Why Allen-Bradley PLCs Are Still the Standard in Industrial Automation

Only a few names have the universal respect and recognition of Allen-Bradley for their reliability, innovation, and solid performance. In a very competitive market, what has made Allen-Bradley PLCs the lasting reference point? It stems from a unique blend of original innovation, a complete and integrated ecosystem, visionary hardware design, and a commitment to fulfilling the industry’s needs. The foresight has allowed Allen-Bradley PLCs to provide industrial control applications uninterrupted to this day, making them the reference point all others are measured against.

The Unrivaled Reliability and Scalability

The historical heritage of Allen-Bradley PLCs would be worthless without a contemporary hardware Portfolio that addresses today’s challenging industrial needs. Rockwell Automation has diversified its products into three separate but cohesive lines of Allen-Bradley PLCs.

ControlLogix PLCs

The ControlLogix family represents the pinnacle of the Allen-Bradley PLC platform. The latest variant, the ControlLogix 5580 (or L8x series), witnesses continuous upgrades. It boasts speeds of a maximum of 20 times faster than its L7-series predecessor. They are also backward-compatible for connectivity with older Allen-Bradley networks such as ControlNet, DeviceNet, and DH+, with high-speed Ethernet/IP to a maximum of 1 Gbps.

CompactLogix PLCs

Meeting the changing of the time requests for a more affordable yet powerful alternative, Allen-Bradley brought forth the CompactLogix family. This line of Allen-Bradley PLCs is derived from the ControlLogix platform into a more compact model, which is especially suitable for standalone or smaller distributed control systems.

Two variants of the CompactLogix family are available for maximum application flexibility. The first one is a modular, but chassis-free, controller that allows the user to configure custom I/O. The second one is an all-in-one unit having embedded digital and analog I/O connections that addresses the design complexity and reduces the footprint for space-constrained installations. Every CompactLogix Allen-Bradley PLC is integrated with an SD card slot for backing up programs and doing firmware updates, as well as a USB port that is built in for fast programming. The most recent models, including the CompactLogix 5380, have two Ethernet ports that can reach 1 Gbps and a user memory of up to 10MB.

MicroLogix and Micro800 PLCs

Since its launch in 1994, the MicroLogix line has been focused on compactness and faster implementation. It is a completely integrated controller with a built-in processor, power supply, and I/O.

The last version, the Micro800 series, is the same scale and continues the tradition with modern improvements. These Allen-Bradley PLCs have embedded I/O terminals and integrated communication channels such as USB and Ethernet. The key feature is the support for front-facing add-on modules. This allows the specific functions demanded by the applications to be added. While earlier MicroLogix controllers are obsolete, their versatility in being used universally is a testament to their durability. The Micro800 series ensures that there is a strong and cost-effective Allen-Bradley PLC for simple tasks such as small conveyor control, simple machine automation, or HVAC control.

Advanced Functions and Thinking Ahead in Allen-Bradley PLCs

Running ladder logic only is not enough for a modern-day automation controller. The latest generations of Allen-Bradley PLCs are constructed with advanced functions embedded, able to cope with the needs of advanced industrial applications.

Integrated Safety and Motion

New Allen-Bradley PLCs, especially the Logix family, integrate discrete control with motion and safety functions all together. Rather than using dedicated single controllers for these functions, the ControlLogix or CompactLogix processor can accomplish sophisticated coordinated motion, servo drives, and safety relay functions. This integrated architecture, called CIP Motion and CIP Safety, executes over plain Ethernet/IP networks. This translates to reduced system design complexity and simpler diagnostics for engineers.

In-Build Connectivity for Industry 4.0 and IIoT

Migration to the Industrial Internet of Things (IIoT) demands controllers with the capability to communicate with upper-level systems easily. The new Allen-Bradley PLCs are engineered with this in mind. Dual, isolated Ethernet ports on the ControlLogix 5580 and CompactLogix 5380 controllers facilitate network segmentation—isolating plant-floor device traffic from traffic destined for manufacturing execution systems (MES) or enterprise resource planning (ERP) systems. SD cards are utilized to make data logging and program version control easier. This embedded connectivity makes systems based on Allen-Bradley PLCs not only strong enough to serve the control work of the day but also fated to be leading sources of information in tomorrow’s intelligent factories.

Cybersecurity and Global Support

With the rising cases of cyber threats, industrial control system security is head and shoulders above the rest. For its Allen-Bradley PLCs, Rockwell Automation has developed a strong cybersecurity system. Recommended practices such as user authentication, access control, and recording of changes prevent unauthorized modifications. Furthermore, the company proactively identifies depths into addressing vulnerabilities and issuing security patches as well as advisories.

Finally, the worldwide support network for Allen-Bradley PLCs is industry leading. No other supplier comes even close when it comes to reliability. With a vast network, Help is always on the way for thousands of distributors, system integrators, and technical support specialists worldwide. Long product lifecycles and the commitment to backward compatibility result in products whose features remain current for quite some time since their replacements are not immediate. This is because their successors have yet to be invented or do not exist yet. Investments in Allen-Bradley PLCs are investments for years, even decades. This decreases the risk of investing, hinders the speed of obsolescence, and ensures that spare parts and technical expertise remain accessible.

Conclusion

As more engineers become familiar with the system, the reduced engineering risk and broad global support network create a value proposition that far outweighs the upfront hardware cost. This commitment to customer success has solidified Allen-Bradley PLCs as the benchmark standard in industrial automation. Come on by and visit our site and see all of the different PLCs, drives, and controllers that can streamline your industrial process. If you need help figuring out just what you need to get started, no sweat, our team is just a phone call away and can help you find just what you need.