The manufacturing sector is always looking for new and better ways to process raw materials and assemble products. From the earliest assembly lines to today's data-driven networks, businesses always want more efficient and flexible tools to get the job done.
For many manufacturers, the best way to achieve this efficiency is with programmable logic controllers (PLCs) and industrial-grade PCs. While these devices operate on similar principles, understanding their diverging roles and strengths is critical to using them correctly.
What Are PLCs?
A programmable logic controller is a very basic computer most often used in industrial automation. First implemented in the 1970s, PLCs are equipped with non-volatile memory used to save control instructions as well as input/output ports that let them receive data and send instructions.
PLCs are most typically used in simple roles that have little variance or unpredictability associated with their operations. For example, automated gate systems use PLCs to control the gate's opening and closing. When the PLC receives a recognized input (such as an authorized code for entry), it commands the gate's motors to activate and open the way (the pre-programmed output). Once a certain period of time or a new input comes in (such as other sensors recognizing when the vehicle has passed through the gate), the PLC orders the gate's motors to close it.
Industrial PCs
PLCs share an operational environment (and, frequently, roles) with industrial-grade PCs. It's important to understand that industrial PCs are a far cry from the standard consumer-grade PC you find at electronics stores. Industrial PCs, whether they be an all-in-one or rugged mini PC, come with industrial-level certifications and testing, such as IEC 60068.
They also integrate features such as fanless cooling for better reliability and a wide range of I/O ports that allow the PC to communicate with various other devices.
How Do PLCs Compare to Industrial PCs?
Comparing a PLC to an industrial-grade PC is like comparing a chihuahua to a rottweiler; they have the same basic concept but vastly differ in scale and power.
Storage Space and Memory
One of the biggest limitations of PLCs is their lack of storage space and memory. Most PLCs only have enough memory to store their operating instructions for whatever their assigned task is.
On the other hand, industrial-grade computers can be equipped with gigabytes worth of RAM and terabytes of storage space. This allows them to store and run more complicated programs and handle a greater variety of responsibilities.
Processing Power
One significant advantage of industrial PCs is that they are equipped with powerful CPUs that allow them to process and analyze greater amounts of data. This, in turn, lets them handle more complex responsibilities, such as managing an entire assembly line rather than just a single machine on the line.
By comparison, the microprocessors used by PLCs are far more basic and less powerful. While this makes them less expensive, it also makes them less capable in terms of raw computing power.
Flexibility
Another aspect to consider about PLCs is that they are designed and programmed for a specific task and cannot easily be repurposed. A PLC in charge of an automatic gate system cannot be reused as an assembly line manager, for instance.
Industrial PCs use popular operating systems such as Windows and Linux to manage their software, allowing them to collaborate with a broader range of programs and devices. As long as the PC has the correct software and I/O ports, it can be disconnected from one workstation and redeployed at another with minimal issues.
Find the Right Solution with Cybernet's Industrial Computers
Both PLCs and industrial-grade PCs have a role to play in a modern manufacturing environment. PLCs are best used in applications with low processing power and data management requirements. Meanwhile, industrial PCs are better suited for high-demand roles or managing multiple tasks simultaneously.
If you're looking for industrial-grade PCs that can fulfill a variety of roles for your business, contact the team at Cybernet Manufacturing. Our range of industrial-grade tablets, mini PCs, and AIOs can cover any requirements you might have and can be further customized to fit your needs.
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