Programmable logic controllers (PLCs) have long served as the foundation of industrial automation, offering dependable control over a variety of processes and equipment.
However, technical improvements have resulted in various alternatives to PLCs, each of which has its own set of advantages & disadvantages.
This post explains some of the most effective alternatives to PLCs, as well as their advantages and disadvantages.
1). Industrial Computers (IPCs)
2). Embedded Systems
3). Soft PLCs
4). Relay logic
5). Cloud-Based Control Systems
1). Industrial Computers (IPCs)
Industrial PCs, compared to regular computers, are specifically engineered to withstand hard working environments. They are totally functional even in hard conditions, can tolerate vibrations, and have been equipped with superior performance technology for prolonged use.
Advantages
Flexibility: Because IPCs may run a variety of software applications, they can be used for activities that require more than simple control.
Powerful processing: With sturdy hardware, IPCs
Complex calculation: Complex calculations and several activities can be handled at the same time, making it ideal for demanding applications.
Disadvantages
Cost: IPCs are more expensive than PLCs, both in terms of initial investment and ongoing maintenance.
Complexity: Setting up and implementing IPCs can necessitate additional technical knowledge, making them less accessible to some users.
2). Embedded Systems
An embedded system is a computer hardware system with software which is based on a microprocessor and is intended to carry out a specific task, either separately or as a component of a larger system.
Advantages
Customization: The embedded systems can be modified for specialized applications, providing great levels of control & efficiency.
Cost-effective: For easy tasks, embedded systems may be less expensive than PLCs, particularly when mass-produced.
Disadvantages
Limited Scalability: Once an embedded system has been created for a given function, it might be difficult to adapt it to other jobs.
Development Time: Developing a custom embedded system takes time and requires significant engineering resources.
3). Soft PLCs
Soft PLCs are software-based versions of programmable logic controllers (PLCs). The word Soft PLC has been around for a long time, & like many technical terminology, it implies something different to everyone.
Advantages
Software-based PLCs run on conventional PCs or servers, lowering hardware costs and facilitating upgrades and adjustments.
Integration: They can simply integrate with existing IT infrastructure & software applications, improving data accessibility.
Disadvantages
Reliability: Soft PLCs may be less robust than standard PLCs, which can be an issue in tough industrial applications.
Delay Issues: Depending on the system, soft PLCs may exhibit increased delay in real-time applications.
4). Relay Logic
Electrical circuits can be controlled using relay logic, which uses relays wired in a particular way.
Relay logic develops electrical circuits that carry out activities such as counting, timing, switching, and logic using electromechanical relays.
Advantages
Simplicity: Relay logic systems are simple to understand, making them ideal for basic control applications.
Low Cost: Relay systems are often less expensive than PLCs, making them an economical choice for simple applications.
Disadvantages
Limited Functionality: Relay logic has less versatility than
Data Management: PLCs can’t handle sophisticated processes (or) data management.
Space & Maintenance: As systems become more complicated, relay panels may become bulky and difficult to maintain.
5). Cloud-Based Control Systems
Cloud-based control systems involve choosing and predefining compute, network, storage, and other sources to meet system needs. In addition to virtualization, software program significance, and dispersed design, it recognizes modularized smooth scale-out and develops a software-driven environment using multiple sets of networked standard equipment based on existing hardware components. Providing the best hybrid cloud deployment solution via the cloud management & control platform.
Advantages
Remote Access: Cloud-based technologies provide users benefit from remote monitoring & control, which allows for greater flexibility and convenience.
Scalability: These systems can quickly expand to handle growing activities without requiring major hardware upgrades.
Disadvantages
Internet Dependence: Cloud-based solutions require consistent internet access, which can be a challenge in rural places.
Security Concerns: Transmitting data via the internet introduces possible security concerns, demanding strong cybersecurity protections.