PLC vs PC Based Control Systems

Control System Introduction

A control system is the layer of system integration that controls the inputs (sensors, gauges, etc.) and outputs (motors, pneumatic system, and devices), which is referred commonly as I/O. Control systems have programming in either a PC or PLC based system to receive signals from the inputs, and then command the outputs to perform an action based on the programming. A thermostat is the most basic version of a control system. When the thermostat measures a temperature from the thermometer (input) the air conditioning or heat is turned on (output). Advanced control systems can utilize massive amounts of information to perform more complex methods of control of a machine or system. It can also integrate with other systems to establish more inputs to perform more decisive action. 

The difference between a PLC and PC based control system

A PC based system resides on a common operating system such as Windows or Linux. Sometimes depending on the complexity of the system it can also utilize a database to store information, but often this information is stored in memory. For more complex systems, such as a Warehouse Control System (WCS) or Warehouse Execution System (WES), it also leverages an external software platform that performs all the complex tasks of communication between a Warehouse Management System (WMS) and other integrated automation or devices. 

A Programmable Logic Controller (PLC) is different from a PC because it has its own programming language and is integrated into the control panel where the I/O is located. They are significantly more robust than PC based solutions because that is their only function. They don’t have to manage databases or store information for long periods of time. They only manage the I/O and communicate with external software that tells the PLC how it should perform certain actions. 

Advantage of a PLC based system vs. a PC based system

There are lots of advantages of a PLC based system versus a PC based system. That’s why the market for PLC’s have grown significantly over the last 10 years. The global PLC market is expected to grow by $2.7 billion at a CAGR of 3.51% from 2021 to 2026. The key advantage is simplicity. Controls engineers are capable of understanding, writing code, implementing, and troubleshooting PLC ladder logic significantly faster than PC based programming. Therefore, the implementation timeline for a project or system is reduced. Longevity is also a key factor. PLC based control systems can last decades vs a PC based system has to be replaced based on the support factor of the operating system, which is typically 5 years. In the event you need an upgrade to a PLC based system a conversion kit is available for controls engineers to easily migrate the code from the older PLC to the modern PLC overnight. However, to upgrade a PC based system, it takes weeks or even months, because the newer operating systems require the code to change as well. If you currently have a PC based system expect to spend hundreds of thousands of dollars every 5-10 years to re-commission your system. 

How can we help?

Top Hat Engineers can upgrade any control system to give you a robust warehouse control system.

Top Hat Engineering has significant experience upgrading old conveyor and control systems. Our engineering team is knowledgeable of almost every PC-based control system on the market today, and we feel the pain those older systems are causing you operationally and financially. Our team is here to give you the guidance and knowledge you need to understand how to upgrade your system to give you the longevity you require while increasing your capability. 

Top Hat Engineering only utilizes Allen-Bradley and Siemens PLC based control systems because we want our customers to have a trusted solution that will last for decades not years. We also want our customers to invest their finances in improving their productivity, and not investing it into aging equipment. Our control system architecture can control every aspect of your warehouse, and once integrated with our WES called Clarity, we can give you the comprehensive warehouse system you require to thrive in this demanding market. 

Please contact Top Hat Engineering today at (813) 588-3398 option 1, or email us at sales@tophatengineering.com