Automation Hardware Revenue by Hardware Class

ABI Research forecasts the industrial automation hardware market to grow at a CAGR of 5.1% between 2023 and 2033, reaching US$64 billion by the end of the forecast period.

We consider the following three hardware classes for this market forecast:
 

1.) Programmable Logic Controllers (PLCs): Computers that control different processes in manufacturing, acting as an interface between devices on the plant floor and a Supervisory Control and Data Acquisition (SCADA) system. They capture data on the plant floor through inputs, the data are then processed and logic is applied based on the given data, and then the PLC executes the logic as an output to connected devices or machines.

PLCs are categorized by this report in four different sizes, defined by the number of Input/Output (I/O) points on the PLC:

• Micro PLCs: Fewer than 32 I/O points

• Small PLCs: Between 32 and 128 I/O points

• Medium PLCs: Between 128 and 1024 I/O points

• Large PLCs: More than 1,024 I/O points

2.) Industrial Personal Computers (IPCs): Industrial computers that run on a Windows or Linux Operating System (OS), so they have wide access to software tools and connectivity options. They possess far greater processing and memory power than PLCs, allowing them to be more capable at managing larger automation tasks. An IPC can be programmed to run the same software functionality as PLCs, alongside possessing the capability to run databases, recipe managers, SCADA, and Manufacturing Execution System (MES) software. The significant drawback to using an IPC over PLC in all scenarios is the higher cost and the fact that they are not always optimized for high performance of deterministic industrial applications in the way that PLCs often are.

IPCs are categorized in this report by the style of design:

• Box (Embedded) IPCs: Compact solutions usually found in control cabinets directly attached to machines or at standard workstations.

• Rack IPCs: Designed specifically to fit into standardized 19” racks.

• Panel IPCs: All-in-one solutions, incorporating both an operator panel and an IPC.

3.) Human-Machine Interfaces (HMIs): At a high level, HMIs are any type of device that allows humans to interact with machines. In reality, HMIs are most commonly located next to, or built into machines. HMIs communicate with PLCs and IPCs to acquire and display information for operators’ use on graphs, charts, and dashboards, supporting the management of SCADA and MES solutions, alongside critical machine actions, such as switching machines on and off or increasing production speed. HMIs are categorized in this report as either fixed or mobile.