PLC vs. PC : Which is Better for Industrial Automation?

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▶ You can read the full post here:

⌚Timestamps:
00:00 - Intro
00:27 - What's a PLC and What's a PC?
01:36 - Differences Between a PLC and PC
03:12 - Advantages of a PLC Over a PC
04:26 - Uses of PLCs
06:15 - Summary

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In this video, we're going to talk about why a Programmable Logic Controller (PLC) is preferable to a Personal Computer (PC) in automation and industrial control systems.

PLCs have been around since the '70s. Original PLCs were single microprocessor devices. They were designed to replace decision-making, hard-wired relays, and timers with a user-created software program performing the required decisions.

All of the field devices monitored and controlled such as switches, sensors, and motors were wired to add-on modules connected to the microprocessor module.

It didn’t take long for the PLC to evolve and include modules capable of analog control and PID-controlled processes.

The PC has also been around for a long time. The term Personal Computer was coined in the '80s as the device was intended to be a single-user desktop computer.

A PLC has a proprietary microprocessor and a unique Operating System.

A PC has an Operating System such as Microsoft Windows, Mac OS, or Chrome OS.

A PLC is programmed using proprietary programming software such as Rockwell Studio 5000, or Siemens TIA Portal. This proprietary software is used to develop programs using one of the IEC 61131-3 standard languages for PLCs.

PC programming is usually done using structured text, and higher-level programming languages like C++.

A major difference between a PLC and a PC is the way each executes a program.

A PLC usually follows a scan-based program execution whereas PC software programs are event-driven.

A PLC is constructed for reliable operation in very harsh industrial environments. It can withstand heat, cold, dust, and other nasty environmental conditions.

A PC was made to sit on a desk or your lap in an environmentally friendly environment.

A PLC was designed with ease of programming and troubleshooting in mind. A PLC is inherently resistant to viruses and cyber attacks as the Operating system is proprietary.

A PC is very susceptible to viruses and cyber-attacks.

A PLC is designed to easily accept expansion. Input/Output Modules can be added to work with more field devices.

PLCs can easily accept modules facilitating industrial communication protocols such as Profibus, CAN bus, Modbus, Ethernet/IP, and others.

A PC is capable of expansion, but not easy to accomplish.

Leading PLC manufacturers include Allen-Bradley, Omron, Siemens, Phoenix Contact, and Schneider.

There’s a new kid on the block called an Industrial PC. It has an Operating System that provides it with the capability to run programs and applications that PLCs can’t.

What separates the traditional PC from the Industrial PC is its design.

Industrial-grade PCs are rated for harsh environments and extreme temperatures and are built to stand up to shock and vibration.

A big advantage of the Industrial PC over the PLC is its programming. An Industrial PC uses the Windows operating system which is recognizable by almost everyone.

Traditional PLC programmers are experts in IEC 61131-3 languages such as Ladder Diagram or Function Block.

A new generation of IT professionals can write control programs for the Industrial PC using higher-level languages like C++.

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#PLC #industrial_automation #realpars

[fernandlust]

And then the poor service engineer sits on site trying to integrate customer requested changes in an industrial PC program. PLC: 15 minutes. PC: one week.

[r_rho]

I've been waiting for this video! Nicely done. Some more content on industrial PC's would be amazing!

[benschemensch]

Great video thanks, but i kind of missed the fact that industrial PCs can be programmed the same way as traditional PLCs with tools such as CoDeSys or TwinCat

[JKTCGMV]

I use your HPHMI videos as a guideline for all my HMI development at work (small-time gigs running on arduinos) and have your HPHMI webpages bookmarked on my work PC

[johnt.]

I've been controlling a distiller using a PC and Labview; Output: Arduino Uno and relay module (Surprincingly very reliable combo). Inputs: Rs232 Weight Indicator, and RS485 temp controllers. No issues for the last 3 years. EMI control techniques is a MUST in this kind of system.

[Techncolorful]

I built PLCs for a living and always wondered this

[schadracktubanamahoro]

Thank you for supporting automation engineers

[JKTCGMV]

I always appreciate how much you interact with your audience through the YouTube comments section!

[mnoxman]

I think of PLCs as being the "minions" monitoring things and alerting me of problems or automatically taking care of some problems. I see the PC as directing many minions.
The problem is a "real time kernel". Unless Microware OS-9 makes a comeback and gets a GUI PLCs have the advantage of being "Real-Time" where as Windows does not have that capability and Linux does have it but it is not simple or reliable yet. In the 80s you u sed things like DOS you made your own custom basic or forth program in the old days to substitute for an OS.

[CThisNikkoStreaming]

Most PLCs ive come across use Pascal, as its an easy language to learn, its pretty straight forward and the easiest language ive come across, but it doesnt hold up as good against other languages, and i preferably would use C++

[dumbtex]

I work with plcs everyday at my job and program on my personal projects using modern microcontrollers using c++ or python, both are awesome in their own ways your video really highlights that. It’s also worth pointing out from my own personal experience the absolute extreme difference in scalability between the two. Plcs are incredibly easy to iterate upon and although industrial pcs are getting better the only way to do it both securely and with the same speed is with an incredible amount of money. Personally I enjoy writing my code using higher level languages because it’s much more capable and shareable, but I think plcs will have their place in one shape or another for a long time to come.

[danielcienfuegos]

Window pc seem to have more issue then all plc I have worked on. I personally prefer PLCs versus industrial PC.

[gbengaoyede]

Can you make a video on industrial pc expansion modules and how it's done?

[falcdprinting]

Can you imagine a plant shutting down because windows is installing updates and needs to reboot ?

I have been in the business of plc programming for 16 years and never have I gotten a request for an automation project running on a pc

[AdaptivePhenix]

Lots of machines die or are sitting idle for the sake of failed, proprietary HMI, which is really dumb when you consider that the most powerful/capable HMI ever created is in most people's pockets. I have been using Android devices (via Bluetooth) for all of my industrial controls for the past eleven years. Android tablet (or switch to a phone in an emergency) talking to a high performance microcontroller (low cost) and galvanically isolated I/O 👍

I also design my boards to use garden-variety, thru-hole components so that in-house techs stand a fighting chance of being able to repair them quickly and inexpensively.

[dzysyak]

I am just wondering, why the most popular operating system - Linux is not mentioned in a video???

[KacperKiler]

Where is LINUX it's know OS, You speak about Using PCs as Controlers what about the Beckhoff its a best example of PLC on windows ?
I don't want to sound mean, have Great day

[fitz]

So in short the benefit of an industrial PC is that it allows you to bypass requirements of IEC-61131? What would be the reasons for wanting to implement IEC-61131 then?

[JKTCGMV]

Do PLC programs accept user input for a GUI well?

[LawFarin]

We just call them IPC’s. Never seen one used as a stand alone controller. Can be done with RIO (remote I/O) over ethernet IP? Our new complex machines that use have them are usually using them for Programs that run the software for all the camera systems we use on our machines.