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Better Option to the Traditional PLC

Updated: Nov 1, 2023

The use of Programmable Logic Controller (PLC) is a popular method of industrial monitoring even though it was first created in the 1960s.

There are many advantages to using PLC such as lower cost, familiarity, mature product, versatility and easy to troubleshoot. However, PLC drawbacks can include less capacity to handle big data, proprietary software and vulnerable to EMI.

The rise of Industry 4.0 avails users to the power of IoT, cloud computing and analytics, AI and machine learning to vastly improve the operations of production facilities. In order to avail ourselves of this new technology we would need to look for more powerful monitoring solutions, much more powerful than what the old PLC technology can offer.

For the purpose of vibration monitoring of rotating machinery a PLC typically allows only for monitoring of overall trend using current sensors (popularly known as 4-20 mA vibration transmitters).

To make use of the power of big data we would need to be able to collect FFT spectrums through the use of a DAQ that is connected to voltage sensors such as our Hansford Sensors, KEMO or Wilcoxon Sensing Technologies range of industrial vibration accelerometers. This big data can then be used for machine learning if we want to move towards the use of AI to predict machine failure.

The use of a DAQ allows the user to send the data to a cloud storage, send alarm warnings and run their own proprietary software. In this way the user is not held hostage to an external software vendor who offers hardware at a low cost but software at a high cost.

If you are a System Integrator or Enduser who is keen to move towards a more powerful DAQ solution that is open source, does not tie you to a proprietary software and offers good pricing to replace the traditional PLC please contact us at for more information.

For the suitable System Integrator we can make available a developer's kit to allow you to be familiar and gain confidence in our solution.


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