“The paradigm shift by manufacturing plants to PC-based controls is a major challenge to the PLC industry,” says a research report from Mindbranch, which apparently thinks highly of PC-based control in industrial environments. “Higher processing power and lower costs for commercial PCs will accelerate the shift to PC-based systems, which will facilitate more advanced networking among fundamentally different controllers. PACs combine PLC ruggedness with PC functionality in an open, flexible software architecture.”
Not so fast, my friends. PLCs have evolved to incorporate analog I/O, communications over networks and new programming standards such as IEC 61131-3. Engineers create 80% of industrial applications with digital I/O, a few analog I/O points and simple programming techniques. Experts from ARC Advisory, Venture Development Corp. (VDC, vdc-corp.com) and the online training source PLCs.net estimate that 77% of PLCs are used in small applications of less than 128 I/O, 72% of PLC I/O is digital, and 80% of PLC applications are solved with a set of 20 ladder-logic instructions.
The PLC market is alive and well for smaller applications, where PACs might be overkill.
The growing market in China also propels PLC growth. “Global economic integration and increasing domestic demand contribute to the emergence of China as the world’s manufacturing hub,” writes Senior ARC Analyst Himanshu Shah. “The fiercely competitive market and the need to improve productivity drive manufacturers to think strategically and increase investments in new technology. “
VersaMax Micro 64 controller supports a connectable memory module to download program changes without a PC. Logic Developer PDA software lets users interface a Palm handheld device to the VersaMax Micro 64. With Logic Developer PDA, users monitor/change data, view diagnostics, force ON/OFF and configure machine setup.
GE Fanuc Intelligent Platforms
800/gefanuc
IndraLogic VE integrates all functions required for automation, controls and diagnostics. With the PLC integrated with the HMI, IndraLogic VE reduces components and cabinet size, and simplifies wiring. Open, industry-standard software-based PLC kernel is hard-realtime.
Bosch Rexroth
847/645-3600
FP-X PLC provides 32 msec per instruction, 32K steps program memory and up to 382 I/O points in a compact brick. Digital I/O, Pulse I/O, analog and communications can be snapped onto the CPU. It has built-in high-speed counters, four axes of motion, USB connection, built-in power supply and removable terminals.
Panasonic Electric Works of America
908/464-3550
PC Worx-programmable ILC 150/155 ETH embedded controllers have eight digital inputs and four digital outputs onboard. Ethernet port allows data exchange to a supervisory system. The I/O can be expanded and the controller can be programmed in several IEC 61131 languages.
Phoenix Contact
717/944-1300
CompactLogix L45 controller can handle eight axes of motion and supports DeviceNet, ControlNet and EtherNet/IP, enabling interaction and data flow from the smallest device up to the enterprise system.
Rockwell Automation
800/223-5354, ext. 2034
CONTROLLER+COMPUTER
eZMP stand-alone controller integrates motion with an expandable, upgradable industrial computer. It supports 64 axes of motion and 17,000 I/O points with Ethernet, USB, video and PCI connectivity. The device also is a SynqNet motion network master for plug-and-play SynqNet amps and devices.
Danaher Motion
866/993-2624
MicroSmart Pentra microcontroller can process basic instructions in 56 nsec. It has field-upgradable firmware and up to seven communication ports. Brick design has 10, 16 or 24 I/O; it has a slim book type for 16 or 32 I/O; it can be customized using add-on modules.
IDEC
800/262-4332
100 Mbit/s 750-841 Ethernet TCP/IP programmable fieldbus controller has a 32-bit RISC processor, 512 KB program memory, 256 KB data memory and 24 KB of retentive memory to connect I/O to Ethernet. It supports HTTP, XML, SOAP, DHCP, DNS, FTP, SNMP and SMTP for connectivity to the machine level.
Wago
800/din-rail
Snap-PAC-S2 industrially hardened, standalone, multi-serial port, dual-Ethernet interface, programmable controller has four serial ports for RS232 or RS485 serial communication and an RS232 point-to-point modem connection for communication over leased lines, radios and cellular networks.
Opto 22
800/321-6786
Simatic S7-200 micro PLC has four and eight-channel modules. EM231 eight-channel analog input module supports unipolar 0-10 Vdc, 0-5 Vdc, 0-20 mA and bi-polar ±5 Vdc, ±2.5 Vdc input signals. EM232 four-channel analog output module supports 0-10 Vdc and 0-20 mA signals; EM231 TC eight-channel thermocouple temperature input module supports seven thermocouple sensor types.
Siemens Energy & Automation
800/Siemens
ELC logic controller has several modules, four controller styles, 1 to 32-bit instructions, remote communication, connectivity to drives and I/O and built-in display. Unit is DIN-rail mountable.
Omega Engineering
203/359-1660
cRIO-9072 and cRIO-9074 CompactRIO systems have an integrated hardware architecture that combines an embedded real-time processor and a reconfigurable FPGA. Engineers can design, prototype and deploy the customizable, commercial off-the-shelf (COTS) hardware systems for embedded machine control and data acquisition systems using LabView.
National Instruments
888/280-7645
CPX/FEC modular terminal with an embedded PLC has IP65/IP67 protection with no need for a cabinet, has 10/100 mps Ethernet, email, OPC and Web server capability, 512 in/512 out with analog and digital I/O, 250 Kb of program memory at 10 bytes per instruction, 1-2 ms per 1K instructions and graphical programming tool in statement list and ladder.
Festo
631/435-0800
EMBEDDED CONTROL
DIN-rail mounted CX1030 embedded PC has a 1.8 GHz Intel Pentium M processor with a cooling module and an exchangeable fan cartridge. It has 256 MB DDR RAM, expandable to 1 GB, boots from Compact Flash with cards up to 4 GB, and two Ethernet RJ 45 interfaces. Operates on Windows CE or XP Embedded.
Beckhoff Automation
952/890-0000
A STRON PULSE
PCM-3240 four-axis stepping/pulse-type servo motor control card simplifies stepping and pulse-type servo motor control, providing added motor performance and fits into a standard PC/104 board, eliminating mechanical interference in the embedded controller. The card’s MCX341-motion ASIC provides 2/3-axis linear interpolation, two-axis circular interpolation and T/S-curve acceleration/deceleration rate.
Advantech, eAutomation Group
800/205-7940
STAND TOGETHER
Ensemble Epaq stand-alone controller for applications from laboratory experimentation and general-purpose positioning to advanced OEM systems controls up to six axes of motion control, and if users need higher current or voltage levels than the integrated amplifiers provide, standard Ensemble drives can be interfaced to operate motors up to 30 A peak power. It can mix and match drive types in the same positioning system using a common programming and control platform.
Aerotech
412/967-6854
FIXED I/O PLC
DL05 and DL06 fixed I/O PLCs can perform motion control applications. For simple counting, positioning with steppers, PLC models with DC I/O support high-speed input or pulse outputs directly from their built-in I/O points. Expansion slots accept analog I/O or an independent high-speed counter module for servo applications.
AutomationDirect
800/633-0405
X20 CPU features a 100 Mbps Ethernet interface for use as an online interface or networking. A CAN and RS232 interface is integrated into the system, which can be rack-mounted. An extended CPU can be used if separate Ethernet, CAN or RS232 interfaces are necessary. It’s equipped with a 25 mm slot for Profibus-DP, CANopen and DeviceNet interface modules to be used.
B&R Industrial Automation
770/772-0400
Solves-It! analog plug-in PLC provides a solution where a small logic controller is required. It programs in ladder logic with function block using PC-based EZ Ladder Lite software included free. The unit accepts 0–5 Vdc differential input. There are two outputs and four others usable as inputs or outputs. One input can be used for a high speed counter. Two potentiometers allow for adjusting setpoints mechanically. Comparison statements can be used within the ladder program for fixed setpoints in a program.
Divelbiss
800/245-2327
MAKE THE MOVE
NextMove e100 motion controller provides real-time control, onboard analog and digital I/O and a USB port for simple connection to PC hosts with ActiveX support tools. It includes support for three traditional analog-controlled servos and four steppers and a CANopen interface for adding local or remote I/O or other components. It links seamlessly into local and wide-area networks and provides simpler system building and commissioning.
Baldor
800/828-4920
EZTouchPLC combines the original EZTouch panel with the functionality of a micro-modular PLC. It integrates users control and visualization needs into one total device for a small to medium machine that requires a touch-type graphical display.
EZAutomation
563/359-7501
FUNCTIONAL, EXPANDABLE
CP1H high-speed micro PLC delivers motion and position control and communications capability. It has four axes of servo motion control, integrates process data with sequential control and uses high-speed multi-axis counter inputs and pulse outputs to calculate inverter positioning and drive chain control.
Omron Electronics
886/88-omron
REAL-TIME MOTION CONTOL
ACR9000 controller processes floating-point calculations onboard in the 100-500 ms range, allowing the controller to serve as a preemptive multi-tasker with up to 24 programs simultaneously. It can handle four communication channels concurrently, allowing communication with the controller for troubleshooting, while leaving the HMI on a production machine fully online and active.
Parker Compumotor
707/584-2541
DAPserver is a PC-based real-time controller in a network-ready package. Web site has code you can copy: practical controls require only 20 lines of code—and users have access to modify the controller for special needs. Additional features include coordinated multi-channel measurements, offloaded statistical analysis, intelligent data selection and alarms.
Microstar Laboratories
425/453-2345
MULTI-LEVEL PLC
Telemecanique Modicon Premium programmable logical controller has multiple CPU levels, plug-and-play rack support and communication protocols, plus memory upgrades. It has integrated multi-axis interpolated motion control, integrated safety relays and reflex functionality. Diagnostic and maintenance capabilities include diagnostic function blocks, run-time screens and field-exchangeable memory.
Schneider Electric
847/397 2600
MOVI, MOVI
Movi-PLC slimline controller integrates PLC control and motion control. IEC 61131-3 and PLCopen motion standard-compliant, the configuration software includes a library of tested standard control and motion function blocks to help set up applications. The basic class manages up to 12 axes synchronously over the system bus. Advanced class handles 64 axes.
SEW-Eurodrive
964/439-8792
MACHINE CONTROLLER PLUS
MP2200 machine controller combines with MotionWorks v.6 to provide a larger, more-configurable rack system with nine slots. Other extended features include 233 MHz CPU, removable Compact Flash memory, USB serial interface and the ability to control up to 256 axes.
Yaskawa Electric America
800/yaskawa
Blue Fusion Model 5300 web-enabled controller lets users choose from multiple CPUs and a variety of analog and digital I/O as well a a motion module to provide a complete machine control solution. Up to 1,024 I/O and 64 axes of motion control can be controlled by a single 5300 system. All models have multiple serial and Ethernet ports for enhanced communication and networking.
Control Technology
508/435-9595
EIGHT IS ABOUT ENOUGH
RMC150E CPU module works with company’s I/O and is programmed using RMCTools software for fluid power and electric servo motion control applications. The CPU can handle eight synchronized axes, and eight dual-loop position-pressure/force axes and reference axes.
Delta Computer Systems
360/254-8688
FUTURE-PROOF PLATFORM
PSS universal communicates via standard fieldbus systems combined with SafetyBus p. Head modules connect to all common fieldbus systems, enabling a structure of decentralized inputs and outputs with pure standard control functions or, in conjunction with SafetyBus p, with pure safety functions. The system meets Cat. 4 in accordance with EN 954-1 or SIL 3 in accordance with IEC 61508, as well as other international standards.
Pilz Automation Safety
734/354-0272
