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PLC, PAC OR IPC?

2023-04-27 3 min read

LinkedIn Facebook Twitter

The vast array of companies producing industrial control systems and the
different lines available from each one can make any manufacturer feel
overwhelmed.

Programmable logic controller (PLC), programmable automation controller (PAC) or
industrial PC (IPC)? With so many options, it’s hard to make an informed
decision. PLCs, PACs and IPCs are all used for the same purpose, that is to
control automation equipment in a manufacturing plant. However, assessing your
application’s needs in terms of size, capacity and compatibility is crucial to
choose the right one to fulfil your automation needs.


A BIT OF HISTORY: THE EMERGENCE OF PLCS

PLCs started to be used in the late 1960s in automotive manufacturing and soon
spread to other sectors where continuous process is required, such as
electronics assembly, food and beverage—for example in bottling and packaging
facilities—and the pharmaceutical industry.

PLCs were introduced to substitute hardware-based relay racks, which had the
disadvantage of taking up a lot of space, consuming massive amounts of
electricity and being very expensive to set up and maintain. In fact, before the
introduction of PLCs, whenever the production process had to be modified
thousands of relays were manually re-wired, an expensive and time-consuming
process.

The first PLC, the Modular Digital Controller (Modicon), allowed to replace
manual rewiring with software program changes. It was designed to be programmed
in a ladder logic, which was similar to the diagrams of relay logic it was
replacing, making the transition from relays to PLCs easier to engineers and
manufacturers.

PLCs started to be commonly used in industrial applications during the 1970s and
early 1980s and since then they have undergone substantial improvements. These
include reduced size, expanded memory and increased processing power. Today’s
PLCs can be very powerful controllers and remain the basic building blocks for
small automation projects.




WHAT IS THE DIFFERENCE BETWEEN PLC, PAC AND IPC?

PLCs have many advantages compared to previous technology and are rugged and
reliable. However, they have a single microcontroller and therefore limited
logic capacity. This makes them unsuitable for complex applications that require
motion control, which can be achieved only by adding separate modules to the
PLCs or by using a hybrid system with one or several PLCs and an industrial PC.
As a consequence, PLCs are ideal for smaller automation projects in which simple
tasks are performed.

PACs offer in fact the same advantages of a hybrid system but without the added
hardware. They mount two or more microcontrollers and have a more sophisticated
logic system than a PLC. As a result, they can operate in multiple domains such
as motion, discrete and process control using a single platform. They also
provide better integration with SCADA, which allows them to manage complex
industry-specific instructions.

Industrial PCs appeared on the market in the 1990s, allowing users to run
PLC-style applications on a regular PC operating system. The first IPCs were not
rugged enough to withstand harsh plant environments and their operating systems
had serious stability issues, but more recent versions have tackled these
problems and are now successfully used in larger applications, alone or in
combination with one or more PLCs. However, if in the 1990s it seemed that IPCs
were about to take over, it is now clear that PACs are leading the field.


WHICH ONE IS BEST FOR YOU?

PACs combine the functionality and reliability of a PLC with the processing
capability of an IPC, which is why they are now the preferred type of controller
in many manufacturing plants. One single PAC can replace several PLCs or a
hybrid system and offer the added advantage of having all applications running
in one single controller.

However, the rule of thumb when choosing a controller is that the size of its
capabilities should match the size of your automation project. In other words,
there’s no need to invest in a PAC or a hybrid system if your automation needs
can be handled by a traditional PLC. Ultimately, if you choose the appropriate
controller for your application’s size and plan some room for expansion, you
will be able to work with it efficiently for decades.

For more information on PLCs, PACs or IPCs, browse our extensive range of parts
today.

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