The role of smart programmable automation controllers

The evolution of intelligent hardware, edge computing, and real-time data acquisition has thrust industrial automation into an era where greater system flexibility has put the role of programmable logic controllers (PLCs) under the spotlight. PLCs have been the beasts of burden for industrial control systems; however, as environments become more demanding and applications more complex, their capabilities are tested. PACs or Programmable Automation Controllers are quickly filling the gap, and this article looks at how they differ from PLCs and when they should be considered as the foundation for a control architecture.

Think of a PAC as the next generation. It is an industrial controller that combines @ the reliability and ruggedness of a PLC, with the processing power, task flexibility, and enhanced data handling capabilities of a PC.

PACs were introduced to address the growing needs for multi-domain control (Logic, motion, process), high speed data acquisition, real time decision making and advanced communication and networking protocols.

In practical terms, PACs support modular I/O, multitasking, floating-point operations, and often come with open software environments for complex control algorithms, data logging, diagnostics, and integration with higher-level systems like  MES.

A PAC might look like a high-end PLC, but its architecture is fundamentally different. The table below illustrates the contrasts.

PLCs remain the controller of choice for solutions involving repetitive execution of simple logic tasks based on point analog and digital IO.

Let us examine some scenarios where a PAC is the obvious solution.

• Multi-Domain control in a single environment
  PACs outclass PLCs at coordinating logic, motion, and process control, eliminating the need for multiple controller types. This is valuable in hybrid industrial systems, including smart manufacturing, robotics, or process automation with complex interdependencies.
• High-speed data acquisition and real-time processing
  PAC’s performance and microsecond accuracy are required when you must sample, process, and react to analog or digital signals at high speed – Hardware-in-the-Loop (HIL) testing, automated validation, or real-time monitoring.
• Embedded intelligence and edge computing
  PACs run custom code, edge analytics, and AI inference models at the machine level—supporting predictive maintenance, adaptive control, or on-device decision-making without relying on cloud connectivity.
• System simulation and test environments
  PACs are the preferred choice for embedded controller testing, such as VCU HIL platforms, where complex signal injection, fault simulation, and synchronised response capture are required.
• Flexible, future-proof automation
  Industrial environments that are integrated with IoT platforms, cloud systems, and machine-to-machine (M2M) networks. PACs offer built-in support for open protocols, cybersecurity, and scalable deployment

PACs signal a shift in industrial control from rigid logic programming to intelligent, data-driven automation. For engineers tackling complex systems, hybrid domains, or high-performance control requirements, PACs offer the flexibility, power, and integration that contemporary projects require.

Elevate Controls has extensive experience and expertise. We integrate NI CompactRIO hardware, LabVIEW Real-Time and FPGA development environments, and other PAC-class solutions, delivering scalable, reliable, and intelligent automation platforms.