Expanding the Traditional PLC
Programmable Logic Controllers (PLCs) have long been the cornerstone of industrial automation. They’re robust, reliable, and built for mission-critical tasks in manufacturing, infrastructure, and utilities. But in today’s fast-evolving landscape, traditional PLCs often fall short when it comes to remote access, simple I/O expansion, and affordability for devices at the edge.
Smart Integration Without Replacing Your PLC System
ControlByWeb devices are a complementary industrial technology that enhance existing PLC systems by filling in the connectivity and control gaps making your automation setup: smarter, more flexible, more cost-efficient, and accessible remotely without replacing your existing PLC or SCADA system.
Communicates via Modbus, MQTT, RESTful API
ControlByWeb devices communicate via industry-standard protocols such as Modbus or MQTT, feature a RESTful API, and can be easily slotted into an existing system, providing remote access to key points wherever necessary. In large systems with widely distributed devices, remote access becomes essential for both convenience and security.
Whether you’re enhancing a SCADA system or creating a custom edge system, CBW fits in effortlessly.
Adding I/O to an Existing PLC System
Instead of investing in expensive, brand-specific PLC modules, ControlByWeb offers nearly plug-and-play I/O devices at a fraction of the cost. Sometimes an existing system might need only a few extra I/O endpoints to optimize the workflow. CBW devices make this simple by including:
- No licensing fees or proprietary software
- Straightforward Ethernet integration
- Optional control logic or additional logging
Each ControlByWeb device has a different combination of on-board I/O, allowing for a simple installation of the few missing pieces of the existing system. Using a CBW device to fill the gap is far cheaper than relying on another PLC.
A Fully Functional – and Optional – Cloud Service
A lack of cloud-based features can make data logging or remote access difficult.
The ControlByWeb Cloud is an optional feature that pairs well with cellular units, enabling access in remote locations. A CBW device can display PLC statuses and control key outputs via the ControlByWeb Cloud, the perfect solution for systems integrators looking for rapid deployment.
*It is even possible to have CBW devices communicate peer-to-peer over the cloud when using a cellular connection. Contact a Sales Engineer to learn more about how to use this feature.*
Real-World Examples
Agricultural Pumps
A PLC handles core timing and logic, while ControlByWeb devices offer browser-based scheduling, email alerts for low water levels, and manual override from a smartphone.
Facility Monitoring
In a commercial building, PLCs track equipment cycles while CBW devices log temperatures, record sensor data, and issue alerts when parameters go out of range. If the PLC provides an alarm, the CBW device can provide email alerts for remote visibility.
Oil & Gas (Level Monitoring)
PLCs provide precise and reliable automation of tank and vessel measurement systems. In these environments, maintaining optimal fluid levels is critical for both safety and operational efficiency.
The application possibilities are endless. With ControlByWeb, existing systems can be retrofitted with these missing features, all for a fraction of the cost of the system.
Built-in Logic for Control Tasks
Depending on the task, you won’t always need or want full ladder logic. ControlByWeb devices include on-board logic features like Scheduled and Conditional tasks and automatic rebooting. This is all done using simple drop-down menus that make programming the device accessible for all end users.
Data related to these tasks can be logged either on the device or shared with the optional ControlByWeb Cloud.
You can even set up failover control where the CBW device steps in if the PLC fails, providing an extra layer of resilience without complicating the system.
*With cellular CBW controllers, a network failover can be established as well, adding yet another backup in case of failure.*
When to Use ControlByWeb in a PLC System
ControlByWeb devices make sense when:
- You need remote visibility without exposing your PLC to external networks
- You want to expand I/O to remote or difficult-to-wire locations
- You require simple logic for alerts, toggles, or timers without programming a full ladder logic routine
- You’re deploying a quick-turn solution for retrofits, edge processing, or pilot projects
More Value, Less Complexity
ControlByWeb isn’t here to replace your PLC, it’s here to make it better. By adding remote visibility, simple control, and affordable I/O, you can enhance your current system without needing to completely overhaul it. Reach out to one of our Sales Engineers to learn more about how you can cut your deployment time from days to minutes and improve your ROI.
