We found 165 posts about Comparison Guides from DO Supply, a global automation parts
reseller focused on hard-to-find and obsolete industrial automation products.
DC drives continue to play a crucial role in heavy industrial applications that need outstanding starting torque, accurate speed control, and quick dynamic response, even though AC variable frequency drives have significantly increased their market share. DC drive technology is still used in a number of industries, including material handling, elevator systems, crane operations, paper making, and metal processing. Performance capabilities, energy efficiency, hardware complexity, and long-term operating costs are all determined by the basic differences between regenerative and non-regenerative DC drives. This page offers a thorough technical comparison of these drives, backed by up-to-date performance measures and industry statistics. The operational quadrant capability represents the most fundamental distinction between these drive types. Source Regenerative PowerFlex DC Drives Non-regenerative drives are commonly one- or two-quadrant converters. A one-quadrant drive provides motoring...
In the modern age, motor control isn’t as simple as it looks. There’s matching nameplate specifications, determining if the load you’re driving needs certain features like regeneration, or even figuring out if it’s worth futureproofing. With VFDs being so common today, it is easy to assume they are always the better answer. But that’s not always the case. Sometimes, less really is more. If the application only calls for smooth starting and stopping, a soft starter could be the cheapest, simplest, and most cost-effective choice. A soft starter, as the name implies, is a motor controller that gradually and smoothly increases a motor’s speed until its desired RPM, rather than slamming voltage into it all at once. This is a desired feature as its ability to reduce inrush current and limit peak electrical demand on motor start-up reduces mechanical stress on the system and prevents overcurrent scenarios. Source SMC Plus Soft Starters Here To achieve this, soft starters use thyristors, or...
A new installation is not the same as a retrofit project. The selection logic for a ControlLogix processor must take into consideration elements that are absent from a greenfield project, and the risks and constraints are different. A processor must fit into a panel sized for a PLC-5 or SLC 500 chassis, communicate with devices never intended for EtherNet/IP, coexist with existing wiring, and be maintainable by a team that has worked on RSLogix 500 for years. A predetermined set of technical criteria must be followed to make the proper choice. That approach is covered from the start in this article. The first task on any ControlLogix retrofit is documenting the full scale of the legacy system, not just the I/O count, but everything the existing controller manages. A practical first pass is to group the 5580 processors by memory class: 1756-L81E for smaller systems, 1756-L82E or 1756-L83E for moderate retrofits, and 1756-L84E or 1756-L85E for larger PLC-5 migrations, high tag counts...
Conveyor systems serve as crucial circulatory networks in warehouses, airports, mining operations, food processing plants, and manufacturing industries. Well-designed conveyors drastically reduce manual material handling while improving operational efficiency and ensuring consistent output quality. Allen-Bradley PowerFlex drives are essential components of modern conveyor systems, whose performance relies heavily on precise control of the connected motors. PowerFlex drives utilize advanced control modes, including Sensorless Vector Control (SVC), Volts/Hertz (V/Hz), and TotalFORCE technology (available on the PowerFlex 755T series), to deliver high-precision regulation of motor speed and torque. This highly precise motor control enables smooth acceleration and deceleration of conveyor systems, significantly reducing wear and tear on conveyor belts, gearboxes, and bearings by minimizing mechanical shock. Selecting the correct PowerFlex drive helps minimize system downtime, enhance...
Choosing the right PanelView HMI is no easy task; it’s not just about the screen size or the communication protocol. A major choice is whether a PanelView terminal will be equipped with a keypad, a touchscreen, or both. PanelView models with a keypad enable a variety of functions under harsh operating conditions that touchscreen interfaces cannot. By understanding the true costs and benefits of these input methods, engineers, operators, and maintenance personnel can select the most appropriate PanelView solution for their application. Modern PanelView families vary widely in the input options available. PanelView 5310 and 5510 terminals use touchscreen input, while PanelView 800 and legacy PanelView Plus 6 models include keypad, touchscreen, or keypad/touchscreen options depending on the model. PanelView Plus 7 Standard terminals are primarily touchscreen-based. The choice of interface affects the operator’s efficiency, navigation speed, maintenance requirements, system reliability...
A graphic terminal remains an invaluable asset within most automated systems. It gives operators a practical way to see what a machine is doing, respond to alarms, adjust process values, and keep production moving without needing to dig through the control cabinet every time something changes. Of course, the effectiveness of the terminal varies depending on factors such as screen size, graphic design, responsiveness, and so on. Because of this, it can get a bit overwhelming trying to spec the perfect HMI for your setup. Today, we’re here to narrow down your search with two popular offerings on the market: The Mitsubishi GOT2000 series and the Allen-Bradley PanelView 5500 series. Both of which are built for a serious industrial environment, yet lean into their own strengths that we will go over to help you make a more informed decision. Before diving into the comparisons, it’s best to go over what each HMI’s family is trying to accomplish. While the Mitsubishi GOT2000 and the...
The PowerFlex product family from Rockwell Automation spans one of the broadest drive portfolios in industrial automation. Engineering the right selection from within that portfolio requires understanding precisely where Rockwell draws the line between its compact and full-size (architecture-class) drive categories, and what technical capabilities exist on each side of that line. PowerFlex drives are broadly categorized into compact-class and architecture-class: compact drives are smaller, cost-effective units for simpler applications, while architecture-class drives are high-performance, feature-rich units for demanding industrial requirements. Here, we will discuss some parameters for comparing the two types of drives. Source PowerFlex 755 Drives Here Rockwell Automation organizes the PowerFlex family into three tiers: compact (component-class), standard, and architecture-class. The compact tier encompasses the PowerFlex 4 , 40 , 523 , 525 , and 527 series. The architecture-class...
An AC drive is basically a device that lets you control how fast and how hard an AC motor runs. It does so by changing the frequency and voltage of the power supplied to the motor. And knowing the difference between a general-purpose AC Drive and a high-performance AC Drive really matters if you’re into modern industrial automation. General-purpose VFDs are widely used because they handle most industrial tasks. But there are times when you need something more powerful and precise; that’s where high-performance drives step in. If you’re an engineer or have to make purchasing decisions, you need to know how these two stack up before you spend a dime. Shop for Allen-Bradley PowerFlex 525 Drives Here A general-purpose AC Drive is designed to suit a wide range of settings, including factories, businesses, and full-scale industrial environments. They’re flexible, so people tend to use them almost everywhere. Maybe you work somewhere that needs a motor control system that’s ready to scale up...
Allen-Bradley CompactLogix and ControlLogix controller platforms play a key role in modern industrial automation. ControlLogix controllers are configurable for safety, standard, Logix SIS, and redundancy applications, facilitating faster system performance, high I/O capacity, enhanced productivity, and improved security for enterprise-level and large-scale automation systems. CompactLogix platforms offer the same core processing capabilities as ControlLogix platforms, but for cost-sensitive, mid-range, or standalone automation applications — often at a fraction of the total ControlLogix investment. Selecting the correct Allen-Bradley controller between the ControlLogix and CompactLogix platforms requires balancing cost, I/O capacity, performance, complexity, and scalability to avoid oversized control panels, redundant programming complexity, and inflated hardware costs. This article explains the technical differences between the two platforms and provides a clear selection criterion...
DC drives and servo drives are two distinct types of motor control devices. DC drives are commonly used for steady-speed and torque control, while servo drives are designed for precise, responsive control of position, speed, and torque. If you want to really get what sets them apart, you have to dig into how they work, what motors they run, and the sorts of things they’re actually used for. A DC drive converts incoming AC power into DC, ensuring the motor receives the correct voltage and current. In many cases, the controller and drive are combined, so commands and motor output go hand in hand. Inside, it all comes down to how the drive handles AC. Many traditional DC drives use SCR-based rectifier circuits to convert incoming AC power into a controlled DC output for the motor armature. Smaller drives may use single-phase rectifier designs, while larger industrial DC drives often use three-phase, six-pulse SCR bridges for smoother and higher-power DC output. This is why you will see...
Selecting a Variable Frequency Drive for a harsh environment application is not simply a matter of matching horsepower and voltage. Ambient temperature, particulate contamination, corrosive atmospheres, moisture exposure, hazardous area classification, and physical installation constraints all impose requirements that eliminate drives from consideration before a single control parameter is evaluated. The Allen-Bradley PowerFlex family spans a wide range of drive architectures, enclosure ratings, and environmental specifications. Understanding which PowerFlex variant is engineered for a given harsh environment determines whether the installation delivers a decade of reliable service or becomes a recurring maintenance liability. A harsh environment for a VFD is any installation condition that exceeds the standard assumptions of a clean, temperature-controlled indoor panel: Ambient temperatures above 40°C or below 0°C Relative humidity approaching saturation Airborne conductive or...
In today’s industrial automation, selecting the most appropriate motion control technology is critical for achieving high system performance, with servo and AC drives leading as the top choices. While they both control electric motors, they operate on distinct principles designed for different industrial applications. AC drives are optimized for energy-efficient, variable-speed, open-loop, or simple closed-loop control of speed and torque. On the other hand, servo drives are engineered for fast response times and high-precision, closed-loop dynamic positioning. Therefore, system engineers need to select a motor control technology that precisely matches the specific requirements of a given application. This article explores the unique operating principles, key strengths, and specific limitations of AC and servo drive technologies to guide your selection process. AC drives, commonly known as Variable Frequency Drives (VFDs), are electronic devices that regulate the torque and speed of...
Industrial automation engineers selecting between the Allen-Bradley ControlLogix 5580 and CompactLogix 5380 rarely face a straightforward decision. Both support EtherNet/IP-based motion and safety and carry the Logix that makes them interoperable within Rockwell’s Integrated Architecture. Beneath that shared surface, however, the two platforms diverge in capacity, scalability, environmental tolerance, and application scope. Understanding where that gap actually matters determines whether a system is appropriately specified or quietly undersized. The CompactLogix 5380 was designed for compactness and self-contained machine control. Its architecture assumes a bounded application, a defined axis count, manageable I/O, and a system that runs on a single machine or in a production cell. The ControlLogix 5580 was designed for a different problem: applications that grow, where multiple disciplines coexist in one program, and where the controller serves as the backbone of a plant-wide...
Upgrading your hardware always feels like a special occasion, especially if it’s for something you handle every day. After all, who doesn’t like faster hardware, more refined software, and a more responsive user interface? The reality becomes a little more complicated when the equipment in question is tied directly to production. In industrial automation, replacing hardware is rarely as simple as unplugging one terminal and mounting another in its place. This hesitation is part of the reason you will still see the PanelView Plus 6 in so many facilities, even with the newer PanelView Plus 7 series on the market. This boils down to compatibility concerns, retrofit cost, downtime windows, network architecture, and operator familiarity. In some situations, moving to a Plus 7 terminal can modernize an entire machine interface. In others, it can create more work than value. Before we get into comparing specifications and features, it helps to understand where these terminals are typically...
In industrial motor control applications, choosing the right starting and control method for high-inertia loads is a decision with significant consequences for equipment longevity, process stability, and energy efficiency. Soft starters and Variable Frequency Drives (VFDs) are the two dominant technologies for this purpose. While both reduce mechanical stress during motor starting, they differ fundamentally in operational scope, torque-control capability, and suitability for specific load profiles. Understanding these distinctions is critical when specifying drive systems for conveyors, centrifuges, fans, pumps, and compressors that impose substantial inertia on the drivetrain. High-inertia loads are characterized by a large moment of inertia (J, measured in kg·m²) relative to the motor’s rated torque. These loads require extended acceleration times to reach synchronous speed and impose prolonged mechanical and thermal stress on both the motor and the driven equipment. Common examples...
