7 Key Benefits of Modular Controllers for Industrial Automation

Modular industrial controllers improve flexibility, scalability, and reliability in automation control systems. Flexible automation controllers simplify integration with legacy equipment, enhancing efficiency and cost-effectiveness for modern industrial facilities.

Using modular PLC solutions and industrial process controllers allows manufacturers to upgrade easily, reduce downtime, and optimize operations. According to data from Siemens, the latest industrial automation devices require up to 66% less effort when programming. This, along with other innovations like flexibility and efficiency, makes industrial automation a must in modern manufacturing.

Here, we’ll explore the top seven benefits of using flexible, modular industrial controllers for streamlined automation control systems and efficient industrial process management.

Benefit 1: Scalability for Growing Operations

Modular industrial controllers are highly scalable automation devices that allow businesses to expand their automation systems without full replacements. The prime reason behind their enhanced scalability lies in the separate, interchangeable components, such as the CPU, power supply, and I/O modules, which can be replaced to accommodate the growing automation needs.

These modular PLC solutions achieve scalability through the following:

• Multiple I/O modules can be added to the PLC system
• Allows technicians to pick and choose which modules to add, like analog I/O, high-speed counters, communication cards, or safety controllers.
• The memory capacity can be expanded to handle more complex programs and data.
• Future-proofs industries by allowing easy upgrades.
• Allows quick replacement of components without the need for entire shutdowns.

Top Examples of Modular System Expansion

A few ways in which the scalability of modular PLC solutions can be seen in action are:

Current Setup	New Requirement	Modular Solution Benefit
8 I/O modules	Add 4 more I/O modules	No need to replace the entire PLC, which reduces cost
1 process line	Add 2 additional lines	Easy integration with the existing controller

Table 1: Examples of modular system expansions for PLCs.

Benefit 2: Cost Efficiency

Modular industrial process controllers can reduce upfront investment by buying only the necessary modules. When compared to monolithic systems, modular controllers have significantly lower maintenance and replacement costs since you only need to repair/ replace the damaged component.

Thus, you only have to pay for the functionalities needed by adding specific modules. This makes upgrades simpler by swapping out the individual modules. Further, modular PLCs can reduce downtime and the cost of overheads associated with upgrades or repairs because individual modules can be serviced or replaced without taking the entire system offline.

The easier troubleshooting, quick maintenance, and simplified retrofitting compared to hardwired systems make repair and upgrades far less expensive and add to ROI.

Benefit 3: Simplified Maintenance

When monolithic systems face component failure, the operations are temporarily shut down for maintenance work. Further, this maintenance work can be significantly time-consuming and even lead to the installation and commissioning of a new system. 

Flexible automation controllers are modular in their design. Thus, engineers and technicians can swap individual modules without affecting the whole system. This leads to less downtime and uninterrupted productivity.

A step-by-step replacement process for industrial modular controllers is as follows:

• Consult technical documentation, follow the safety protocols, and power down the system. 
• Allow the internal controllers sufficient time to discharge before touching the components.
• Identify and document which modules are being replaced or worked on.
• Disconnect the wiring carefully, remove the old/existing module, and replace it with the new one.
• Reconnect the wiring and check if all connections made are correct and secure.
• Reassemble the enclosure and restore power to the system.
• Once the PLC boots up, you may test the system and upgrade documentation.

Recent PLC components and modules also have a provision for “hot swaps”. This allows replacement of modules without the system being shut down.

Benefit 4: Enhanced Flexibility

Modular PLC solutions make it easy to keep up with evolving industrial needs by making it easy to adapt to changing production requirements. These devices can be easily reconfigured to automate control systems that handle different processes.

These make the existing system future-proof and customization easy to achieve. Further, the ability to reprogram them allows quick, cost-efficient upgrades to the production pipeline without major hardware changes. 

Thus, these flexible automation controllers can support both simple industrial applications with batch processes and complex automation tasks that involve a high number of I/O points.

Comparison of the Flexibility Offered By Industrial Process Controllers

The flexibility of modular industrial process controllers in comparison to monolithic systems can be explained better with the help of the following table:

Controller Type	Reconfiguration Time	Adaptability	Maintenance Complexity
Modular PLC	1 – 2 hours	High	Low
Monolithic PLC	1 – 2 days	Low	High

Table 2: Comparison of modular and monolithic PLCs.

Benefit 5: Integration with Legacy Systems

Modular industrial controllers have high compatibility and are designed to operate on the same interface as older machinery, as well as newer systems. This helps industries avoid full-scale replacement while modernizing their automation control systems. 

This industrial integration process requires evaluating factors like compatibility, communication protocols (like Modbus or Ethernet/IP), bridging protocol gaps, and planning data exchange. 

The stepwise method that needs to be followed for the integration of modular automation control systems for legacy equipment is as follows:

• Map the existing system and identify the limitations it has in terms of compatibility and communication protocols.
• Plan a detailed integration strategy by choosing communication protocols and deciding what data needs to be migrated to the new system.
• Be sure to address the compatibility gaps between the new and older systems.
• Choose a compatible hardware and implement a gateway to connect and translate data between the PLC’s protocol and TCP/IP.
• Develop the control logic for the system and test it thoroughly.

In case of complex industrial integrations that call for significant upgrades, you may consult the experienced control system integrators who have expertise in various industrial control systems, protocols, and data translation techniques.

Benefit 6: Improved Reliability and Safety

The modern modular PLC solutions are designed with higher redundancy and reliability. These redundant modules enhance the system’s overall reliability. Further, they enable fault isolation to prevent complete system failures.

You may also opt for dedicated safety PLC modules that come with integrated safety functions and fail-safe operations. With predictable failure modes, these devices allow rapid problem-solving and initiate safe shutdowns when necessary, minimizing danger and damage.

Further, these PLCs have durable hardware designed to withstand harsh industrial environments. Additionally, the inherent modularity and built-in diagnostics of these PLCs simplify maintenance and troubleshooting.

To add a layer of security, engineers can also use the pre-approved safety function libraries and simulation tools and password-protect the systems to prevent unauthorized access or modification, ensuring integrity.

Benefit 7: Advanced Monitoring and Control

Modern industrial PLC controllers are designed to continuously collect, monitor, and process input data, and enable predictive maintenance and process optimization. The advanced monitoring techniques work on the basis of the following:

• Real-time data acquisition from sensors and connected devices.
• SCADA and HMI integration offer a centralized, user-friendly graphical interface for operators for process visualization.
• Collected data can be used to monitor machine behaviour, enabling proactive maintenance.
• Through advanced diagnostics and fault detection, these devices offer quick identification and resolution of faults and on-site troubleshooting.
• The input data logged through real-time monitoring can be used for trend analysis and detecting production patterns.
• Modern automation control systems also come equipped with IoT and Cloud Connectivity for remote monitoring and analysis.

Monitoring Features of Modular Controllers

The features of modular industrial controllers that can be used for monitoring are as follows:

Feature	Description	Benefit
Remote access	Monitor controllers from anywhere	Faster response to issues
Data logging	Track process parameters	Predictive maintenance
Alarm management	Automatic fault alerts	Minimize downtime

Table 3: Monitoring capabilities offered by industrial controllers.

Wrapping Up

Scalability, cost efficiency, simplified maintenance, flexibility, integration, reliability, and advanced monitoring are the key benefits of modular PLC solutions available to industries. Thus, adopting modular industrial controllers that offer flexible automation is key to improving industrial efficiency and ROI.

Stepping Up Industrial Automation With Modular PLC Solutions

Ready to make your industrial processes future-proof? Consult industrial automation experts and upgrade your automation control systems with modular PLC solutions today.

Frequently Asked Questions

What Are the Most Common PLC Programming Languages? 

The popular PLC programming languages used by most industries include Ladder Logic, Structured Text, Function Block Diagram, Instruction List, and Sequential Function Chart.

Why is Redundancy Important in PLC Systems?

Redundant systems (presence of standby components as backup) help prevent system failure, protecting critical equipment, enabling easier maintenance, reducing downtime, and keeping essential processes running.

What Are Some of the Biggest Challenges That You Can Face When Implementing Industrial Automation?

The biggest challenges here include the initial investment cost, integration of new systems with existing (legacy) equipment, the workforce being resistant to change, and ensuring robust cybersecurity measures to protect connected systems from threats.

Is Industrial Automation Relevant Only Meant for Large Companies?

While large companies opt for extensive automation, small and medium-sized enterprises (SMEs) can also benefit by implementing flexible automation solutions that boost productivity and efficiency without massive investments.