Programmable Logic Controller vs Arduino Which One Should You Choose?

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Introduction: PLCs and Arduino in Automation

Programmable Logic Controller vs Arduino are both used for automation, but they serve different purposes. PLCs are industrial workhorses, while Arduino is ideal for prototyping and small projects. This guide compares them side-by-side and helps you choose the right tool for your needs.

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Key Differences at a Glance

Feature	PLC	Arduino
Durability	Industrial-grade, rugged	Consumer-grade, needs protection
Cost	200–200–5,000+	20–20–100
Programming	Ladder logic, structured text	C/C++ (Arduino IDE)
Real-Time Performance	Excellent (deterministic)	Good (but not real-time)
Best For	Factories, heavy industry	Hobbyists, prototypes

PLC vs Arduino: Detailed Comparison

1. Hardware & Durability

PLCs:
✔ Built for harsh environments (dust, moisture, vibrations)
✔ Wide operating temperature range (-20°C to 60°C)
✔ Long lifespan (10+ years)

Arduino:
✔ Not inherently rugged (needs enclosures for industrial use)
✔ Limited temperature range (0°C to 40°C typically)
✔ Shorter lifespan in demanding conditions

Winner: PLCs for industry, Arduino for controlled environments

2. Programming & Ease of Use

PLCs:
✔ Use ladder logic (easy for electricians)
✔ Structured text & function block options
✔ Requires proprietary software (e.g., TIA Portal, RSLogix)

Arduino:
✔ Uses C/C++ (better for programmers)
✔ Open-source IDE with vast libraries
✔ Easier to start for hobbyists

Winner: Arduino for beginners, PLCs for industrial standards

3. I/O & Expandability

PLCs:
✔ Modular design (add more I/O easily)
✔ Supports high-current outputs (relays, motor drives)
✔ Industrial communication (Ethernet/IP, Profibus)

Arduino:
✔ Limited built-in I/O (6–20 digital pins)
✔ Needs shields for expansion (extra cost)
✔ Basic serial/UART communication

Winner: PLCs for scalability, Arduino for small projects

4. Cost Comparison

Item	PLC Price	Arduino Price
Entry-Level Unit	200–200–500	20–20–50
Software	500–500–2,000 (often licensed)	Free (Arduino IDE)
Expansion Modules	100–100–1,000+	10–10–50 (shields)

Winner: Arduino for budget projects, PLCs for long-term ROI

5. Real-World Applications

Where PLCs Excel:

Factory automation
Oil & gas control systems
High-reliability processes

Where Arduino Shines:

Home automation
Robotics prototypes
IoT sensor networks

When Should You Use Arduino Instead of a PLC?

✅ Prototyping – Test ideas cheaply before industrial deployment
✅ Education – Learn automation basics without expensive hardware
✅ DIY Projects – Smart home devices, custom gadgets
✅ Low-Cost Automation – Small machines with simple logic

Example: A small 3D printer controller could use Arduino, while a full production line needs a PLC.

Top Arduino Boards for Industrial Prototyping

If you need an Arduino-like device for near-industrial use, consider:

1. Arduino Portenta H7

✔ Dual-core processor (real-time capable)
✔ Industrial temperature range (-40°C to 85°C)
✔ Ethernet & CAN bus support

2. Teensy 4.1

✔ Extremely fast (600 MHz)
✔ Lots of I/O pins
✔ Good for high-speed control

3. Industrial Shields (Arduino-Compatible)

✔ Ruggedized for factory use
✔ PLC-like form factor
✔ Supports Modbus RTU/TCP

How to Make Arduino More Like a PLC

If you need Arduino to behave more like a PLC:

Use a Real-Time OS (FreeRTOS)
Add Industrial I/O Shields (Opto-isolated inputs/outputs)
Implement Redundancy (Fail-safe circuits)
Protect the Board (DIN-rail enclosure, surge protection)

Warning: Arduino still won’t match a true PLC’s reliability in critical applications.

FAQs: PLC vs Arduino

Q: Can Arduino replace a PLC in industry?

A: Not usually. PLCs are certified for safety, reliability, and long-term operation. Arduino is great for prototyping but not for mission-critical systems.

Q: Which is easier to program?

A: Arduino (for coders), PLC (for electricians used to ladder logic).

Q: Can I connect Arduino to a PLC?

A: Yes! Use Modbus, Ethernet, or 4-20mA signals to make them communicate.

Q: What’s the best PLC for Arduino users to try?

A: Click PLC (AutomationDirect) – Affordable and easy to learn.

Q: Is Raspberry Pi better than Arduino for PLC-like tasks?

A: No. Raspberry Pi runs Linux (not real-time). Arduino is better for control logic.

Final Verdict Programmable Logic Controller vs Arduino ?

Choose a PLC if:
- You need industrial reliability
- Long-term operation is critical
- Safety certifications matter
Choose Arduino if:
- You’re prototyping or learning
- Cost is a major factor
- Flexibility is more important than ruggedness

Hybrid Approach: Use Arduino for proof-of-concept, then migrate to PLC for production.

Ready to Get Started?

For PLCs: Try Siemens S7-1200 (beginner-friendly)
For Arduino: Start with Arduino Mega 2560 (lots of I/O)

Which one fits your project? Let us know in the comments!