Edge Programmable Industrial Controllers (EPICs) are becoming increasingly popular.
However, edge computing places high demands on local data processing capabilities, which traditional PLC controllers can no longer handle. In recent years, in factory environments, edge programmable industrial controllers (EPICs) have shown a strong trend of replacing traditional PCs, servers, and older hardware.
Edge controllers are designed to improve the efficiency of existing automation systems while reducing complexity and cost of ownership. They can handle a wider range of automation functions, including those traditionally requiring PCs or other dedicated equipment. Edge controllers integrate multiple functions such as PLC controllers, PCs, gateways, motion control, I/O data acquisition, fieldbus protocols, machine vision, and device networking. They enable motion control, data acquisition, computation, and cloud connectivity, as well as collaborative remote industrial cloud platform control at the edge to achieve intelligent production line control.
The software architecture of edge controllers is basically a two-layer architecture of cloud and edge. On an innovative software platform configured at the edge (where data is generated), an ecosystem of applications and tools is created by integrating user management, networking, security and hardware interfaces, which users can use to provide richer functionality to processes than before.
Advantages enable automation and promote the convergence of IT and OT.
Edge controller devices leverage the latest IT communication and IoT technologies while retaining the OT advantages of PLCs/PACs. Edge controller communication operates on two distinct levels: one is I/O for acquiring industrial equipment and process data, and communication with other industrial control devices, falling under the OT domain; the other is communication between edge devices and OT data centers and cloud servers, falling under the IT domain, i.e., the Industrial Internet of Things. As a physical interface between IT and OT, edge controllers enhance the interface and computing capabilities of industrial equipment beyond simply fulfilling workstation or production line control functions, thereby improving the applicability of industrial equipment and promoting the convergence of IT and OT to a certain extent. Therefore, the combination of various edge controller technologies can meet diverse application needs, making it highly suitable for industrial applications.
Unlike traditional PLCs, edge controllers offer complete connectivity solutions, including acting as OPC or Message Queuing Telemetry Transport (MQTT) servers. Because edge controllers are built for industrial environments and are ready to use out of the box, unlike PC-based solutions, they require minimal IT intervention. This shifts the burden away from IT and allows operations and engineering departments 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. Compared to flat file storage, it also improves process-level flexibility and responsiveness. Store-and-forward technology can also establish fault tolerance in the event of network instability.
Furthermore, in terms of network security, edge controllers address modern security challenges by simplifying the control system and leveraging both design and operational tools. Edge controllers embed higher security standards, requiring user authentication and supporting multiple access levels. However, because they are network-facing, they include standard network protections such as internal firewalls to block unauthorized access, Ethernet interfaces to isolate trusted and untrusted traffic, SSL/TLS encryption, and authentication.
The application of edge programmable industrial controllers is becoming increasingly common, leading to the emergence of new varieties in the industrial automation market and attracting widespread attention. Mainstream products include Honeywell's ControlEdge PLC, OPTO 22's Groov EPIC, Mitsubishi Electric's MELIPC MI5000, MI3000, MI2000, and MI1000, Advantech's WISE-5580 industrial IoT edge controller, Dongtu's NewPre3100 and NewPre2100 universal edge controllers, and JIHENG Technology's KAGO series edge controllers, among others.
As more and more industrial enterprises embark on their digital transformation journey, their demand for the integration of IT and OT is becoming increasingly strong. In today's era of continuous intelligent development, edge controllers, which incorporate edge technology solutions, are perfectly suited to this trend, and this is also a future development trend for PLCs.
