{"id":132007,"date":"2025-09-15T02:01:15","date_gmt":"2025-09-15T07:01:15","guid":{"rendered":"https:\/\/www.controleng.com\/?p=132007"},"modified":"2025-09-15T08:04:26","modified_gmt":"2025-09-15T13:04:26","slug":"selecting-the-right-controller-type-for-the-automation-application","status":"publish","type":"post","link":"https:\/\/www.controleng.com\/selecting-the-right-controller-type-for-the-automation-application\/","title":{"rendered":"Selecting the right controller type for the automation application"},"content":{"rendered":"\n<h4 class=\"wp-block-heading\">Industrial controller selection insights<\/h4>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Explore industrial controller selection advice from system integrators experts, also instructors in a September <em>Control Engineering<\/em> webcast.<\/li>\n\n\n\n<li>Understand physical requirements for an industrial controller and that you may not get the best controller, but the best controller for the application.<\/li>\n\n\n\n<li>See the webcast for more advice: Register for the <em>Control Engineering<\/em> webcast, \u201cHow to select the right controller type for the automation application,\u201d archived until Sept. 25, 2026.<\/li>\n<\/ul>\n\n\n\n<p>Get advice on \u201c<a href=\"https:\/\/event.on24.com\/wcc\/r\/5060437\/B8E7A107A08112332D0BBF3E982F1C5F\" target=\"_blank\" rel=\"noreferrer noopener\">How to select the right controller type for the automation application<\/a>\u201d from <em>Control Engineering<\/em> in a Sept. 25 webcast (archived for a year); webcast instructors provide controller selection advice below. The instructors (Figure 1) are:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Jon Breen, founder\/owner, Breen Machine Automation Service LLC<\/li>\n\n\n\n<li>Vinoth Upendra Janardhahan (\u201cVinoth\u201d), automation engineer, CDM Smith.<\/li>\n<\/ul>\n\n\n\n<p>Moderator for the webcast is Mark T. Hoske, editor-in-chief, <em>Control Engineering<\/em>.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Industrial controller selection advice<\/h2>\n\n\n\n<p>\u201cAutomation and controls applications are growing in numbers and breadth across industries, and it\u2019s critical to ensure the selected and applied automation controllers are fit for purpose,\u201d according to the webcast description. It continues: \u201cFor most applications, more than one controller type may be suitable. How should you choose from among programmable logic controllers (PLCs), programmable automation controllers (PACs), industrial PCs, embedded controllers, edge devices, human-machine interfaces (HMIs) and hybrid controllers that may be integrated with or combined in computers, drives, robotics, vision and input\/output (I\/O) devices and systems? Should you mix and match vendors or stay with one ecosystem? Way beyond initial cost, criteria may include environment speed, operating system, cybersecurity, standards, interoperability, lifecycle, communications, training and more.\u201d<\/p>\n\n\n\n<figure class=\"wp-block-image aligncenter size-full is-resized\"><img loading=\"lazy\" decoding=\"async\" width=\"797\" height=\"426\" src=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/09\/CTL250925_WC_Controller-Selection-preview-Fig2-tips-J.Breen_.png\" alt=\"\" class=\"wp-image-132013\" style=\"width:900px\" srcset=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/09\/CTL250925_WC_Controller-Selection-preview-Fig2-tips-J.Breen_.png 797w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/09\/CTL250925_WC_Controller-Selection-preview-Fig2-tips-J.Breen_-300x160.png 300w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/09\/CTL250925_WC_Controller-Selection-preview-Fig2-tips-J.Breen_-768x410.png 768w\" sizes=\"auto, (max-width: 797px) 100vw, 797px\" \/><figcaption class=\"wp-element-caption\">Figure 2: Practical advice for industrial controller selection, according to Jon Breen, founder\/owner, Breen Machine Automation Service LLC, includes focusing on application needs and technical features. Courtesy: Control Engineering webcasts<\/figcaption><\/figure>\n\n\n\n<h2 class=\"wp-block-heading\">Perhaps not the best controller, but the best for the application<\/h2>\n\n\n\n<p>\u201cI\u2019ll say up front that you\u2019ll never have the time to select the \u2018best\u2019 controller,\u201d Breen explained in his notes for the webcast (Figure 2). \u201cAs with most engineering applications, we\u2019re going to lean on rules of thumb and experience to quickly narrow the list of options to something that will work reliably for a reasonable cost (good not best).\u201d<\/p>\n\n\n\n<p>By focusing on specific industrial controller application needs, it allows the vague terms related to industrial controllers be vague, Breen noted.<\/p>\n\n\n\n<p>\u201cThe first thing I ask when I\u2019m looking at a new application is about brand,\u201d Breen said. It\u2019s common to standardize on a single brand for a lot of good reasons &#8211; fewer software licenses, fewer spare parts, less training, etcetera, but this can also come with some risks.\u201d<\/p>\n\n\n\n<p>Having one brand of industrial controller for an application, Breen said, \u201calso dramatically simplifies the process of selecting a controller because that brand will usually have three lines to choose from &#8211; small, medium and large. But this also comes with some tradeoffs.<\/p>\n\n\n\n<p>\u201cIf that brand doesn\u2019t support certain functions, you just can\u2019t have them. And if that brand finds itself preferred for many customers, it\u2019ll raise prices without offering more features.\u201d<\/p>\n\n\n\n<p>Breen called it a \u201cconsumer-defined monopoly,\u201d noting that with the supply chain issues over the pandemic, many customers were \u201cforced to consider other options, and some of them were very happy with what they found.\u201d<\/p>\n\n\n\n<p>Breen\u2019s not locked into any one supplier forever, though. \u201cI do encourage teams to standardize, but to keep an open mind and deliberately reconsider every few years. The controller selection often has broad-reaching implications for the rest of the control system.\u201d<\/p>\n\n\n\n<figure class=\"wp-block-image aligncenter size-large is-resized\"><img loading=\"lazy\" decoding=\"async\" width=\"1024\" height=\"576\" src=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/09\/CTL250925_WC_Controller-Selection-preview-Fig3-process-V.U.Janardhahan-1024x576.png\" alt=\"\" class=\"wp-image-132014\" style=\"width:900px\" srcset=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/09\/CTL250925_WC_Controller-Selection-preview-Fig3-process-V.U.Janardhahan-1024x576.png 1024w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/09\/CTL250925_WC_Controller-Selection-preview-Fig3-process-V.U.Janardhahan-300x169.png 300w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/09\/CTL250925_WC_Controller-Selection-preview-Fig3-process-V.U.Janardhahan-768x432.png 768w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/09\/CTL250925_WC_Controller-Selection-preview-Fig3-process-V.U.Janardhahan-1536x864.png 1536w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/09\/CTL250925_WC_Controller-Selection-preview-Fig3-process-V.U.Janardhahan-900x506.png 900w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/09\/CTL250925_WC_Controller-Selection-preview-Fig3-process-V.U.Janardhahan-400x225.png 400w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/09\/CTL250925_WC_Controller-Selection-preview-Fig3-process-V.U.Janardhahan.png 1920w\" sizes=\"auto, (max-width: 1024px) 100vw, 1024px\" \/><figcaption class=\"wp-element-caption\">Figure 3: Selection process for industrial controllers includes defining application requirements, such as scale, speed, control type and environment. Courtesy: Control Engineering webcasts<\/figcaption><\/figure>\n\n\n\n<h2 class=\"wp-block-heading\">How to define industrial controller application requirements<\/h2>\n\n\n\n<p>Vinoth, in preparing for the webcast, discussed four steps to define the requirements of the industrial controller application (Figure 3).<\/p>\n\n\n\n<p>1. Scale: Controllers have limits on how many I\/O modules or points they can handle. For example, a small PLC might support a few dozen I\/Os; meanwhile a large PAC or DCS can scale to thousands with distributed I\/O racks. If you underestimate I\/O count, you might select something that runs out of capacity, forcing you to add another controller mid-project. It\u2019s prudent to not only count current I\/O but also add an allowance for future expansion.<\/p>\n\n\n\n<p>2. Speed and performance: If your process is time-critical, say we\u2019re dealing with a high-speed packaging line that needs millisecond decisions, you need a controller known for fast cycle times (PLC might cycle in 5-10 ms, which is fine, but a DCS might be 100 ms, which could be too slow in that case). Also, if you have a lot of interlocking and motion, a PAC might be required. On the other hand, if it\u2019s a slow process (like environmental temperature control where things change over minutes), you don\u2019t need to pay for a premium Controller, rather a robust, steady controller is more important.<\/p>\n\n\n\n<p>3. Type of control. Discrete-heavy projects suit PLCs, analog process loops suit DCS or PACs with strong PID capability. Motion needs either a PAC with motion modules or dedicated motion controllers. Safety adds another layer \u2013 emergency shutdowns may require safety-rated PLCs or redundant controllers.<\/p>\n\n\n\n<p>4. Environment: It\u2019s one thing to see a controller work in a lab, or on a plant floor next to a furnace or out at a remote well in the desert. Temperature range, humidity, corrosive atmosphere, electrical noise \u2013 all these factors can rule out some options. PLCs are generally built tough, but industrial PCs need hardened designs. Vibration also is a factor, for example, controllers on skid-mounted equipment or near high electro-magnetic interference (EMI, from large motors, for instance) need shock resistance. Power is another consideration \u2013 some remote controllers can run on 24 VDC from a solar panel, while others need clean AC power. Physical space: if you only have a tiny junction box available, you might need a micro-PLC or embedded controller; if you have a full control room, a rack system is okay.<\/p>\n\n\n\n<p>So, tailor the hardware based on physical conditions, Vinoth added.<\/p>\n\n\n\n<p><strong>Mark T. Hoske<\/strong> is editor-in-chief, <em>Control Engineering, <\/em>WTWH Media<em>,<\/em> <a href=\"mailto:mhoske@wtwhmedia.com\" target=\"_blank\" rel=\"noreferrer noopener\">mhoske@wtwhmedia.com<\/a>.<\/p>\n\n\n\n<p><strong>Keywords<\/strong><\/p>\n\n\n\n<p>Industrial controller selection, PLC selection<\/p>\n\n\n\n<p><strong>Consider This<\/strong><\/p>\n\n\n\n<p>Are you getting all you need from your industrial controllers, or are you past-due for upgrades?<\/p>\n\n\n\n<p><strong>Online<\/strong><\/p>\n\n\n\n<p>Register for the <em>Control Engineering<\/em> webcast, \u201cHow to select the right controller type for the automation application,\u201d archived until Sept. 25, 2026, here:<\/p>\n\n\n\n<p><a href=\"https:\/\/event.on24.com\/wcc\/r\/5060437\/B8E7A107A08112332D0BBF3E982F1C5F\" target=\"_blank\" rel=\"noreferrer noopener\">https:\/\/event.on24.com\/wcc\/r\/5060437\/B8E7A107A08112332D0BBF3E982F1C5F<\/a><\/p>\n","protected":false},"excerpt":{"rendered":"<p>Control Engineering offers an hour of webcast instruction with practical advice for \u201cHow to select the right controller type for the automation application\u201d on Sept. 25, and this article offers related advice on industrial controller selection.<\/p>\n","protected":false},"author":56,"featured_media":132012,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"pgc_sgb_lightbox_settings":"","footnotes":""},"categories":[104070],"tags":[110679,110069,109340,110684,110681,110682,110680,110683],"tracking-metrics":[],"display-location":[109353],"class_list":{"2":"type-post"},"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v25.9 - https:\/\/yoast.com\/wordpress\/plugins\/seo\/ -->\n<title>Selecting the right controller type for the automation application - Control Engineering<\/title>\n<meta name=\"description\" content=\"Control Engineering offers an hour of webcast instruction with practical advice for \u201cHow to select the right controller type for the automation application\u201d on Sept. 25, and this article offers related advice on industrial controller selection.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/www.controleng.com\/selecting-the-right-controller-type-for-the-automation-application\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Selecting the right controller type for the automation application - Control Engineering\" \/>\n<meta property=\"og:description\" content=\"Control Engineering offers an hour of webcast instruction with practical advice for \u201cHow to select the right controller type for the automation application\u201d on Sept. 25, and this article offers related advice on industrial controller selection.\" \/>\n<meta property=\"og:url\" content=\"https:\/\/www.controleng.com\/selecting-the-right-controller-type-for-the-automation-application\/\" \/>\n<meta property=\"og:site_name\" content=\"Control Engineering\" \/>\n<meta property=\"article:publisher\" content=\"https:\/\/www.facebook.com\/ControlEngineeringMagazine\" \/>\n<meta property=\"article:published_time\" content=\"2025-09-15T07:01:15+00:00\" \/>\n<meta property=\"article:modified_time\" content=\"2025-09-15T13:04:26+00:00\" \/>\n<meta property=\"og:image\" content=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/09\/CTL250925_WC_Controller-Selection-preview-Fig1-JonBreen-VinothUpendraJanardhahan.png\" \/>\n\t<meta property=\"og:image:width\" content=\"994\" \/>\n\t<meta property=\"og:image:height\" content=\"560\" \/>\n\t<meta property=\"og:image:type\" content=\"image\/png\" \/>\n<meta name=\"author\" content=\"Mark T. 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