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This section provides an overview for programmable controllers as well as their applications and principles. Also, please take a look at the list of 23 programmable controller manufacturers and their company rankings. Here are the top-ranked programmable controller companies as of January, 2025: 1.CAREL INDUSTRIES S.p.A., 2.Advanced Micro Controls, Inc., 3.Emerson Electric Co..
Table of Contents
A programmable controller is a control device with a built-in microprocessor.
Normally, inputs from sensors and switches in equipment are output to motors, displays, and other devices via mechanical relays, timers, and other control mechanisms. In contrast, a programmable controller controls the operation of a device using an internal program, without the need for mechanical relays or other control mechanisms.
Since there are fewer mechanical contacts, the device can be controlled without contact wear and defects between electronic components, cumbersome input/output devices, and wiring between mechanical relays for control. In addition, electrical wiring can be simplified, facilitating downsizing and mass production of devices.
Figure 1 shows a simple example of a control panel that uses mechanical relays, timers, etc. to control lamps.
Programmable controllers are used in a wide range of fields, including factory automation systems, automobiles, home appliances, and industrial equipment. They are mainly used in industrial and commercial equipment.
Examples of commercial applications include their use in large washers and dryers with sequence control because they are cheaper and more robust than using a PC. Another factor is that they usually do not require cooling systems because there is no graphics board and the microprocessor generates little heat.
Programmable controllers can be either all-in-one, in which all the electronic components necessary for operation are built in, or modular, in which you select each functional component yourself.
It is important to select the memory, processor, and output/input terminal specifications according to the electronic device to be used.
A programmable controller consists of an input module, an output module, a processor, and memory. The input module is connected to sensors and switches. The processor processes that input data based on the internal program stored in the memory and outputs it to motors, displays, communication devices, etc.
If you wish to change the operation of an electronic device equipment controlled by the programmable controller, you do not need to make any changes to the wiring or other components. You only need to change the program code, which saves time and labor costs.
Programs used in programmable controllers include the ladder method, SFC method, flowchart method, and stepladder method, with the ladder method being the most common. In the ladder method, programs are written on a PC by connecting symbols such as relays, switches, and timers between two parallel lines like a ladder.
This method is easy to learn because the program code can be created using a graphical user interface.
If you work in production, you may have heard the term “sequencer.” As it turns out, there is no difference between a programmable controller and a sequencer.
Sequencer refers to the trade name of Mitsubishi Electric's programmable controller. It was marketed under the name Sequencer as a mechanical device that enabled sequence control and remains in use today as another name for programmable controllers.
Generally, a PC is used to store a program in a programmable controller. Each company that sells controllers sells PC software for editing the programs stored on them.
Serial signals have long been used for connection to PCs. In the past, many PCs had serial ports permanently installed, but these days serial ports are rare.
Also, serial signals required matching COM ports or installing special drivers. In recent years, sequence editing is often performed using USB ports, which do not require COM port matching and are familiar to general users.
It is also now possible to edit multiple controllers from an Ethernet port when available.
*Including some distributors, etc.
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Siemens USA was established in Washington D.C. in 1988, and is the American branch of Siemens AG, the German manufacturer, supplier, and distributor of automation, electrification, and digitalization products established in 1847. The company’s extensive product portfolio includes smart infrastructure products, power generation and transmission products such as gas turbines and transformers, and medical imaging as well as laboratory diagnostics products such as CT scanners and MRI machines. It also offers mobility products and automation management software. The company operates throughout North and South America, and is certified to ISO 9001, ISO 14001, ISO 27001, and OHSAS 18001 standards.
Gefran is an Italian manufacturer of industrial process automation systems that was founded in Provaglio d'Iseo, Brescia in 1960. The company produces regulatory drives and inverters, various sensors, and automation components such as programmers and controllers. It also offers tailor made systems for specific industrial processes, including thermoforming, injection molding, and extrusion. Gefran products are primarily used in factory automation, as well as by clients in the metalworking, plastics, material handling, and food processing sectors.
Schneider Electric S.E. is headquartered in Rueil-Malmaison, France, and has been operating since 1836. Schneider Electric provides a number of products and services including electrical car charging, energy management software, surge protection devices, load banks, servers and HMIs, valve and valve actuators, feeder automation, grid automation, and SCADA software products, data center cooling and software, home automation and security, light switches, motion control and robotics, signaling units, solar and energy storage, RFID systems, as well as other hardware, services, and software.
LOVATO Electric S.p.A., founded in 1922 and based in Bergamo, Italy, is a manufacturer and designer of low-voltage electrical devices for industrial applications. The company offers a wide range of products such as Motor Protection circuit breakers, Contractors, electromechanical starters and relays, variable speed drives, and soft starters among others. The company holds UNI ISO 45001: 2018, ISO 1400: 2015, and ISO 50001: 2018 certificates. The company’s laboratories are certified to conduct type testing under ACAE control to issue ACAE certifications which are recognized by the European Union and valid across the wold.
Ohkura Electric Co., Ltd. was established in 1933 and is headquartered in Tokyo, Japan. The company is a manufacturer and designer of measuring and flow control products for industries such as power generation, manufacturing, and semiconductors. The company has three product groups: Industrial Instruments Group, Telemetering & Control Group, and Semiconductor Equipment Group. The Industrial Instruments Group’s products include systems equipment, pressure transmitters, electrometers, and gas monitors as individual components and as systems. The Telemetering & Control Group products include transmission systems, modems, and power converters. The Semiconductor Equipment Group products include renewable equipment, furnaces, and precision thermometers.
Initially established in 1938, Shibaura Machine has three-quarters of a century providing Comprehensive technology and supporting the “monozukuri” of the world. With the technical and development capabilities of the Shibaura Machine Group, various machines and services create rich value and contribute to the creation of an industrial base. Working on the eight technical platforms, they develop and manufacture a wide range of production devices that meet the needs of the times, delivering the best solutions by combining our accumulated excellent know-how and the latest technology. Shibaura Machine uses its knowledge of modern global standards of advanced technology to support Japan and the world.
IDEC Corporation was founded in 1945 and is headquartered in Japan as the manufacturer of automation and control products. The company provides solutions that meet the evolving needs of customers. With a focus on areas such as IoT implementation, automation advancements, and manufacturing site safety, IDEC offers a diverse range of products such as electromechanical control products such as relays, timers, and switches. The company also manufactures automation products, such as Micro Programmable logic controllers, power supplies, and touch-screen displays. Their goal is to help businesses adapt to changing technologies, improve operational efficiency, and prioritize safety in industrial environments.
B&R Industrial Automation GmbH, founded in 1979 with headquarters in Austria, is a manufacturer of automation technology, including a complete portfolio of robotics, automation, and software. The company's standard and tailored products are used in the automotive, maritime, medical device assembly, packaging, and plastics markets, among many others. The product line includes industrial PCs, I/O systems, robotics, and software for industrial components. B&R joined the ABB Group in 2017 to specialize in the integration of technology and sophisticated engineering to provide industries with solutions for machine and factory automation, motion control, and integrated safety technology.
ICP DAS Co. Ltd., established in 1993 and headquartered in Hsinchu County, Taiwan, is a manufacturer of automation products and solutions. Operating in over 100 countries, the company is engaged in developing a wide range of products, including remote I/O controllers, distributed I/O modules, I/O data acquisition boards, programmable automation controllers, and industrial communication modules. The company provides its services in several regions such as the United States, Europe, and China, ensuring its products meet the needs of a global industrial automation clientele.
Omron Corporation, started in 1933 and headquartered in Kyoto, Japan, is a manufacturer of automation components, equipment, and systems, and it developed the first contactless proximity switch in 1960. It has four domains, including industrial automation, electronic components, healthcare, and social systems, and it provides products and services in around 120 countries and regions. Some of its products include microsensing devices, access control systems, industrial robots, surveillance cameras, and blood pressure monitors. In 1971, it developed the first online cash machine, and in 1972, it established Japan’s first welfare factory.
Founded in 1890 in Missouri, Emerson Electric Co., is a technology and engineering company that provides various solutions for customers in industrial, commercial, and consumer markets globally. Business segments include automation solutions, AspenTech, and commercial & residential solutions segments. The Automation Solutions segment offers measurement and analytical instrumentation, industrial valves and equipment, and process control software and systems. The AspenTech segment provides asset optimization software for enhancing performance through a combination of modeling, simulation, and optimization capabilities. The Commercial & Residential Solutions segment offers residential and commercial HVAC products, system protector and flow control devices, and IoT thermostats.
Advanced Micro Controls, Inc. (AMCI), founded in 1985 and headquartered in Terryville, Connecticut, USA, is a manufacturer of industrial control products. The company specializes in enhancing PLC-based automation systems with its specialized position sensing and motion control technology. It offers PLC network products with uniform motion programming, specialty I/O devices such as relay boards and sensor interfaces, and position sensing equipment, including heavy-duty rotary shaft sensors. Additionally, the company provides motion control solutions that can be seamlessly integrated into existing systems.
Phoenix Contact is headquartered in Blomberg, Germany, originally founded in 1923. Phoenix Contact’s Israeli subsidiary was founded in 2006 and located in Quadima Tzoran. Phoenix Contact provides tools and components for e-mobility, power, infrastructure, process industry, production manufacturing, system manufacturing, and others. Phoenix Contact’s product lines include automate including cloud computing, connect including PCB terminal blocks, “mark, assemble, and install” including hand tools, “supply, charge, and protect” including power distributors, and “switch, measure, and monitor” including relays and optocouplers.
Koyo Electronics Co., Ltd. was founded in 1955 and began manufacturing and selling portable radios, and in 2022 the company name changed to JTEKT ELECTRONICS CORPORATION. Based on human respect, KOYO uses wisdom and imagination to provide good value and contribute to developing a safe and fulfilling society.
Mitsubishi Electric Corporation (Mitsubishi EC) is a Japanese multinational manufacturer of electrical as well as electronic products and systems originally established in 1921 by Mitsubishi Shipbuilding Co., now known as Mitsubishi Heavy Industries, Ltd. Based in Tokyo, Japan, the company produces home appliances, HVAC products, and automotive equipment, as well as factory automation and communication systems. These supply consumers and clients internationally throughout the residential, commercial, and industrial sectors. Mitsubishi EC has several subsidiaries operating globally; some as distributors of its products. Some of its notable subsidiaries are Mitsubishi Electric Power Products, Inc. and Mitsubishi Electric Automation, Inc.
CAREL INDUSTRIES S.p.A., founded in 1973, is a manufacturer and distributor of evaporative cooling and humidification refrigeration, air conditioning, and heating systems for industrial, residential, and commercial applications. The products include pressure control solutions, speed controllers and inverters, water treatment systems, isothermal humidifiers, and programmable controls. The Burgine-based Via Dell'lndustria company provides technical support, field services, spare parts, digital services, and product maintenance. The company provides technology solutions to data centers, hypermarkets, museums, theaters, and printing industries.
Twin City Fan & Blower, started in 1974 and based in Minneapolis, Minnesota, is a manufacturer of custom, semi-custom, and standard fans. Its products include centrifugal fans, pressure blowers, and air kits, and it sells both heavy-duty industrial process fans as well as commercial supply and exhaust fans for HVAC. It has ten facilities in the USA and operates in other countries like Brazil, Europe, and Singapore. The company uses the 5S methodology in its plants and has testing laboratories that can carry out services like AMCA 250 Jet Fan Thrust Testing, mechanical run testing, and modal analysis testing.
Moxa Inc. is a manufacturer of networking and automation technology for the industrial sector that was established in 1987 in Taipei, Taiwan. The company produces items designed to enable Industrial Internet of Things (IIoT) functionalities via interconnectivity between devices or equipment. These include industrial edge computers, ethernet switches, and isolators for legacy device connectivity. It also offers additional services including personnel training, technical support, and custom product design. The company mainly serves clients in the mining, automation, and transportation sectors.
Rockwell Automation, Inc. was founded in 1903 and is headquartered in Milwakee, WI. Rockwell Automation provides industrial automation and digital transformation solutions around the world. Rockwell Automation operates through their intelligent devices, software & control, and lifecycle services segments with both hardware and software products and services. The Intelligent Devices segment offers drives, motion, safety, sensing, industrial components, and configured-to-order products. The Software & Control segment provides control and visualization software and hardware, information software, and network and security infrastructure solutions. The Lifecycle Services segment provides consulting, professional services and solutions, and connected and maintenance services through independent distributors.
Delta Electronics was founded in 1971 in Taipei, Taiwan. Delta Electronics is a global provider of power and thermal management solutions, serving power electronics, automation, and infrastructure. Delta’s power electronics division sells components such as inductors, power and system components such as industrial power supplies and external adapters, fans and thermal management such as DC brushless fans and motors, and automotive electronics. Automation includes industrial automation and building automation subdivisions. Infrastructure includes ICT infrastructure, energy infrastructure & industrial solutions, and display & visualization. Delta Electronics also provides solutions for data center, telecom energy, and EV charging.
OMRON Corporation is a Kyoto based electrical equipment manufacturing company founded by Kazuma Tateisi in 1933. OMRON’s product portfolio includes medical equipment like nebulizers and digital thermometers, automated teller machines for the finance industry to AC, DC and custom control systems for the oil and gas industries. The company has over 30,000 employees and offers its products and services in 120 countries. It primarily serves the healthcare, energy, casino, and automated test equipment industries.
Control Components Inc. is a wholesale distributor of safety and electrical products that was established in 1985 and is headquartered in Pelham, Alabama. The company's portfolio is ever-growing, and it's a complete machine safety and factory automation solutions provider. It distributes solutions to the automotive, OEM, and industrial markets. Some of the company's products include sensors, industrial communication, process measurement, and control panel devices. Additionally, its staff offers consultancy services on selecting products that fit the client's needs and budget.
Ranking as of January 2025
Derivation Method| Rank | Company | Click Share |
|---|---|---|
| 1 | Emerson Electric Co. |
11.3%
|
| 2 | CAREL INDUSTRIES S.p.A. |
9.4%
|
| 3 | Advanced Micro Controls, Inc. |
9.4%
|
| 4 | LOVATO Electric S.p.A. |
9.4%
|
| 5 | IDEC Corporation |
7.5%
|
| 6 | Shibaura Machine |
7.5%
|
| 7 | Omron |
7.5%
|
| 8 | Pelham Location |
5.7%
|
| 9 | Gefran SpA |
5.7%
|
| 10 | B&R |
3.8%
|
Derivation Method
The ranking is calculated based on the click share within the programmable controller page as of January 2025. Click share is defined as the total number of clicks for all companies during the period divided by the number of clicks for each company.Number of Employees
Newly Established Company
Company with a History
*Including some distributors, etc.
*Including some distributors, etc.
| Country | Number of Companies | Share (%) |
|---|---|---|
|
Japan
|
7 | 50.0% |
|
Italy
|
3 | 21.4% |
|
United States of America
|
1 | 7.1% |
|
France
|
1 | 7.1% |
|
Germany
|
1 | 7.1% |
|
Taiwan
|
1 | 7.1% |
290 products found - Page 1
290 products - Page 1
NST Co., Ltd.
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