PLCs are, and will continue to be used heavily in industrial sectors, automation, manufacturing, and

public infrastructure (like wastewater treatment, electric utilities, gas utilities, traffic control
systems, bridge and railroad controls, etc). PLCs are a popular option because of a few key points…

A.) They are robust to withstand harsh environments commonly found in an industrial setting, such
as widely varying temperatures, humidity, electromagnetic interference (EMI) noise, current flows,
and shocks and vibration. Most PC based systems would not stand well in this kind of environment.

B.) PLCs are dedicated controllers meant to run the specific application code for the machines task
and in real time. In a PC based system, there may be a delay from when an input is given, until a
desired output is achieved. A PLC is meant to process information in real-time and adjust or react to
the process very quickly, usually within milliseconds (mS). In a motion controlled or process
controlled environment, missing an input or not actuating an output in time could mean the end of a
critical manufacturing process, loss of profits, life, or a major event like a fire, overflow of a tank, or
an explosion.

C.) PLCs do not freeze up like PCs do. The PLC is meant to just loop through all of the code endlessly
and is dedicated to that specific task. PLCs may halt due to a major or minor error, that may stop the
processor from executing code (this is usually due to poor programming, such as a math overflow,
infinite loop, watchdog scantime error, or buffer overflow). When this halt happens, there is other
code that can be programmed to help properly shut down the process in a safe manner.

D.) You may see HMI servers like Rockwell’s Factory Talk View Site Edition or Wonderware. These
are SCADA applications (Supervisory Control and Data Acquisition) that are meant to communicate
with the PLC at a higher level in the MES pyramid (Level 2). The PLC does the dirty work on the
manufacturing floor or an industrial environment, the SCADA server or PC sits in a nice clean Server
room/datacenter at Level 2 in the MES pyramid. The different PLCs are controlling processes on the
plant floor or other industry and the SCADA system is monitoring and allowing supervisory control to
operators, technicians, and engineers.

E.) PLCs will continue to remain popular because a large sum on the code is written in ladder logic
and is very familiar with most of the technicians and electricians that can read ladder logic and
electrical blueprints. It gives them enough of a tool to go online with a processor with at least read
access and troubleshoot why a process is not working, such as seeing a sensor is not on or a motor
contactor is not starting. It is more cost effective to have a team of technicians rather than full time
engineers to open the program every time there is a problem. PLCs support is also heavily invested
in by various manufacturers of industrial hardware, such as supporting add on code and instructions
and drivers to specific PLCs.
F.) Finally, depending on the model you chose, some PLCs may be very economical and cost effective
for controlling a small machine rather than the cost of paying 5–10 times more for a PC based
system, that would also require additional hardware to interface with hardwired IO systems.