Since the invention of programmable logic controllers (PLCs), all types of controllers have made their way into industrial facilities. Good examples include programmable automation controllers (PACs), edge programmable industrial controllers (EPICs), and now, web-based controllers. In this post, we take a closer look at web-based controllers to answer the main question, “How do they work?”

What is a Web-Based Controller?

The technological climate is fast changing how we interact with different machines and equipment in industrial settings. Endless runs of wires and cables are becoming an old-fashioned type of connection with the introduction of web-based equipment. As the name suggests, web-based controllers are devices designed to monitor, run, and gather data from devices online. They are part of modern smart devices and help take automation technology to the next level.

The controllers are made of a number of components, including software, credentials, gateways and badge readers. In most cases, the software has to be installed and updated on your manufacturing site and work together with the plant’s internet network and sensors attached to different equipment. With a laptop, computer, tablet or smartphone linked to the company's management and internet system, you can access and control a plant's operations remotely.

Types of Web-Based Controller Systems

Web-based controller systems can be categorized into two; the browser-based type and the cloud-based model. If you opt for the browser-based model, it implies that you have to use an appropriate browser, such as Chrome, Edge, or Firefox. On your device, you access the manufacturing facility and control different aspects via a browser. For a small manufacturing facility, this is the most recommended model.

If your facility is a large or more complex industrial unit, a cloud-based controller will be a better option. This is a type of IP-based control system that gives you access to the remote console via a secure server. Unlike a web-based control, which only provides access to give you control, a cloud-based model allows for more actions, including data storage, networking, and servers.

No matter the method you prefer for web-based controllers, it is important to have the right IT infrastructure and support for higher efficiency. The system also required regular software updates for proper performance.

What are the Benefits of Web-Based Controllers?

The primary goal for the adoption of web-based controllers in manufacturing plants is to promote automation. As an important concept for the 4.0 industry, automation is expected to grow and hit 296 billion dollars by 2026, a huge jump from 157.04 reported in 2018. With web-based controllers, you can automate almost every aspect of your industrial facility’s operations. Well, you no longer have to worry about the conveyor belt system developing issues or boiler malfunctioning and risking a disaster. Other benefits of using web-based controllers include:

• Helps to Cut Down Costs of Operations

Unlike the wired controllers, web-based models require limited wiring. Therefore, you will not incur a lot of costs buying cables and running them from one point to another. This implies that even related maintenance will be pretty easy and fast.

• Diagnostics and Upgrades Are Pretty Easy

With smart devices used in web-based controllers, diagnosing the system’s challenges is pretty easy. Most of them come with a self-diagnostic system, which makes identifying issues and addressing them straightforward. Also, updates can be accessed easily from the device manufacturers and software developers for optimal performance.

• An Excellent Way for a Plant that Deals With Hazardous Materials

If your workplace is classified as harzadous because it handles items such as flammable materials or there is a risk of dangerous fumes, web-based controllers can be a great way to operate safely. When you control most of the operations remotely with web-based controllers, there will be little or no need to have staff in the production area. This means reduced risks of injuries, fatalities, or related compensations.

• A Good Way to Optimize the Production of Your System

When installing web-based controllers, the rule of thumb is that you should start with a comprehensive review of production needs and automation of the plant. Automation means that you can operate your industrial facility at optimal capacity for longer. For example, it is possible to operate the boilers, motors, and presses over the weekends, at night, and even on public holidays.

• You Can Access and Control Your Facility Remotely

Unlike most controllers, where you are required to be within the manufacturing premise, web-based controllers are different. Even if you are back at home, it is possible to control different systems of the facility and get the system running at full potential. Therefore, there will be no reason enough to halt production because you are away.

If you run an industrial facility, automation is crucial for success, and web-based controllers come in handy to make it possible. They make it possible to remotely access, control the operations on the facility and optimize production. Remember to maintain the machinery in top condition for the controllers to work well.