1. Edge Programmable Industrial controllers (EPIC) are becoming increasingly popular

Today, edge computing, as an important supplement to cloud computing, has received more and more attention in building connected factories. Edge computing realizes the analysis, processing and storage of data at the edge of the network, which not only reduces the dependence on the cloud, but also improves the security of data.

However, the edge computing puts forward high requirements on the local processing ability of data, and the traditional PLC controller is no longer competent for such work. In recent years, edge Programmable Industrial controllers (EPics) are poised to replace traditional PCS, servers, and legacy hardware in factory environments.

Designed to improve the efficiency of existing automation systems while reducing complexity and cost of ownership, edge controllers can handle more automation functions, including those traditionally performed by PCS or other dedicated devices. The edge controller can integrate PLC controller, PC, gateway, motion control, I/O data acquisition, fieldbus protocol, machine vision, device networking and other functions in one body, while realizing device motion control, data acquisition, computing and cloud connection, and cooperating with remote industrial cloud platform on the edge side to achieve intelligent production line control.

The software architecture of edge controllers is essentially a cloud and edge two-tier architecture that integrates user management, networking, security, and hardware interfaces on an innovative software platform configured at the edge (where the data is generated) to create an ecosystem of applications and tools that users can use to deliver richer functionality to the process than before.

2. Advantages enable automation and promote the integration of IT and OT

Edge controller devices take advantage of the latest advanced technologies in IT communication and the Internet of Things, while retaining the advantages of PLC/PAC in OT. The communication of edge controller has two different levels: one is to collect the I/O of industrial equipment and process data, and to communicate with other industrial control equipment, which belongs to the OT category; The other is the communication between edge devices and OT data centers and cloud servers, which belongs to the category of IT, that is, the category of industrial Internet. As a physical interface between IT and OT, on the basis of completing the control functions of workstations or production lines, the interface capability and computing power of industrial equipment are improved, and the applicability of industrial equipment is improved. Therefore, the integration of IT and OT can be promoted to a certain extent. Therefore, the combination of edge controller technologies can meet a variety of application needs, so it is very suitable for industrial applications.

Unlike traditional PLCS, edge controllers are able to provide a complete connectivity solution, including acting as OPC or message queue telemetry Transfer (MQTT) servers. Because edge controllers are built for industrial environments and work out of the box, unlike solutions for PCS, edge controllers require little IT involvement. This shifts the burden away from IT and allows operations and engineering to fully automate control. Costs are generally lower due to simplified hardware and software licensing.

In terms of data processing, edge controllers can store data, preprocess data, respond to local requests, and forward normalized data to central storage. This reduces the need for a central network and servers. It also increases process-level flexibility and responsiveness compared to flat file storage. Store-and-forward technology can also build fault tolerance in the case of network stability problems.

In addition, in terms of network security. Edge controllers solve modern security problems by simplifying control systems and utilizing two tools: design and operation. Edge controllers embed higher security standards, require user authentication and support multiple levels of access. But because they are network-oriented, they include standard network-derived protections, such as an Ethernet interface to block unauthorized internal firewalls, an Ethernet interface to separate trusted and untrusted traffic, and SSL/TLS encryption and authentication.

At present, the application of edge programmable industrial controller is more and more common, and new varieties have appeared in the industrial automation market, which has attracted wide attention. Mainstream products include Honeywell’s ControlEdge PLC, OPTO 22’s groov EPIC, Mitsubishi Electric’s MELIPC MI5000, MI3000, MI2000, MI1000, Advantech’s Industrial Internet of Things edge controller WISE-5580, Dongtu NewPre3100 and NewPre2100 edge universal controller, Jihecheng Technology KAGO series edge controller, etc.

As more and more industrial enterprises embark on the journey of digital transformation, enterprises have an increasingly strong demand for the integration of IT and OT. In the continuous development of intelligence today, the edge controller combined with edge technology solutions just adapt to this trend, which is also a trend in the future development of PLC.