I. Core Views
1.1 The hardware scalability of Mitsubishi and Siemens PLCs is significantly different
Mitsubishi PLC has certain characteristics in terms of hardware scalability. Some series of Mitsubishi PLC products are widely used in small projects, and their hardware expansion is relatively flexible. Different modules can be added according to actual needs, such as analog input and output modules, communication modules, etc. For example, Mitsubishi FX2N series has expandability such as extended input and output, analog control and communication, link function, etc. However, compared with Siemens, Mitsubishi may be slightly insufficient in communication interface. For example, all series before Mitsubishi FX3U have a pitiful 422 ports, and the speed is 9.6K. If you need to connect to smart instruments and other devices, you must purchase special modules separately.
Siemens PLC performs well in hardware scalability. It has rich communication interfaces and supports multiple communication protocols, making data transmission and remote monitoring more convenient. For example, the CPU226 and CPU224XP of Siemens series PLCs are equipped with 2 485 ports, namely PPI ports, as standard, with a maximum communication speed of 187.5K. In terms of scalability and compatibility, Siemens PLC can be easily integrated with other devices and systems, providing more possibilities for the construction of enterprise automation systems.
1.2 Hardware scalability affects enterprise automation system construction decisions
Hardware scalability plays a vital role in the design, upgrade and maintenance of enterprise automation systems. During the design phase, if the PLC has good hardware scalability, the enterprise can make reasonable plans based on future development needs to avoid over-investment or later upgrade difficulties. For example, if Siemens PLC is selected, its good scalability allows the system to take into account possible future business growth and technology updates during design, and reserve expansion space in advance.
During the upgrade phase, PLCs with strong hardware scalability can more easily add new functional modules and improve system performance. For example, Siemens PLCs can easily add various functional modules to meet the ever-changing production needs of enterprises. Mitsubishi PLCs may need to purchase additional special modules when upgrading, which increases costs and complexity.
During the maintenance phase, PLCs with good hardware scalability are easier to troubleshoot and repair. Because production can be quickly restored by replacing the faulty module instead of the entire system, downtime and maintenance costs are reduced. For example, Siemens PLCs use a modular design, and when a module fails, it can be quickly replaced without affecting the normal operation of other parts.
II. Market Analysis
2.1 Application Status of Mitsubishi and Siemens PLC in Different Industries
In the machinery manufacturing industry, Mitsubishi PLC is widely used in small and medium-sized machinery manufacturing enterprises because of its high cost performance and relatively simple operation. For example, in the control of some small machine tools, Mitsubishi PLC can meet the basic logic control and motion control needs. According to statistics, in small and medium-sized machinery manufacturing enterprises, Mitsubishi PLC has a market share of about 30%. Siemens PLC occupies a dominant position in large machinery manufacturing enterprises. Its powerful functions and good scalability can meet the control needs of complex automated production lines. In large machinery manufacturing enterprises, Siemens PLC has a market share of up to 50%.
In the power industry, Siemens PLC is widely used in power generation, transmission and substation due to its stable performance and rich communication interfaces. For example, in the construction of smart grids, Siemens PLC can realize remote monitoring and control of power equipment and improve the reliability and stability of the power grid. In the power industry, Siemens PLC has a market share of about 40%. Mitsubishi PLC is relatively rarely used in the power industry, mainly in the control of some small power equipment, with a market share of about 15%.
In the chemical industry, both Mitsubishi PLC and Siemens PLC have certain applications. Mitsubishi PLC is used to control simple process flows in some small chemical companies. Siemens PLC, on the other hand, can achieve precise control of complex chemical production processes in large chemical companies with its good scalability and compatibility. In the chemical industry, Siemens PLC has a market share of about 45%, and Mitsubishi PLC has a market share of about 25%.
2.2 Enterprise demand trend for PLC hardware scalability
With the continuous improvement of enterprise automation level, the demand for PLC hardware scalability in the process of automation upgrade is also increasing. The main influencing factors are as follows:
First, changes in market demand have prompted enterprises to continuously adjust production processes and product structures, which requires PLC to quickly adapt to new production needs. For example, as consumers' demand for personalized products increases, companies need more flexible production systems, which requires PLCs to have good hardware scalability so that new functional modules can be quickly added to achieve flexible production.
Secondly, the continuous advancement of technology has also promoted the demand for PLC hardware scalability in companies. For example, with the development of Internet of Things technology, companies need to connect PLCs with other devices to achieve data sharing and remote monitoring. This requires PLCs to have rich communication interfaces and good scalability so that they can be easily integrated with other devices.
Finally, cost factors are also one of the important factors that companies consider. PLCs with strong hardware scalability can reduce the upgrade costs of companies to a certain extent and avoid waste caused by overinvestment. For example, an enterprise can choose a PLC with a certain degree of scalability in the early stage, and gradually add new functional modules as the business develops without replacing the entire system, thereby reducing upgrade costs.
3. Product Research
3.1 Hardware Scalability Features of Mitsubishi PLC
3.1.1 Scalability of Input and Output Modules
The transistor type of Mitsubishi PLC input module has the advantages of fast response speed and long life. Transistor input can realize functions such as high-speed counting, and is suitable for occasions with high response speed requirements. For example, in some high-speed automated production lines, the transistor input module of Mitsubishi PLC can accurately capture the signals of high-speed moving objects and provide timely input signals for subsequent control actions.
Mitsubishi PLC output module has the characteristics of large current and can directly drive some large power loads. For example, some models of Mitsubishi PLC output modules can provide output currents of up to several amperes, meeting the control requirements of some high-power motors, solenoid valves and other equipment. At the same time, Mitsubishi PLC output modules also have a variety of output types, such as relay output, transistor output, etc., and users can choose according to actual needs.
3.1.2 Extension modules and compatibility
Mitsubishi PLC extension modules are rich in variety, including analog input and output modules, communication modules, special function modules, etc. Analog input and output modules can realize the acquisition and control of analog signals such as temperature, pressure, and flow, meeting the processing requirements of continuously changing signals in industrial automation processes.. The communication module can realize data transmission and communication between Mitsubishi PLC and other devices, such as connecting with host computers, touch screens, smart meters and other devices.
In terms of compatibility, Mitsubishi PLC expansion modules are compatible with Mitsubishi series PLC hosts and can be easily installed and configured. At the same time, some Mitsubishi PLC expansion modules can also be compatible with other brands of equipment to a certain extent, such as connecting with other brands of sensors, actuators and other devices through specific communication protocols. However, compared with Siemens, Mitsubishi PLC may be slightly lacking in compatibility, especially in connecting with some non-traditional industrial equipment, which may encounter some difficulties.
3.2 Features of Siemens PLC hardware scalability
3.2.1 Rich communication interface and protocol support
Siemens PLC supports multiple communication protocols, such as PROFIBUS, PROFINET, MODBUS, etc. These communication protocols play a vital role in hardware expansion. For example, PROFINET is an open, standard real-time industrial Ethernet standard. Siemens PLC can achieve communication connection with on-site distributed stations (such as ET200S, ET200SP, etc.) through PROFINET to achieve efficient distributed control.
MODBUS protocol is a simple, economical and open and transparent communication protocol. Siemens PLC, as a client or server of Modbus TCP communication, can communicate with different types of devices, improving the compatibility and scalability of the system. In addition, Siemens PLC also supports OUC communication, including TCP/IP communication, ISO_on_TCP communication and UDP communication, to meet the needs of communication methods in different application scenarios.
3.2.2 Powerful distributed IO expansion function
The distributed IO expansion of Siemens PLC has significant advantages. For example, Siemens PLC distributed I/O ET200M supports both Profibus and Profinet fieldbuses, can expand up to 8 or 12 signal modules, and the modular IO system has an IP20 protection level, which is particularly suitable for high-density and complex automation tasks. By configuring the active backplane bus module, ET200M can support hot swapping with power on, improving the reliability and maintainability of the system.
In terms of application scenarios, distributed IO expansion can meet the needs of decentralized equipment layout in large-scale automation systems. For example, in some large factories, production equipment is distributed in different areas. Through distributed IO expansion, the equipment in each area can be connected to the central control system to achieve centralized monitoring and management. In addition, distributed IO expansion can also be applied to some occasions with high real-time requirements, such as the control of high-speed production lines. By placing IO modules near on-site equipment, the delay of signal transmission can be reduced and the response speed of the system can be improved.
IV. Competition Landscape
4.1 Competition between Mitsubishi and Siemens in Hardware Scalability
Mitsubishi PLC has certain advantages in hardware scalability. Some of its products are suitable for small projects, with relatively flexible expansion and relatively low cost. For example, in a small automation system, Mitsubishi FX series can add various expansion modules according to actual needs to meet different control requirements. However, Mitsubishi PLC is relatively weak in communication interface, and its speed and compatibility may not be as good as Siemens.
Siemens PLC performs well in hardware scalability, has rich communication interfaces and protocol support, and can be easily integrated with other devices. For example, PROFINET protocol can achieve efficient distributed control to meet the needs of large automation systems. In addition, Siemens PLC has powerful distributed IO expansion functions, such as ET200M can support hot swapping with power on, which improves the reliability and maintainability of the system. However, the price of Siemens PLC is relatively high, which may be cost-intensive for some small enterprises.
4.2 Comparison of hardware scalability of PLCs of other brands
In addition to Mitsubishi and Siemens, PLCs of brands such as Omron and Delta also have their own characteristics in hardware scalability.
Omron PLC has relatively good hardware scalability and supports multiple communication protocols and expansion modules. For example, Omron CP series and CS series PLCs can be connected to other devices by adding communication modules to meet different application requirements. However, compared with Mitsubishi and Siemens, Omron PLC may be slightly lacking in functions and performance.
Delta PLC also has certain advantages in hardware scalability and is relatively affordable. Delta PLC can realize analog input and output, communication and other functions by adding expansion modules, and is suitable for small and medium-sized automation systems. However, Delta PLC may not be as competitive as Mitsubishi and Siemens in high-end applications.
In summary, different brands of PLC have their own advantages and disadvantages in hardware scalability. When choosing a PLC, enterprises should consider the characteristics of each brand according to their actual needs and budget and choose the most suitable PLC product.
V. Risk Analysis
5.1 Hardware Scalability Risks Brought by Technology Updates
With the rapid development of technology, PLC hardware is also constantly being updated. This may cause mismatches in hardware scalability in installed PLC systems. For example, the emergence of new communication technologies, sensor technologies, and actuator technologies may require PLCs to have higher communication speeds, more communication interfaces, and stronger processing capabilities. If the PLC used by an enterprise cannot keep up with the pace of technological development in a timely manner, it may face the risk of insufficient hardware scalability.
According to statistics, in the field of industrial automation, the technology update cycle is usually 3-5 years. During this cycle, new technologies and products continue to emerge, which may cause the old PLC system to gradually fall behind. For example, when an enterprise needs to connect a new smart device to the PLC system, it may find that the existing PLC does not have the corresponding communication interface or protocol support, making it impossible to integrate the device. This mismatch problem not only affects the production efficiency of the enterprise, but also may increase the upgrade cost of the enterprise.
In order to cope with the hardware scalability risks brought about by technological updates, enterprises can take the following measures: First, when choosing PLC, they should fully consider its future scalability and choose products with rich communication interfaces and protocol support and easy to upgrade. Second, they should establish a regular technical evaluation mechanism to keep abreast of the development of industry technology, evaluate the scalability of existing PLC systems, and plan upgrade plans in advance. Third, they should maintain a good cooperative relationship with PLC suppliers, obtain technical support and upgrade services in a timely manner, and ensure that the PLC system can adapt to the needs of technological development.
5.2 Risks of improper enterprise selection
When choosing a PLC, if the enterprise does not have a good understanding of hardware scalability, it may face a series of risks. First, the enterprise may choose a PLC with poor hardware scalability, resulting in the inability to meet the needs of business growth and technology updates in the future production process. For example, the enterprise initially chose aAlthough a small PLC can meet the current production needs, as the business develops, when more input and output points, communication interfaces and functional modules need to be added, it is found that the PLC cannot be effectively expanded and the entire system has to be replaced, resulting in huge waste.
Secondly, enterprises may make wrong choices because they do not understand the hardware scalability of different brands of PLCs enough. PLCs of different brands have differences in hardware scalability. Some brands may have advantages in communication interfaces, types of expansion modules and compatibility, while some brands may be more attractive in terms of price and ease of use. If enterprises do not fully consider these factors when choosing PLCs, they may choose products that are not suitable for them.
In order to avoid the risk of improper selection by enterprises, enterprises should do a good job of research and evaluation when choosing PLCs. First, you need to understand your own production needs and future development plans, determine the required number of input and output points, communication interface types and functional modules, etc. Second, you need to compare PLCs of different brands to understand their hardware scalability characteristics, prices, after-sales services and other information. Third, you can refer to the successful cases of other companies and learn from their experiences and lessons in choosing PLCs. Fourth, you can have in-depth communication and exchanges with PLC suppliers to understand their product features and technical advantages and obtain professional advice and solutions.