INTRODUCTION

A PLC is a ruggedized, digital industrial computer control system that is preprogrammed to carry
out automatic operations in industrial processes. The PLC continuously monitors and receives
information from input devices or sensors, processes the information, and triggers the connected
output devices, to complete the task in the industrial process or machinery. Programmable
Controllers are similar to industrial computers. PLCs can work as standalone units that can
continuously monitor and automate a process, specific machine function. PLCs can be
networked; such a network can control an entire production line. PLCs can be adapted to monitor
and control many sensors and actuators; they process electrical signals and use them to carry out
preprogrammed commands for almost any application. PLCs are used in industrial automation to
increase reliability, system stability and performance, minimizing the need for human operators
and the chances of human error.

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 OBJECTIVE OF THE PROJECT
The primary objective of this project report is to conduct a comprehensive analysis and
comparison of commercially available Programmable Logic Controllers (PLCs). The report aims
to provide valuable insights into the key features, functionalities, and performance metrics of
PLCs offered by major manufacturers in the industrial automation market. By examining and
evaluating different PLCs, the report seeks to assist decision-makers and professionals in
selecting the most suitable PLC for specific industrial applications. Additionally, the report aims
to highlight emerging trends in PLC technology and anticipate future developments in the field
of industrial automation.

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 PLC OVERVIEW
A programmable logic controller (PLC) is a small, modular solid state computer with customized
instructions for performing a particular task. PLCs, which are used in industrial control systems
(ICS) for a wide variety of industries, have largely replaced mechanical relays, drum sequencers
and cam timers.

PLCs are useful tools for repeatable processes because they have no mechanical parts and they
can gather information. Each central processor unit (CPU) continually loops through an input
scan, program scan, output scan and housekeeping mode, repetitively performing a single task
while monitoring conditions. The information the controller gathers can be used as feedback to
guide needed changes and improvements to processes, some of which can be performed
automatically according to the device’s coding.

PLCs take up less space, perform more complex tasks and are more customizable than the
mechanical technologies they have replaced. They are known for their ability to operate
continuously without maintenance and have had a great impact on digitizing a great many
industries, particularly manufacturing. The first PLC, for example, was invented by Dick Morley
in 1969 for General Motors and performed uninterrupted for 20 years before being retired.

Five programming languages are used to code PLCs, as specified by International

Electrotechnical Commission (IEC) 61131. They are Ladder Logic, Function Block Diagram
(FBD), Structured Text (ST), Instruction List (IL) and Sequential Function Chart (SFC). Should
significant code changes be required and the PLC's memory is embedded, the controller can be
recoded in place. When the PLC's memory is not embedded on the circuit board and significant
code changes are required, the memory can be removed from an exterior slot on the PLC and
replaced without requiring the assistance of a programmer on site.

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 List of best PLC manufacturers

1. Siemens
2. Rockwell Automation
3. Mitsubishi Electric
4. Schneider Electric
5. ABB
6. Honeywell
7. Bosch
8. Omron
9. Fuji Electric
10. Hitachi
11. HIMA
12. Delta Electronics
13. Eaton
14. Panasonic
15. Toshiba
16. Yokogawa
17. Phoenix Contacts
18. Fatek

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1. Siemens
Siemens is a German based industrial manufacturing company and their PLC brand
name is Simatic. By using a Simatic PLC we can control many automation processes in
the industry. In this type of PLC, the field devices are connected through Profibus, the
programming language which will be used to do the program will be ladder logic.

List of Siemens PLC models

 S5 – Step 5
 S7 – Step 7
 STEP 7 – S7 -200, S7 -300, S7-400, S7 – 1200, S7 – 1500

Major features

Predictive maintenance

In the Simatic PLC, there is a machine learning algorithm that is capable to collect a lot
of critical data from the process and due to this ability, the Simatic PLCs are capable to
detect any machine problem before it could occur. Some examples of the data which
would be gathered to do the preventive maintenance will be the rotation speed of the
spindle and also the required power for the drive system.

Performance insight app

This is another feature of the Simatic PLC there is a Simatic performance insight app
which is developed in the siemens Mind-Sphere platform. The advantage of this app is
that the operator doesn’t need to be around the computer for the whole day. In case if
there is any variation in the threshold then the mind-sphere would send a message to
the operator’s device.

2. Rockwell Automation

Rockwell Automation is an American based industrial manufacturing company. The PLC

brand of Rockwell automation is Allen Bradley. Allen Bradley makes PAC as well as PLC.
The major types of Allen Bradley PLCs are MicroLogix, CompactLogix, and Control Logix.
We can use an Allen Bradley PLC for complex and simple applications.

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 List of Rockwell Automation PLC models

 Large PLCs – ControlLogix -5580, 5570

 Small PLCs – Compact Logix -5380, 5480, 5370, 5580
Smart guard-600, SLC -500

 Micro PLCs – Micro- 870, 850, 830, 820

Large, small, and micro-PLC’s

Large PLC’s

The large PLCs are controllogix5580, and controllogix5570. The major feature of the
Control Logix 5580 is high-performance communication and motion control. The major
feature of the Control Logix 5570 is that it offers good safety, and it can handle extreme
temperatures.

Small PLC’s

The types of Allen Bradley’s small PLCs are Compact Logix5480, 5380, and 5370. We can
use these small PLCs for high-speed applications, motion applications, and also they can
be used for applications from small equipment to a high-performance indexing table.

Micro PLC’s

The major types of Allen Bradley’s micro-PLCs are micro870, 850, 830, and 820. The
micro-PLCs are designed for big machine control applications, the micro-PLCs have
better I/O capabilities and they also support good I/O points with high performance.
The micro-PLCs also have better embedded motion capabilities.

Free Allen Bradley software

Allen Bradley provides free software which is the RS-Logix500 and it consists of an RS-
Logix emulator and due to this, we don’t need a PLC to run and test our program.

Mitsubishi

Mitsubishi Electric is a Japanese electrical and electronics manufacturing company. The

PLC brand of this manufacturer is MELSEC, the system usability is improved by the

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 intuitive engineering software. The MELSEC IQR PLCs would help us to visualize the
entire plant in real-time.

List of Mitsubishi PLC models

 MELSEC IQ-R series

 MELSEC IQ-F series
 MELSEC IQ-Q series
 MELSEC L-series
 MELSEC F-series
 MELSEC QS/WS series
 MELSEC A-series
4. Schneider

This is a French manufacturing company that provides energy and automation digital
solutions. Their major PLC series is MODICON they also create PAC controllers too.
These PLCs provide safety to simple to complex functions for all industrial applications.

 SoMachine software is used for intuitive machine programming

 IIOT ready logic and motion control
 Good communication with the help of 5 embedded ports
 Communication ports act as Ethernet & CAN open master and also certain other
features such as data logging, web server and FTP server
List of Schneider PLC models

 Eco Structure Machine Expert

 Modicon Easy M100
 Modicon Easy M200
 Modicon -M221, M241, M251, M262, M258
PAC controllers

 Ecostructure Control Expert

 Modicon -Mc80
 Modicon – M340
 Modicon – M580, X80
Safety PLC

 Preventa XPS MC, XPS MP

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 5. ABB

ABB is a Swedish company and its operation is based on automation, robotics, power,
and also huge electrical equipment. AC500 series are their major PLCs these PL’s can be
used in large and small automation systems.

 All the AC500 models can receive different terminal units and this would provide
interfaces for communications
 Additional communication slots are available for communication modules
 The supported modules are Profinet, Profibus DP, Ethernet, etc.
List of ABB PLC models

 AC 500 series – For complex machinery

 AC 500eCo series– Compact PLC for smaller application
 AC 500s series– Safety PLC
 AC 500 XC series – PLC for extreme condition
 D0 810
 PM573
6. Honeywell

Honeywell is an American company that mainly operates in the aerospace, building

technologies, safety and productivity solutions, and also performance materials and
technologies.

 Really compact
 More than fifty I/O modules are available
 Major standard programming can be done such as LD/SFC/ST
 Lot of modular components are available such as CPU, power supplies, I/O modules
 Supports HART
 It can be connected to multiple devices with the help of open protocols such as
EtherNet/IP, Modbus
List of Honeywell PLC models

 Master Logic PLC series – ML 200, ML 50, ML 200R

 Control Edge PLC series – HC 900

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 7. Bosch

This is a German company which deals with Engineering and technology. The Indralogic
XLC PLC is the major PLC. In this type of PLC, the device communication is done by the
real-time Ethernet SERCOS3 and these PLCs are capable to do multiple machine
controls.

 Machine codes are generated by fast compilers and function libraries

 We can do the programming and diagnostic functions in a single environment
 Motion control is flexible
 This PLC can be connected to various communication networks
 Communication between the controllers and the system peripherals is done through the
real-time Ethernet sercos3
List of Bosch PLC models

 IndraLogic XLC– L25, L45, L65, L75

 IndraLogic L – L20, L10, L40
8. Omron

Omron is a Japan based electronic company the major PLC series of the Omron is the CJ
series. We can use the Omron PLCs for single machines and also for large machines.

 Micro PLCs are available for smaller machines

 The Cp1H compact PLCs have a high-speed counter and pulse outputs
 Multi-axis position control
 The compact PLCs are composed of onboard and add-on I/O, such as analog, digital,
and temperature sensor unit
 Hot swapping of CPU, Power supplies, and I/O units can be done to reduce the
downtime
List of Omron PLC models

 Compact – CJ2, CP2E, CJ1

 Modular – CP1L, CP1E
 Rack – CP1H, CS1D, CP
 Safety PLC – NX7, NX1, NX1P, NJ
9. Fuji Electric

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 Fuji Electric is a Japanese electrical equipment company, this PLC can achieve high
speed processing. It has three types of tasks and they are default, period, and event
task. This PLC is complying with the international standards.

 Positioning function
 The SPF PLC can be connected to the Monitouch through the ladder port
 Simulation and resume function
 CPU has a built in ethernet
 USB interface
 Dual control CPU
 Multi axis servo system application
List of Fuji PLC models

 MICREX – SX series – SPH, SPF, Common to SX

 MICREX F series – F30, F50, F55, F60, F70, F80H, F100, F120H, FTK, FTU
 FLEX PC series – NB0, NB1, NB2, NB3, NB4, NB5, NB6, NJ, NS

10. Hitachi

Hitachi is a Japanese company, and they have a lot of products and services such as
automotive systems, defense systems, consumer products and digital media, Electronic-
systems and a lot more.

 Built in microprocessor
 It is composed of expansion module buses
 It supports all the PLC programming languages
 Transistor or relay outputs
 It supports high speed counters (200KHz) and timers
 High speed PWM output(200Khz)
List of Hitachi PLC models

 Compact PLC – Micro EHV+, Micro EH, and web controller

 Modular series – HX, EHV+, EHV, EH-150, H-series

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 11. HIMA PLC

HIMA is a German company, which provides smart safety solutions for industrial
applications. HIMA provides safety controllers such as Himatrix, and Hiquad x. we can
use these controllers for the safety and operational purpose of the pipeline, turbine, and
also for deep-sea applications.

 Dual processor would check itself and each module so good safety
 Flexible adaptation due to the modules and functional blocks
 Better system availability due to the cross wiring of CPU and I/O layers
 Each module has redundancy options such as I/O modules, I/O racks, etc.
 The HiquadX can be connected to any process control system
 Himatrix communication is done safe Ethernet
 It can be used in extreme conditions such as deep-sea, it can handle temperatures from
-25C to -75C

List of HIMA PLC models

 HIQuad X – H41X, H51x, H41q, H51q

 HIMatrix – F30, F35, F60

12. Delta Electronic

This is a Taiwan based electronics manufacturing company, delta PLC’s can be used with
high level automation applications. These PLCs have modularized hardware structure,
and also integrated software and because of this, they can be used with various process
control applications.

 Compatible with all types of automated equipment

 Accurate positioning control
 EtherCAT/CAN open motion control interface
 High speed pulse output
 Supports PID autotuning
List of Delta electronic PLC models

 Compact PLC – AS series & AX-3 series

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 Mid-range PLC – AH series
 High speed PLC – DVP series
DVP series – DVP EH3, DVP-ES3, DVP ES2, DVP Ec3

13 Eaton

Eaton is a power management company Eaton PLCs are one of the major compact PLCs
which is available in the market. The Eaton PLCs are mostly the half size of the normal
PLC.

 Small size PLC’s

 By the ELCsoft programming software, the program can be moved from one controller
to the other
 Flexible interface
 Ethernet onboard
 Smart wire DT master for lean automation
List of Eaton PLC models

 Nano PLC – Easy E4series

 Compact PLC – XC152s
 Modular PLC – XC -100, 200,300
14 Panasonic

Panasonic is a Japanese company that manufactures industrial and consumer electronic

equipment. We can use the Panasonic PLCs for a wide variety of industrial applications.

 Ethernet, Modbus, and MC protocol

 Sensor connections can be easily done by using RS 485 and Rs 232c
 Open network is supported
 FP0H can transfer information to PC or server
 Built in 4 axis pulse output
 High speed counter input and pulse output
 Built in multipoint PWM output
List of Panasonic PLC models

 FP0H series – AFP0HC32P, AFP0HC32EP, AFP0HC32T, AFP0HC32ET

 FPXH series – AFPXHC60P, AFPXHC30PD, AFPXHC30P, AFPXHC60PD
 FP7 – AFP7CPS31S, AFP7CPS31, AFP7CPS31ES, AFPSWC
15. Toshiba

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 Toshiba is a Japanese company, their products and services are industrial, power, etc.
Toshiba manufacturers have many electronic components such as semiconductors,
hard-disk, etc. Toshiba also makes PLC and their major PLC series is V200.

 Optional add on I/O expansion module

 Due to its high-speed it can be used with sophisticated machine control applications
 Wide range of I/O modules: PWM outputs, HS I/P
 Networking – Modbus, master-slave
 High efficiency operation due to the low resistance on MOSFET’s
List of Toshiba PLC models

 V200
 T1-16s
 V2000
 S2E/S2T
16. Yokogawa

This is a Japanese electrical engineering and software company. Yokogawa has only a
single PLC series which is the FA-M3. This PLC is known for its operating speed. It has
high speed instruction processing response and scan.

 High speed processing: 3.75ns for basic instructions, 7.5ns for application instructions
 Fast constant scan can be achieved is possible due to the sensor control function
 High speed response for interrupts
 High speed scan
List of Yokogawa PLC models

 FA-M3 series
 FNC-500
 FCN-500
 FCJ
17. Phoenix Contact

Phoenix Contact is a German company and they are the manufacturers of industrial
automation, interface solutions, and electronic equipment. The phoenix contact PLCs
have IP20 and IP65/67 protection. These PLCs are programmed with high level
languages such as C++, Simulink, etc.

 Suitable for harsh environment

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 Ethernet interface can be used for coupling to other interfaces or controllers
 These PLC’s can be used for building automation
List of Phoenix contact PLC models

 EPC 1522
 EPC 1502
 AXC FXT SPLC 1000
 AXC F 1152
 AXC F3152
18. Fatek PLC

Fatek is a Taiwanese PLC manufacturing company, their major PLC series are FBS and
Hb1 series. These PLCs consist of better communication features, there are five
communication ports for the FB series and thus it can be connected to different
intelligent peripherals.

 Communication – RS232, RS485, Ethernet, CANopen, and Zigbee

 Compact and rugged due to the system on chip
 Hardware cost is reduced because of the system on chip
List of Fatek PLC models

 FBs series
 B1/B1z series
 HB1 series

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 Comparison of PLC manufacturers

Sl PLC PLC Brand

PLC Models Features
no Manufacturer name

Integrated system functions, Motion

S7200, S7300,
1 Siemens Simatic control, Closed-loop PID control, Signal
S71200, S71500
acquisition/output

Control Logix
Rockwell Allen 5580, Compact Automatic diagnosis, high-speed motion
2
automation Bradley Logix 5380, applications, built-in energy storage
Micro 870

Direct data collection & analysis, Real-time

Mitsubishi MELSEC IQ-R, factory data collection, Reduction of
3 MELSEC
Electric IQ-F, Q series operating cycle time due to high-speed
motion control

All programming, visualizing, and

MODICON easy
commissioning can be handled by one
M100, M200,
4 Schneider MODICON intuitive tool, M241 PLC has 5 embedded
MODICON
ports, a Motion controller, and IIOT ready
M221, M241
logic

Good range of I/o cards, modules, and

5 ABB AC500 AC500 xc, s, eco interfaces, Four interfaces can be integrated
into each CPU

6 Honeywell Master- ML200, ML50, Operates in peer to peer environment or in a

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 SCADA topology, Ethernet-based I/o bus controller,
Logic
High-speed scanning

Real-time communication system based on

Rexroth Ctrlx, ILC-CML, Ethernet, Synchronized motion control, I/O real-
7 Bosch
ICL ILC-XM time data processing is done really quick in
different operating modes

CPM1A, 2A Cj2M supports more than 2500 digital and pulse

8 Omron CJ
CP1E, CP1L I/O, It also supports 5000-60000 program steps

32-bit high-performance processor, Various motion

WSZ, SPH control like speed control, torque control, and
9 Fuji Electric MICREX SX
series, SPF position control. CPU has built-in ethernet
capability

Micro EHV,
1 Superlative networkability, 32-bit RISC processor,
Hitachi EH & H EHV+, HX, EHV,
0 Built-in RTC, It supports IEC61131-3 programming
EH 150

Quick response time, Compatible with numerous

1 HI-Matrix, HI- industrial network protocols, H41x supports 224
HIMA HI PLC’s
1 Quadx I/O, H51x is a modular type and it can be extended
to thousands of I/O

32bit SOC CPU supports 32 extension modules or

DVP s22, DVP
1 Delta up to 1024 I/O’s, Position controls up to 8axes,
Delta PLC SE series, DVP
2 Electronic Supports PID auto-tuning, Built-in high-speed
SS2series
counters

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 32-bit 400mhz RISC CPU, Ethernet interface, Many
XC compact, XC
1 modules can be added due to the DIN-rail, There is
Eaton EasyE4 modular, easy
3 no need for interface devices due to its
e4nano PLC
communication ability.

This PLC has various functions such as PID,

1 FPxh series, Adaptive filter, Electronic cam control, High-speed
Panasonic FP
4 FP0h series,Fp7 counters and pulse output, I/O points up to 382,
Multi-axis interpolation

1 T1 16s PLC, IEC 61131 programming option, Motion control,

Toshiba V2000
5 V200 PID function, ASCII communications

1 Yokogawa Yokogawa High-speed IPRS, 100 k step program can be

FA M3
6 Electric PLC scanned in 1ms, Quick response to interrupts

RFC high-performance controllers, High-level

1 Phoenix Phoenix ILC and AXC
programming languages are used, These PLC’s can
7 Contacts PLC series
be used in a harsh environment

4 sets of H/W high-speed counters/timers, 16 high

1 FBS series, Hb1 speed interrupts, Compact and rugged, System on
Fatek FBS
8 series chip CPU, Noise immunity, More than 300
instructions for the FB series, Hardware logic solver

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 Advantages and Disadvantages

The followings are the advantages and disadvantages of PLC:

Advantages Disadvantages

Reliability Initial cost

Versatility Programming skills

Ease of use Limited flexibility

Cost-effectiveness Complexity

Safety Maintenance

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 Future Trends
Internet of Things (IoT) Integration:

One of the key trends driving the future of PLC technology is its integration with the Internet of
Things (IoT). PLCs are evolving to become an integral part of interconnected systems, allowing
seamless communication and data exchange between devices, sensors, and cloud platforms. This
integration opens up new possibilities for real-time monitoring, predictive maintenance, and
optimized performance across industrial processes.

Edge Computing and Edge PLCs:

With the rise of edge computing, PLCs are also adapting to this paradigm. Edge PLCs are
designed to perform data processing and control tasks at the network edge, closer to the source of
data generation. This enables faster response times, reduced latency, and improved reliability.
Edge PLCs are particularly beneficial in applications where real-time decision-making is critical,
such as autonomous systems or remote monitoring.

Artificial Intelligence (AI) and Machine Learning (ML) in PLCs:

The integration of AI and ML capabilities into PLCs is set to revolutionize automation processes.
PLCs equipped with AI algorithms and machine learning models can learn from data patterns,
predict equipment failures, optimize energy consumption, and adapt to changing operating
conditions. This advancement empowers PLCs to make intelligent decisions and continuously
improve system performance.

Cybersecurity and PLC Safety:

As industrial systems become more interconnected, ensuring the security of PLCs becomes
paramount. The future of PLC technology includes robust cybersecurity measures to protect
against cyber threats, unauthorized access, and data breaches. This includes encryption protocols,
secure network architectures, and regular updates to address vulnerabilities. Additionally, safety
features within PLCs, such as fail-safe mechanisms and built-in diagnostics, will continue to
evolve to enhance operational safety.

Open-Source PLC Programming:

Open-source PLC programming environments are gaining popularity, offering flexibility, cost-
effectiveness, and community-driven development. This trend allows developers to customize
and tailor their PLC programs to specific needs, fostering innovation and collaboration within the
automation community. Open-source platforms also provide opportunities for knowledge sharing
and rapid prototyping of PLC-based solutions.

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 Conclusion

In conclusion, the analysis and comparison of commercially available Programmable

Logic Controllers (PLCs) have provided valuable insights into the dynamic landscape of
industrial automation. Through a meticulous examination of key features, functionalities, and
performance metrics offered by major manufacturers, this report aims to assist decision-makers
in selecting the most suitable PLC for their specific applications.The comparative study revealed
notable variations among PLCs, highlighting the diversity in processing speed, memory capacity,
communication protocols, and I/O capabilities. Manufacturers such as Siemens, Allen-Bradley,
and Mitsubishi each bring unique strengths to the market, catering to the diverse needs of
industries.Advancements in PLC technology have been evident throughout the report, with a
focus on software environments and the integration of innovative features. The case studies
showcased successful implementations of PLC systems across various industries, underscoring
the adaptability and reliability of these automation solutions.While PLCs continue to play a
pivotal role in industrial automation, it is crucial to acknowledge both their advantages and
limitations. The real-world applications discussed in this report emphasize the positive impact of
PLCs on efficiency, control, and monitoring within industrial processes. Looking to the future,
the report has explored emerging trends in PLC technology, indicating a trajectory towards
increased connectivity, flexibility, and scalability. As industries evolve, PLCs are anticipated to
adapt to meet the changing demands of automation. In essence, this project report serves as a
valuable resource for professionals and decision-makers seeking to navigate the complex
landscape of commercially available PLCs. The insights provided herein contribute to informed
decision-making, ensuring the seamless integration of PLC systems into diverse industrial
settings.

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 References

 https://automationforum.co/leading-plc-manufacturers/
 https://aspiringyouths.com/advantages-disadvantages/plc/
 https://www.linkedin.com/pulse/future-plc-technology-emerging-trends-
innovations-solutions#
 https://www.jakelectronics.com/blog/how-plcs-are-becoming-an-industry-
standard

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