In the industrial Internet of Things (IIoT), there’s technology to fill every niche of data capture and control. Physical devices act as the bridge that connects data and systems. Traditionally, this has been the role of PLCs (programmable logic controllers). They are robust devices that offer a range of features, processing power, and I/O capabilities. Edge controllers now offer many of the same features in a smaller package.
There aren’t exactly size categories for controllers. (You don’t go shopping for a medium or large like a sweater.) Still, some are large and powerful, bringing endless connection points and speedy processors. They also carry an equally hefty price tag and limitations on where—and how—they’re installed. This is where an edge IoT controller really stands out. They may be more limited in function, but they’re smaller, flexible, and more affordable. They often run on more lightweight software or an embedded UI (which is the case for ControlByWeb® controllers).
Edge controllers are smaller, more flexible, and more affordable; they often run on lightweight software or an embedded UI.
Learn more about the differences between regular PLCs and edge controllers and see when edge data devices are an ideal choice for seamless automation solutions.
Understanding Traditional PLCs vs Edge Controllers
Edge controllers are compact and cost-effective automation devices that offer numerous advantages over traditional PLCs. While regular logic controllers are often built for larger-scale industrial applications with significant I/O needs, edge controllers are specifically designed to excel in smaller automation projects that require less complex control systems and data capture at, well, the “edge.” Here are the primary differences:
Compact & Efficient
Edge controllers are significantly smaller and more power efficient than regular PLCs, making them ideal for space-constrained applications where size is a factor. A large PLC will fit the bill for avionics, factory lines, and offshore drilling rigs—but good luck getting one to fit into a solar-powered, offsite control box. PLCs typically require higher voltage levels in the range of 110V to 240V AC. Edge controllers, on the other hand, often work with 24V DC.
The compact size and less restrictive power requirements give edge controllers a key advantage. The smaller devices have an easier time fitting in a small control panel or mobile application. Controllers (like many of our 400 Series devices) are compatible with Power Over Ethernet or standard 9-28VDC. Others can use batteries as the primary source of power or a backup. They are easy to mount on a DIN rail, secured in a control box, or embedded directly onto machinery.
Despite their small size, edge controllers still offer a wide range of input and output options, allowing for the control of various devices and sensors. This makes them suitable for a wide range of applications, from simple automation tasks to more complex control systems.
Easier to Use
An edge controller will often be simpler to set up, since there are less inputs, outputs, and other components. There may be features in a PLC that will need to be ignored or, worse, get in the way while tailoring it to a specific application.
One aspect that makes all the difference when installing and monitoring a controller of any size and capability is the interface and software. Unfortunately, it’s all too common for manufacturers to burden their hardware with overly complicated software and user interfaces. They’ll often include the same UI as more complex controllers. This makes the experience more consistent across their device lineup but defeats the simplicity of an edge controller. This is an area where ControlByWeb controllers really stand out.
Our controllers use no-code programmable logic that allows you to set conditional logic through drop-down menus—it doesn’t get any easier than that. Having a simplified UI saves time and allows additional users to make changes as necessary without being stonewalled by dense ladder logic. Customers are impressed with how easy it is to set up and use our devices.
“Easy to configure … solid customer support.”
“Easy to configure, solid documentation, solid customer support before and after purchase.”
Flexible & Scalable
Edge IoT controllers can “power up” with modular capability, which allows additional controllers and relays to connect to the master unit. Peer-to-peer capability can even make that added I/O work wirelessly. This is ideal in settings where it would be difficult or impossible to hardwire the full application. The X-600M web-enabled I/O controller, an expandable controller, can handle up to 64 I/O cards for a staggering 1,024 I/O points. (Not bad for what could be considered a “micro” controller.)
Modular designs enable integrators to customize the control system without extensive rewriting or reprogramming, ensuring the system can easily accommodate future changes or expansions. And, while not unique to edge controllers, having multi-protocol support allows a controller to work with a broader range of systems and SCADAs, sharing data with other automation devices or cloud-based platforms.
Scalability is another key advantage. Users can start with a basic setup and gradually add more modules or features as their automation needs grow. This makes edge controllers a cost-effective solution, as users only need to invest in the necessary components at each stage of the system’s development.
Overall, the flexibility and scalability of IoT controllers provide users with the freedom to adapt and expand their control systems as needed, ensuring long-term compatibility and cost efficiency.
More Affordable
With an edge controller, you aren’t paying for features and I/O that you don’t need. They’re still plenty robust and a perfect fit for a broad range of applications even at a lower price. This is especially important for systems integrators who build all-in-one solutions at scale and have a shorter list of needed components and capabilities.
As needs change over time, it’s less expensive to add compatible components to an existing installation as opposed to replacing an entire module. Scalability equals money saved in the long run.
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Integrating Edge Controllers With IoT & Industry 4.0
There are plenty of use cases for a IoT controllers without sacrificing any features and hardware. With their numerous advantages, these flexible devices have become increasingly popular in industries such as building automation, remote reboot, and process control. They are a natural fit for capturing data at the edge and a key part of the advancement into Industry 4.0.
These devices often come with built-in communications capabilities, allowing them to connect to networks or other controllers. This enables remote monitoring and control of automation systems. Users have nearly real-time access to data, remote troubleshooting, and the ability to adjust the control logic without being physically present at the site. Some controllers, including ours, are cloud-compatible, further expanding the connected ecosystem of automation devices.
With the increasing adoption of Industry 4.0 technologies across industries, the ability of edge devices to integrate seamlessly is a significant advantage. They allow integrators to future-proof their automation systems and stay ahead in the era of digital transformation.
Why Choose ControlByWeb® IoT Controllers
The world of industrial automation offers a dizzying number of options when choosing controllers, relays, sensors, software, and more. It’s important to choose components that will stand the test of time and offer the flexibility to adapt as needs change and systems grow. ControlByWeb edge devices are a great option for their ease of use, robust features, and in-house support. Controllers include an intuitive web-based interface that allows users to quickly set up logic, configure I/O, and monitor the system. Everything we make is designed, sold, and supported in-house at our home office in northern Utah. Our products have been shown to be reliable and secure by nature with decades of use cases across all sorts of industrial applications.
Get in touch with our team or schedule a 15-minute demo to learn more about our products and see why systems integrators, engineers, and technicians turn to ControlByWeb for their industrial IoT needs.
