Choosing The Appropriate Industrial Automation Controller For A Process

Industrial applications require the controlling equipment, including enclosures and panels, for many different reasons. These panels (offered by reputed and credible control panel manufacturers) can provide for cost effective operations and convenient controls as well. With the adoption of digital computers and the availability of new technologies, we now have the Programmable Logic Controller (PLC) panels and systems that can be used to control many different processes of an industrial facility.

Choosing The Right Automation Control System

The Programmable Automation Controller (PAC), the Industrial Personal Computer, and the Programmable Logic Controller are all designed to control particular processes and the unique constraints of the manufacturing environment. However, there can be subtle differences between these automation controllers. For instance, a PLC may have a simpler execution for programs. At the same time, the PAC uses advanced computer languages, including C++ or C. Therefore, a PAC can be more versatile with its open architecture. The memory on a PLC is limited, and the input and output are discrete. That is why the PLC is preferred for smaller automation operations and is a cost-effective choice. The large scale automation programs and architectures (which are more complicated) may utilize the PAC.

Automation can also be broken down into smaller compartments when a more modular approach is required. However, In the integrated production and manufacturing systems, a single and large controller is enough for complete control. It communicates via the Ethernet includes all the remote input and output controllers and bases. Below are some other factors to consider when choosing an automation controller for your industry.

Input-Output Count

There can be many different inputs and outputs, including analog sensors, digital sensors, control valve actuators, and others. While most industries choose the right controller following their present requirements, they do not evaluate the requirement that they may have in the future. Other considerations for automation control include determining the appropriate real-time communication processes as well as the physical location of the different input-output terminals.


Many new-age plants require that the enterprise systems, PLC, and the input-output systems have proper communication channels among them. Communications may also take place between the HMI or Human Machine Interface and controllers. Internet-of-things and sensors are new additions, and hence open communication options should be preferred.

Hardware and Software

Some of the essential hardware requirements in an automation controller may relate to battery backup., memory amount, and the speed of the scanning time. The quality of the software is of immense importance as well. It should provide for convenient use and possess the training resources. Other vital considerations here may include remote access, data logging, and preferences. The controllers with convenient programming languages and software can be preferred for simple operations, but other avenues should be considered when the requirements are more complex.

Talking to a leading control panel manufacturer will solve many of your dilemmas. However, you should gather the different details of your processes before approaching one.