More modern smart control technology like programmable logic controllers (PLCs), programmable automatic controllers (PACs), and industrial PCs (IPCs) are better equipped to handle these demands. Controllers are crucial in an automated system, as they are responsible for sending signals in order to execute an action.

However, PLCs, PACs, and IPCs are often mistakenly interchanged. While they serve a similar purpose, it’s important to choose the right controller that will best fit your use case. This guide explores the pitfalls of using old technology and how to find the smart control system for your needs.

Disadvantages of Old Technology

1. Frequent Downtime Leading to Production Delays
   

   Older machines are more prone to malfunctions, crashes, and unplanned downtime as components wear out over time. As machines age, the risk of failure increases, and finding replacement parts for outdated systems can become increasingly challenging. 

   This leads to longer repair times and longer periods of machine inactivity, which, for manufacturers, disrupts production and becomes more costly. 

2. Cybersecurity Vulnerabilities
   

   Another disadvantage of older industrial machinery is its vulnerability to cyber threats. Most outdated systems lack modern cybersecurity features, making them an attractive target for hackers. 

   Malware, ransomware, and data breaches can expose a company’s sensitive information and disrupt operations. Cyberattacks on manufacturing plants can halt production altogether, leading to costly repairs and loss of valuable data.

3. Manufacturing Compliance Issues
   

   According to the Australian AS4024.1501 Safety of Machinery rules, outdated industrial equipment may not meet current safety, environmental, or regulatory standards. Under these regulations, machinery and equipment must be designed and built to prevent failure. Failure to replace outdated equipment could increase risks and compromise critical safety systems.

PLC vs. PAC vs. IPC: How Are They Different?

Choosing a controller will depend on the application. PLCs and PACs are similar in function, however, a PAC will have additional features. Meanwhile, an IPC can run the same software that a PAC does, but it will come with the features of a traditional PC.

To better examine these features, let’s look at the use cases of the three, and their application focus.

PLCs

PLCs are typically used to control a relatively small number of I/O. They can communicate with network devices, but will need add-on modules to expand their functionality. The expansion can help the PLC accommodate a wider range of communication protocols, upgrade its internal storage, and even help with additional functions, such as motion control and temperature control.

IPD has a selection of PLCs that can support industrial machinery. For example, the IDEC MicroSmart FC6A PLC has a 2,060 I/O capacity, perfect for demanding environments. The FC6A Plus also comes with embedded web server functions, supporting EtherNet/IP™ protocol.

PLCs are ideal for straightforward applications, with the ability to control I/O for reliability and optimisation. It can be used in discrete manufacturing or for basic automation tasks.  

PACs

While PLCs operate better on simpler applications, PACs thrive in more complex systems. PACs have better processing power and memory than PLCs, which allow them to be more suitable for larger processes and accommodate the integration of multiple systems.

PACs are well-known for their ability to be programmed in languages more structured than ladder logic, which is what PLCs use. The Emerson PACSystems™ RSTi CPE20 compact controllers, for instance, offer open programming and open communications to simplify connectivity to traditional sensors and external analytics platforms.

PACs also tend to come in modular design, so then can handle communication with a wide variety of network devices and can even work with remote I/Os, remote panels, and drives.

IPCs

If you need a more robust system to support your automation process, IPCs are the best choice. They offer the same benefits that PACs do, but they provide more capabilities, such as the ability to run middleware. Alongside its functions as a controller, IPCs can run software such as SCADA, MES, protocol converters and more.

The Emerson RXi2-EP is an industrial powerhouse that offers mid-range computing capabilities to run HMI, historian, and analytics applications. It is the ideal choice for working with big loads of data, with high-speed Ethernet ports for fast data transfer and communication.

However, IPCs tend to rely on operating systems such as Windows or Linux, which might not always be optimised for demanding industrial applications. On the other hand, PLCs and PACs are better equipped to handle those demands as soon as they are running. 

Boosting Industrial Productivity with Smart Control Systems

Understanding the best use cases for PLCs, PACs, and IPCs will help optimise automation processes and ensure that it gets the support it needs. For robust but simple, standalone machinery, PLCs are the perfect choice. For complex networks, PACs are preferred. And, lastly, to get additional functionality, IPCs will work great.

By finding the right smart controller, manufacturers can unlock the full potential of their industrial machines, driving productivity improvements, cost savings, and enhanced competitiveness in the market.  

IPD offers a comprehensive range of high-quality controllers, including a variety of PLC, PAC, and IPC products. These controllers are designed to suit various industrial applications, providing reliable and efficient control solutions. To learn more, get in touch with us today at 1300 556 601 or visit our website.