by networked modules connected to the field sensors and actuators.

G-code (abbreviation for geometric code; also called RS-274, standardized today in ISO 6983-1) is the most widely used computer numerical control (CNC) and 3D printing programming language. It is used mainly in computer-aided manufacturing to control automated machine tools, as well as for 3D-printer slicer applications. G-code has many variants.

G-code instructions are provided to a machine controller (industrial computer) that tells the motors where to move, how fast to move, and what path to follow. The two most common situations are that, within a machine tool such as a lathe or mill, a cutting tool is moved according to these instructions through a toolpath cutting away material to leave only the finished workpiece and/or an unfinished workpiece is precisely positioned in any of up to nine axes around the three dimensions relative to a toolpath and, either or both can move relative to each other. The same concept also extends to noncutting tools such as forming or burnishing tools, photoplotting, additive methods such as 3D printing, and measuring instruments.

An electrical enclosure is a cabinet for electrical or electronic equipment to mount switches, knobs and displays and to prevent electrical shock to equipment users and protect the contents from the environment. The enclosure is the only part of the equipment which is seen by users. It may be designed not only for its utilitarian requirements, but also to be pleasing to the eye. Regulations may dictate the features and performance of enclosures for electrical equipment in hazardous areas, such as petrochemical plants or coal mines. Electronic packaging may place many demands on an enclosure for heat dissipation, radio frequency interference and electrostatic discharge protection, as well as functional, esthetic and commercial constraints.

A fieldbus is a member of a family of industrial digital communication networks used for real-time distributed control. Fieldbus profiles are standardized by the International Electrotechnical Commission (IEC) as IEC 61784/61158.

A complex automated industrial system is typically structured in hierarchical levels as a distributed control system (DCS). In this hierarchy the upper levels for production managements are linked to the direct control level of programmable logic controllers (PLC) via a non-time-critical communications system (e.g. Ethernet). The fieldbus links the PLCs of the direct control level to the components in the plant at the field level, such as sensors, actuators, electric motors, console lights, switches, valves and contactors. It also replaces the direct connections via current loops or digital I/O signals. The requirements for a fieldbus are therefore time-critical and cost-sensitive. Since the new millennium, a number of fieldbuses based on Real-time Ethernet have been established. These have the potential to replace traditional fieldbuses in the long term.