The modern world is powered by data. It’s the premise behind the Fourth Industrial Revolution (commonly called Industry 4.0) and has unlocked virtually unlimited potential for data-driven applications. What used to take months to record, collect, and utilize now happens in a matter of milliseconds.
A major component of Industry 4.0 is the Internet of Things, or IoT. IoT is the network of physical objects that allow for the exchange of data through the internet. This ranges from consumer technology to industrial applications. On the industrial end, IoT controllers are used to bridge the gap between sensors (data capture) and central systems (logical control, data logging). There’s a need to consistently record data and share it across components, software, or personnel to keep things operating smoothly.
But how is this data shared? Most commonly through a traditional PLC (programmable logic controller) or an edge IoT controller. You can dive into the differences in our Traditional PLCs vs Edge Controllers article. Controllers bring data capture and logic to all sorts of industrial applications, anything from a factory assembly line to a ventilation system to a pumping station.
In this blog post, we will delve into the world of PLCs, explaining what they are, how they work, and their significance in the realm of industry. We’ll also see how ControlByWeb® edge controllers stand out as an alternative to the traditional PLC.
Determine the best products for your application with our Sales Engineers.
What is a Programmable Logic Controller?
Programmable logic controllers have been around since the 1960s. They are sometimes referred to as “IoT controllers,” “controllers,” or “relays.” PLCs are used to control and automate industrial processes and machinery. Broadly speaking, a PLC is a specialized computer that reads signals from sensors and switches—inputs—and sends data or a command through an output. Edge controllers perform many of the same tasks with less I/O and raw processing power in exchange for more flexibility for edge data applications.
PLCs and edge controllers are designed to perform specific tasks, monitor inputs, and make decisions based on pre-programmed logic. At their core, controllers are designed to operate in cycles, detecting the states of inputs and then determining how outputs should be affected. In this example using our X-412™ edge analog relay, a simple conditional task is created to control a tank pump. A liquid-level sensor feeds data back to the X-412, which will then determine whether the pump motor should be on or off based on the tank level.
By automating tasks, controllers minimize downtime and increase productivity. They also allow for redundancy in systems that are critical to maintain or physically remote. PLCs and edge controllers are found across numerous industries, including manufacturing, water/wastewater treatment, smart greenhouses, parking lots, and so much more. Visit our applications page to get an idea of the broad scope of applications where data makes a difference.
Components of PLCs & Edge Controllers
A typical IoT controller consists of several key components:
- CPU (Central Processing Unit): The brain of the device, responsible for executing the program and making decisions.
- Input Modules: These modules connect to sensors and other input devices, allowing the controller to gather data.
- The type of sensor a controller can use is dependent on the input type as well as voltage. To ensure you’re using the right device for the job, contact our sales team.
- Output Modules: Output modules connect to actuators and devices, allowing the device to control machinery and processes.
- Memory: PLCs and edge controllers have volatile (RAM) and non-volatile (ROM) memory for storing the program and data.
- Communication Ports: Some controllers are equipped with ports for connecting to networks and other devices.
- Power Supply Input: Controllers will either accept power through a regulated power supply or Power Over Ethernet (PoE) switch.
What’s an “Edge” Controller?
A common IoT term is edge data. This refers to the information collected at the edge of a network, close to the source of data generation. An edge controller is a device that brings processing out to the edge where the data is captured. This approach contrasts with traditional methods where data is sent to a centralized cloud or data center for processing.
Introducing ControlByWeb Edge Controllers
ControlByWeb is a leading manufacturer of industrial automation and control solutions, including IoT controllers for logical control at the edge. Our devices are known for their reliability, versatility, and ease of use. Here are a few notable features that help our products stand out:
- Web-Based Control: ControlByWeb devices can be accessed and configured remotely via a web browser. They are also compatible with the optional ControlByWeb Cloud.
- Wide Range of Inputs/Outputs: Our controllers offer a variety of input and output options, allowing them to adapt to various industrial applications.
- ControlByWeb devices are compatible with expansion modules and are also P2P-enabled, allowing for one device to act as a master to control, monitor, and log many additional I/O points—over 1,000 with the powerful X-600M™!
- Built-in Communication: ControlByWeb modules can connect through Ethernet, and certain models have WiFi and cellular capability, simplifying integration into existing networks.
- User-Friendly Interface: The intuitive web-based interface makes it easy to program and monitor these controllers.
- No-Code Logic: The intuitive web-based interface utilizes drop-down menus, making it easy for anyone to program scheduled and conditional tasks—no code necessary.
Subscribe to Our Newsletter
Newsletter Subscription
Sign up for our newsletter to receive information regarding new products and exclusive offers.
Follow Us on Social
Driven by Data
Traditional PLCs and edge controllers are crucial components in the world of industrial automation. These specialized computers perform a wide range of tasks, from process control to data handling, making them indispensable in various industries. ControlByWeb modules stand out as a reliable and user-friendly option, offering web-based control at the edge and a wide range of features to meet diverse industrial needs.
As automation continues to shape the future of industries, understanding IoT technology and I/O control is essential for those looking to stay at the forefront of Industry 4.0. These controllers play a pivotal role in many industrial fields, optimizing processes and ensuring efficiency and precision.
The ControlByWeb Difference
For help with your industrial application, get in touch with our team or schedule a 15-minute demo to get a feel for our devices.
