Modern Automation Needs Both: PLC and Embedded Systems

Many automation systems today are under high efficiency pressure. Standard components such as PLCs (programmable logic controller) often reach their limits when it comes to details, integration depth, or specific requirements. Customized embedded systems offer an exciting complement or alternative here, which can make sense both technologically and economically. In this blog, we explain what embedded systems enable, how CSA designs and applies them, and in which cases they even surpass classic PLC solutions.

What Are Embedded Systems?

An embedded system is application-specific electronics, usually with a microcontroller and tailored firmware. The system is directly embedded into a device or machine and performs specific tasks such as control, communication, or monitoring. Unlike PLCs, embedded systems are not off-the-shelf plug-and-play solutions but are optimized for the specific application.

Advantages Compared to PLCs

Embedded systems offer significant advantages in many areas:

• Flexibility in Design: Hardware and software can be tailored exactly to the application.
• Real-Time Capability: Embedded systems are extremely fast and can meet hard real-time requirements.
• Security: Security levels can be implemented application-specifically (e.g., Secure Boot, Cryptography).
• Cost: Significantly cheaper than PLCs in larger volumes.
• Energy Efficiency: Minimal power consumption through optimized hardware.
• IoT Integration: Ideal for modern Industry 4.0 solutions.
• Updates & Maintenance: OTA updates, simple version control via Git.
• Long-Term Availability: No dependency on manufacturer cycles.
• Future-Oriented: Already today capable of running simple AI models – direct processing within the system, increased data protection.

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  When Is a PLC Useful?

  A PLC has advantages when:

• Standardized Requirements: When processes are clearly defined and unchanged.
• Very Low Volumes: Development costs for embedded systems are not worthwhile.
• Certified Safety Architecture: When, for example, SIL-compliant solutions must be immediately available.
• External Maintenance: When maintenance effort is deliberately delegated to manufacturers or external partners.

Tailor-Made Embedded Systems from CSA

CSA develops customized embedded solutions from specification to series production. Our process guides projects successfully through the entire development cycle:

1. Analysis & Specification:
   Requirements gathering, identification of integration points, creation of concepts, and feasibility studies.
2. Hardware and Firmware Development:
   Design and implementation of efficient and robust solutions for real-time, safety, and IoT applications.
3. Integration & Validation:
   Integration into existing systems, simulation, and system testing.
4. Certification:
   Standards-compliant development and support of testing processes according to relevant standards (e.g., CE, EMC, etc.).
5. Series Production:
   Preparation for industrial manufacturing, including BOMs, production documents, and coordination with EMS providers.

Practical Examples from CSA Projects

More Efficient Production:
For a leading automation manufacturer, we developed an embedded system that made process control more efficient. By using customized electronics, we were able to reduce cycle time.

Higher Availability:
In the manufacturing industry, we developed an embedded system for precise control of production equipment. By integrating safety functions and real-time data processing, we were able to increase system availability.

Real-Time Data:
For an industrial IoT company, we integrated an embedded system that captured real-time data from production machines and made it accessible via a cloud system. This enabled direct integration into the ERP system and optimal monitoring and control of production.

Embedded Systems vs. PLCs: A Direct Comparison

This comparison shows: PLC solutions have their fixed place in the industry. Especially for smaller quantities, proven plug-and-play applications, or certified standard systems.

Customized embedded systems offer clear advantages when maximum adaptability, energy efficiency, targeted integration, or IoT capability are required – for example, in new or particularly demanding automation solutions.

In many cases, both approaches complement each other meaningfully: A classic PLC can be extended by an embedded system to take over additional functions, smart interfaces, or specific tasks. This creates hybrid systems that combine the best of both worlds: standardized and at the same time adaptable.

Conclusion

The decision between PLC and embedded systems strongly depends on the application context, the objectives, and the existing systems. While PLC solutions are proven, robust, and quickly deployable, customized embedded systems offer compelling advantages when it comes to specific requirements, flexibility, scalability, or deep integration.

Especially in modern industrial environments with high demands on real-time processing, energy efficiency, and communication interfaces, embedded systems set new benchmarks. They do not have to replace classic PLC solutions but can complement and extend them in a targeted way.

At CSA, we help you recognize the potential of this technology for your application and make the best possible use of it.

We invite you to share your questions, experiences, or ideas with us. Either in the comments, by email, or directly at our booth at SINDEX. Let us find out together how embedded systems can meaningfully complement or further develop your automation solution.