The Top Performing PLCs of 2022

Introduction

Programmable Logic Controllers (PLCs) are ruggedized computing devices used to control electro-mechanical processes, mainly in industrial settings. The PLC continuously monitors the state of connected input devices or sensors and collects the status information as input data. It then processes the input data and makes appropriate decisions based on pre-programmed parameters to control the state of the connected output devices. This way, PLCs can automate a specific industrial process, machine function, robotic device, or even an entire assembly/production line.

Initially, PLCs were developed to replace complicated relay-logic control systems in automobile industries. Today, however, PLCs provide a comprehensive range of functions including controlling inputs and outputs, drives and motors, timing and counting functions, communications, as well as processing digital and analog signals in a variety of industrial and commercial applications. According to a PLC-industry analysis report by TechNavio, the market size of Programmable Logic Controllers is expected to grow by US$ 2.70 billion from 2021 to 2026, at a compound annual growth rate (CAGR) of 3.51% during the 5 years. The increasing need for small and industrial automation solutions is one of the key factors driving the growth of the PLC market.

This article lists the top-performing PLCs from popular PLC manufacturers in the 2022 market year; the list is in no particular order.

SIMATIC S7-1500 PLC

The SIMATIC S7-1500 is the fastest Programmable Logic Controller (PLC) manufactured by Siemens for digitized automation. It is available in fail-safe and standard versions. This controller has a modular design and it includes a comprehensive range of signal I/O modules and technology modules for special technological functions like counting. Several communication modules are also available for distributed or centralized network configurations; these modules function as PLC interfaces to the plant or machine being controlled. The SIMATIC S7-1500 controller is scalable in terms of its functionality; thus, users can customize the assemblies and functions that perfectly match their machine designs or application requirements.

Additionally, there are various SIMATIC S7-1500 CPU versions available in different performance classes. For example, the highest performance SIMATIC S7-1500 PLC class that covers the most sophisticated requirements of high-availability configurations and advanced motion control applications is available with two high-end SIMATIC S7-1500 CPUs, namely:

• The CPU 1518HF-4 PN combines functional safety with high performance for high-availability configurations.
• Fail-safe CPU 1518TF-4 PN/DP and Standard CPU 1518T-4 PN/DP CPUs designed for high-end motion control tasks and the most complex technological applications.

With the SIMATIC S7-1500 PLC, manufacturers can achieve maximum process performance and increased productivity thanks to the PLC’s fast backplane bus in combination with a PROFINET connection that provides a short response time, and high-performance CPUs providing a command processing time of up to 1 ns (nanosecond). Also, the deterministic time response provided by the PROFINET network ensures reproducibility and high precision in the microsecond (µs) range.

Allen-Bradley ControlLogix PLCs

ControlLogix is a high-performance PLC-based control platform from Rockwell Automation. It’s designed to deliver high-speed system performance, high capacity, and optimized system productivity for a wide range of demanding industrial applications. ControlLogixPLC systems provide multiple categories of control including process, discrete, sequential, drive, safety, and motion control in combination with state-of-the-art I/O and communication modules in a compact, cost-effective package.

In addition, ControlLogix control systems utilize a common control platform with a single development framework to provide high-performance capabilities in an easy-to-use programming environment, for all control disciplines. This seamless integration between ControlLogix controllers, the programming software, and ControlLogix I/O modules minimizes the development time and related costs during commissioning and normal PLC operation. For example, for a fully integrated ControlLogix system, users can perform both standard and safety control operations in the same chassis, while leveraging the system’s high availability and extreme environment operating capabilities to meet multiple application needs.

Top-performing Allen‑Bradley ControlLogix PLCs include:

• ControlLogix 5580 Controllers: This family of PLCs consists of ControlLogix 5580 Standard controllers and GuardLogix 5580 Safety controllers, which provide multi-discipline control for motion, process, discrete, and safety applications. These controller series use a certain framework as the standard development environment to optimize productivity, as well as reduce system complexity and commissioning time. This architecture also supports Integrated Motion over Ethernet/IP industrial network for high-speed motion control applications. In addition, it provides various safety solutions including SIL3/PLe and SIL2/PLd. Ideally, ControlLogix 5580 PLCs are well-suited for applications that require high availability, high-performance I/O, enhanced communications, and advanced motion control for up to 256 axes, whereas GuardLogix 5580 controllers are optimized for standalone or networked standard and safety control applications. These controllers also incorporate improved security mechanisms such as centralized access control and authentication to help keep your control systems secure.

• ControlLogix5570 Controllers: These are high-performance PLCs available in safety, standard, On-Machine, and extreme temperature models, ideal for discrete, high-availability, motion, and process control applications. They use common network protocols and more as part of the Rockwell Automation Integrated Architecture system. This integrated design framework supports Integrated SERCOS motion, Integrated Motion on Ethernet/IP, and analog motion.

MELSEC iQ-F PLC Series

MELSEC iQ-F is a next-generation series of compact PLCs from Mitsubishi Electric; it’s an improved version of Mitsubishi’s MELSEC-F PLC Series. This controller series is designed on the concepts of superior drive control, outstanding performance, and user-based programming–concepts previously limited to larger MELSEC PLC control systems.

To achieve excellent performance, the   MELSEC iQ-F series features the following: an enhanced high-speed system bus, advanced SSCNETIII/H support, extensive built-in functions, varieties of communication networks (such as RS-232, RS-485/422, CC-Link V2, and CC-Link IE Field Network), enhanced security functions, a battery-less PLC system, and an improved engineering environment with simple and convenient parameter settings.

Also, the MELSEC iQ-F PLC platform is powered by a high-speed CPU with the capacity to execute an LD (Ladder Diagram) instruction in 34 nanoseconds (ns). This CPU can also execute multiple programs as well as handle Structured Text (ST) programs and Function Blocks. In addition, the MELSEC iQ-F CPU module has exceptional built-functions such as high-performance counters that allow the MELSEC iQ-F PLC to capture high-speed signals from sensors and encoders; this makes high-speed control possible with simple programming.

In essence, MELSEC iQ-F PLCs are suitable for networked and standalone higher-performance applications aiming at enhanced productivity, reduced system development time, enhanced product quality, and fewer downtimes.

Schneider Modicon M221 PLC

Modicon M221 (Catalog No. TM221C…) is a Programmable Logic Controller developed by Schneider Electric under the “Modicon PLC” brand name. This PLC is designed for hardwired architectures and it provides the best-in-class performance for its size. It features a USB port, SD card, 9 discrete inputs, 2 analog inputs, 7 relay outputs (Normally Open) with 10bit input resolution, a Run/Stop switch, a broad choice of expansion I/O and cartridge extension, as well as serial line and Ethernet ports, which are powerful features for machine automation.

Schneider Modicon M221 logic controllers offer the following benefits:

• Embedded machine safety with the Modicon TM3 safety-enhanced I/O system.
• Scalable machine control, which allows an easy upgrade to higher-performance Modicon PLC platforms for improved efficiency.
• Ethernet connectivity, wireless access, and web server connections to simplify system integration and maintenance.
• A high degree of flexibility, allowing easy addition of different modules such as safety modules, Lexium servo drives, and an extensive line of digital and analog Input/Output modules.
• Minimal installation requirements, as it’s available in book or brick format.

Also, you can boost the performance of a Modicon M221 controller with a dedicated application cartridge for various applications like packaging and hoisting. With a Modicon M221 PLC, you can achieve benchmark performance and increased profitability for an extensive variety of applications due to the controller’s tremendous versatility.

Omron CS1 PLC

The CS1 PLC-Series by Omron Corporation is designed for medium to large-scale control systems, and it can handle a variety of control tasks from machine control to process control. Omron’s CS1-Series fast and powerful CPUs are available in two processor speeds (20 ns and 40 ns), each in different memory capacities. Also, besides the basic CPU versions, other CS1 CPU models are available for dual redundant operation which supports hot-swapping of CPUs, I/O units, and power supplies to reduce downtime. In addition, the CS1 CPUs allow programming flexibility through the use of IEC standard languages – Ladder Diagram (LD) and Structured Text (ST).

A typical Omron CS1 PLC features the following units:

• Basic I/O Units: Available for primarily any control application and wiring method. For example, the CS1W-B7A basic I/O unit can transmit up to 16 points of Input and Output signals per word, with just a pair of cables.
• Special I/O Units: These are used for handling advanced machine control requirements, such as networked communications, position control, and temperature control. Available CS1 special I/O units include the CS1W-PTS, CS1W-CRM21, CS1W-PDC/PTW/PTR, CS1W-AD, CS1W-MAD44, CS1W-DA, CS1W-CT021/041, CS1W-PMV, CS1W-V680C11/V680C12, etc.
• CPU Bus Units: These are used to handle special I/O and communication requirements to achieve advanced motion control, position control, and networked communications. Available CS1 CPU Bus units include the CS1W-EIP21, CS1W-SPU01-V2/SPU02-V2, CS1W-CLK, CS1W-ETN21, CS1W-FLN22, CS1W-DRM21-V1, CS1W-PRM21, etc.
• Communications Coupler: This unit enables EtherNet/IP or EtherCAT network communications. For example, the NX-EIC202 Coupler unit enables the CS1 PLC to connect to Ethernet/IP industrial network.

Note: Since CS1 PLCs are rack-mounted controllers, they can be configured from a wide selection of CPU units, CPU Bus units, and Special I/O units. For larger control systems, a basic CS1 CPU can support up to 5,120 digital Input/Output points over 7 expansion racks, and can still be expanded further with rack extenders to hold a maximum of 80 I/O units. Also, a CS1-based control system can support analog Input/Output modules, motion, and position control modules, safety and interrupt relays, as well as loop control modules. In addition, CS1 logic controllers do support several communication protocols, including Serial and Ethernet/IPcommunications.

These controllers are well-suited for advanced motion control applications, complex robotics, and machine vision systems. Essentially, Omron CS1 PLCs offer the highest I/O responsiveness for improved I/O processing and refresh rates–they significantly reduce I/O processing time– compared to other PLC brands. They are also equipped with advanced data control functionality to control machine motion with greater precision. In addition, with their higher processing power, Omron CS1 PLCs are finding success in Internet of Things (IoT) and Industry 4.0 applications.

Available Omron CS1 Controller Variants

• CS1G and CS1H Controllers: These are multi-application programmable logic controllers with a wide variety of control functions. You can use the CS1G and CS1H controllers in an extensive range of applications from machine control to information management.
• CS1D Controllers: These controllers have redundant CPU units and can be configured for a duplex operation to provide system redundancy.

Emerson RX3i PLC

The RX3i PACSystem controller is a revolutionary racked-based PLC system for automation control, from Emerson Automation (previously GE IP). It’s a robust and highly capable PLC platform with all the comprehensive features you would expect from a world-class PLC system, including:

• Built-in tools that enable high availability configurations, ensuring maximum reliability in critical applications.
• Integrated control platforms that are based on Emerson Reflective Memory technology, such as HMI editors, high availability, process, logic, and motion control functions that improve system performance and flexibility.
• High-performance I/O and advanced diagnostics that maximize system productivity and minimize costly downtimes.
• Modular design and numerous expansion options, including advanced power management. These options make the Rx3i PACSystem a perfect solution for discrete, hybrid, and process control applications.
• A wide range of hot-swappable and pluggable I/O modules cover analog, digital, and specialty I/O types. These modules allow users to customize the right mix of I/O for their RX3i PLC systems, with a variety of current capacities and voltage ranges supported to meet different application needs.
• High-speed interfaces that provide rapid and consistent data transmissions. Both PROFINET System Redundancy (PNSR) and Ethernet Global Data (EGD) network interfaces are supported.
• Gigabit speed and bump-less switchover to ensure high availability, thereby preventing unexpected system failure.
• Interoperability extends the RX3i lifecycle and reduces operating costs.

ABB AC500 PLC

AC500 PLC is a scalable Programmable Logic Controller platform from ABB Ltd. It is designed to provide different performance levels for small, medium, and high-end automation systems. It features a wide array of I/O, communications, and performance capabilities for various industrial applications. These features make the AC500 PLC an ideal choice to implement and manage high availability, condition monitoring, motion control, extreme environments, networking, and safety solutions. This PLC can also handle complex, high-speed industrial machinery.

Available AC500 I/O modules include DC and AC digital I/O modules, current I/O modules, and voltage I/O modules. For I/O hot-swapping, special terminal units are used. Supported communication modules include DeviceNet, Serial, EtherCAT, PROFINET, Ethernet, CANopen, Profibus DP, Modbus TCP, etc.

In addition, the ABB AC500 PLC platform offers interoperability as well as software and hardware compatibility from compact logic controllers to high-end and safety PLCs. Essentially, the standard AC500 PLC is available in different PLC variants ranging from models with a memory capacity of 128 KB (kilobytes) for small applications to models with a high memory capacity of 160 MB (megabytes) for larger applications. Other AC500 PLC variants provide specialized functionalities. Popular AC500 PLC variants include:

• AC500-eCo: This is a small-sized, compact PLC platform with a few I/O points integrated into its processor module. It offers optimally flexible and economical configurations suited for automation solutions in small-scale applications.
• AC500-S: This PLC platform features safety-rated (SIL3, PL e) logic controllers and I/O modules. It’s designed to provide integrated safety for critical applications involving machinery, process, or factory automation.
• AC500-XC: This is an extreme condition AC500 PLC variant with extreme operating temperature capabilities, immunity to hazardous gases and vibration, and can function reliably in humid environments and at high altitudes. It is used in applications where extreme environmental conditions may exist.