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05
2024
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The next Generation of machine controllers - five key features of open automation controllers
Image source for this article: SIEMENS
By Dave Cameron and Bosch Rexroth
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There are five key characteristics to consider when evaluating an open controller platform.
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Programmable logic controllers (PLCS), or automation controllers, have been the most critical "smart" devices driving advances in automation efficiency, productivity, and flexibility.
Over generations, they have leveraged processor power, software maturity, and the development of high-speed communication architecture protocols to transform industrial automation. A new generation of machine controllers is revolutionizing the industry, offering groundbreaking open and ease-of-use technology while still supporting the complex functions required for current and future automation systems.
The wider world of information technology (IT), with an open software architecture, is exemplified by smartphones and their app-based capabilities. In contrast, controller technology remains relatively closed, resulting in automated original equipment manufacturer (OEM) systems that lack long-term flexibility and control capabilities. However, a new generation of machine controllers is overcoming these limitations and enabling more versatile innovations.
Here are five key characteristics to consider when evaluating open controllers.
01
Application based (App) architecture
One of the most significant differences between past and present machine controller platforms is: How open is the platform? How much is application based? In modern machine controllers, there is a flexible open software architecture that allows Oems to choose the application they need or use any open source software. They can use software they develop themselves on an open platform, leveraging their expertise in automation and control to create machine-specific applications (apps) in any programming language that suits their needs.
02
hardware
Leading controller vendors are introducing Linux-based multicore processors with the speed and complexity to meet the most demanding requirements. Multi-core processors offer key advantages in application-driven architectures. Controllers are now being asked to perform a wider range of functions simultaneously to enable core automation, I/O, and motion sequence control of machines.
03
connectivity
The latest controllers are rapidly spreading support for the EtherCAT® protocol, which is used as the de facto standard bus in demanding industries such as semiconductor manufacturing. EtherCAT also has the advantage of being motion control-centric, which is a valuable asset for automation applications.
04
Openness remains key
The controller line also supports other popular protocols (such as Sercos, EtherNet/IP, or Profinet), which provides greater flexibility. There is also growing support for emerging protocols such as OPC Unified Architecture (OPC-UA) and time Sensitive Networking (TSN). Machine controllers configured with this open architecture can provide valuable, future-proof solutions.
05
Stability and scalability
Intelligent scalability is a key advantage of the new generation of open machine controllers, where the underlying platform can be extended with additional application capabilities. The core architecture allows Oems to scale as needed, rather than having dozens or hundreds of different controllers with hardware-specific functions.
A new generation of machine controllers that responds to the demands of Industry 4.0, offering openness and application-driven ease of use and flexibility, will soon enable manufacturing companies to view their PLCS as smartphones for automation, rather than components destined for obsoleence.
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