The development of industrial automation and industrial robots has been extremely rapid in recent years. Two solutions exist for the automatic control systems of machinery and robots: PC-based control systems and industrial computer-based control systems. However, in practical applications, the industrial computer-based solution is more practical. Although PC-based control systems have indeed brought significant changes to the automatic control of machinery and robots during their development, repeated comparisons and verifications in practical applications have revealed many disadvantages and shortcomings compared to industrial computer-based control systems. So why are PC-based control systems so rare in real-world control applications? Why do automatic control systems tend to use industrial computers?
Because PC-based control systems are more fragile than dedicated controllers, they are more susceptible to damage from collisions or other forms of disruption. Furthermore, using PC-based systems complicates startup and makes cost savings less effective. Insufficient system security is also a significant concern. Therefore, PC-based control systems are often considered inefficient and unsafe, leading manufacturers to increasingly opt for dedicated controllers.
When security management software is embedded in an industrial PC, its basic function is to maintain the normal operation of the system. However, there may be some unpredictable risks involved. For example, if a virus infiltrates the control software or the firewall is reset, some basic functions of the system may fail or become paralyzed.
Process control systems are more sensitive to interruptions in their control programs than to machine operation itself, and system failures are more likely to cause production stoppages. Therefore, ensuring system stability is a critical factor. If a robot's control system malfunctions, we can at most stop the production line for that robot. However, if the process control system malfunctions, it may cause the entire production line to stop, leading to a series of serious consequences.
However, the hardware systems of industrial control computers are now very robust, capable of withstanding harsh industrial environments such as strong earthquakes and high temperatures. They are as stable and reliable as traditional PLC control systems. Many people associate industrial computers with Windows systems, believing they are susceptible to damage and prone to failure. However, industrial computers support Linux, Windows, or other vendor-developed software systems. Furthermore, their reliability has significantly improved: the systems have real-time monitoring capabilities, and some users combine FPGAs with high-performance data processors, running real-time control systems on FPGAs.
Of course, research on the rationality of control is ongoing, especially in the field of control requiring backup systems. For situations requiring unbuffered switching from one system to another, PC-based controllers demonstrate greater advantages. With a DCS system, a single-loop controller, or some PLC-based control systems, the control program and software control are relatively independent, making industrial PC control simpler and more convenient to operate than direct program control.
