As a business manager or owner, you must have wondered about the brains behind industrial automation. Two key players in this rapidly evolving landscape are Programmable Logic Controllers (PLCs) and Industrial PCs. These devices are known for their ability to seamlessly operate countless manufacturing processes.
But what are the underlying differences between the two? You must be aware of these differences before investing in any one of these industrial automation solutions. So, gear up to explore the differences between a PLC and an industrial PC.
What is PLC and Industrial PC?
Before jumping to the differences between the two, let’s start with the basic and understand these devices first.
A Programmable Logic Controller (PLC) is an industry-level programmable computing device used to automate manufacturing processes. To summarize, a PLC functions like the brain of an industrial automation setup, controlling and monitoring the functioning of input devices. Besides this, it also handles decision-making, which controls the functioning of input devices.
It was developed in the 1960s and has since been an integral part of industrial automation. The best part about a PLC is that it’s modular, flexible, and robust, which makes it perfect for all applications across various industries.
From manufacturing production to automobile automation, it’s used in a wide range of industries, including the steel industry, food processing systems, etc. A PLC has some pre-programmed parameters, allowing it to control many processes from one location at once.
Now, let’s look at what an industrial PC is. An industrial PC (IPC) refers to more technologically advanced and robust computers that are designed specifically for industrial purposes. Industrial PCs are more reliable and dependable, built to work under tough conditions with exceptional precision.
Do you think that an industrial PC works differently than your desktop or laptop? Well, not exactly. Both of them use the same technology and devices. The only difference between them is the processing power and other technological advancements made to the basic desktop version.
Industrial PCs can perform a wide range of functions, including process control, data acquisition, etc. Moreover, they are also flexible and can be customized to meet the specific functional demands of the industry. It’s why you’ll find an industrial PC in every industry, from water treatment plants to the transport industry.
Differences between PLC and Industrial PC
Both PLC and industrial PC are used in industries. But what are the underlying differences between the two? Let’s explore.
1. Working
The working of a PLC involves a real-time operating system and some pre-programmed parameters, using which it receives input from various connected devices. Then, it uses the parameters for decision-making. The operating system plays a crucial role in its functioning and is designed specifically to limit the functionality of a PLC for control purposes.
On the contrary, an industrial PC also works using an operating system. But it’s more flexible, which allows it to be used for applications other than control. However, its wide functionality also comes with a vulnerability to cyberattacks.
2. Size & Build Quality
PLCs are huge and difficult to mount. Moreover, even if you successfully mount one, its heat dissipation will be limited, which will lead to overheating. However, industrial PCs win here due to their compact size and features, which make them perfect for an industrial environment. Some of these features include its wide temperature range, fanless design, high IP rating, etc.
3. Storage
PLCs typically have limited onboard storage compared to industrial PCs. The storage capacity of a PLC is typically sufficient for storing the necessary program instructions and data specific to the automation task at hand. PLCs are designed with non-volatile memory, such as flash memory or battery-backed RAM, to store the logic and program code.
On the other hand, industrial PCs can incorporate larger storage capacities, including hard disk drives (HDDs) or solid-state drives (SSDs), which enable them to store extensive amounts of data, software applications, and operating systems.
4. Programming
Industrial PCs use common, easy-to-handle programming languages such as .NET, C, etc. Moreover, their operating systems include the widely used ones, such as Windows or Linux.
However, PLCs use proprietary vendor language, which is specifically mentioned in the IEC 61131-3 standard. Thus, to use a PLC, you will need technical assistance from an expert. Whereas working with an industrial PC is as easy as handling your desktop or laptop.
5. Processing Power
PLCs are equipped with microprocessors designed for real-time control tasks. These microprocessors are optimized for executing ladder logic, function block diagrams, or other programming languages used in industrial automation. While PLCs excel at managing high-speed I/O and handling smaller automation projects, their processing power is generally limited compared to industrial PCs.
Like workstation computers, industrial PCs feature more powerful processors that provide greater computational capabilities. These processors can handle computationally intensive tasks, such as complex mathematical calculations, data analysis, and running resource-demanding software applications.
6. Security
Compared to industrial PCs, PLCs are much more secure as they have a strict operating system that is quite difficult to tamper with. However, industrial PCs now come with TPM 2.0 embedded on their motherboards for advanced security.
7. Expansion Capabilities
Programmable Logic Controllers(PLCs) and Industrial PCs differ in terms of expansion capabilities. PLCs typically have limited expansion options, often relying on dedicated modules for specific functions.
In contrast, Industrial PCs offer more versatile expansion capabilities through their expansion slots. These slots allow for the addition of various hardware components, such as wireless cards, 5G modules, SSD storage, and GPU accelerators. This flexibility enables Industrial PCs to adapt to evolving technological requirements and consolidate multiple functions within a single system.
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FAQs: Difference between PLC and PC
1. What is a PLC?
A Programmable Logic Controller (PLC) is an industry-level programmable computing device used to automate manufacturing processes.
2. What is an industrial PC?
An industrial PC (IPC) refers to more technologically advanced and robust computers that are designed specifically for industrial purposes.
3. Discuss the processing power of a PLC.
PLCs are equipped with microprocessors designed for real-time control tasks. While PLCs excel at managing high-speed I/O and handling smaller automation projects, their processing power is generally limited compared to industrial PCs.
4. Which of the two has better expansion capabilities: PLC and industrial PC?
PLCs (Programmable Logic Controllers) and Industrial PCs differ in terms of expansion capabilities.
5. Which of the two has better security features: PLC or industrial PC?
Compared to industrial PCs, PLCs are much more secure as they have a strict operating system that is quite difficult to tamper with.
Wrapping Up
Both PLCs and industrial PCs are key drivers in the field of automation and control systems. But they do have some differences. To sum up, PLCs offer robustness, real-time control, and reliability. This makes them ideal for industrial applications with high demands for stability.
On the other hand, Industrial PCs provide versatility, scalability, and advanced computing capabilities. This makes them suitable for complex processes that require extensive data analysis and integration with various software applications.
So, explore more of these devices before choosing the right one for your business. Also, to help you in your industrial automation journey, we present to you our solution, QodeNEXT. Get in touch with us now to help you make the best choice to manage your fleet and optimize your process!
