Industrial PCs: The Cornerstone of Complex Control in the IIoT Revolution

Automation technologies and the Industrial Internet of Things (IIoT) are reshaping modern manufacturing, and the demand for robust control hardware is rising in tandem. Yet this critical aspect often fades into the background while attention is given to advanced software. Stephen Hayes, Managing Director of Beckhoff UK, stresses the need for a holistic approach that places Industrial PCs (IPCs) at the heart of complex control solutions.

Over the last decade, forward‑thinking leaders and industrial software pioneers have championed the promise of the IIoT. Powered by data, connected systems, and evolving network topologies, the IIoT is positioned to transform industry, offering early adopters gains in efficiency, productivity, and profitability.

In 2019, Microsoft’s IoT Signals report projected that 94% of businesses would be using IoT by the end of 2021. Fast forward to the pivotal year, and a Ubisense survey found that 43% of manufacturers no longer understand the value of IoT. This disconnect largely stems from how the concept has been framed.

While IoT and connected devices are novel in some sectors, they are a long‑standing reality for many manufacturers. When the IIoT is viewed simply as connected industrial systems and advanced automation, the intrinsic value becomes clearer, reflected in the widespread adoption of these technologies.

However, the perceived separation between automation technology and IIoT has led some leaders to prioritize software as the sole driver of digitalisation. Software is undeniably vital, but it cannot deliver its full potential without the underlying hardware—particularly IPCs—that can process control and system data in real time.

Consider the example of plant management: the right software package ensures data is communicated and managed efficiently, and complex control programs run smoothly. Yet, if field‑level IPCs lack the computing power to handle control or system data, the software’s value is severely diminished.

Beckhoff UK argues that the current narrative around the IIoT has misdirected focus toward software functionality alone, overlooking the crucial synergy between hardware and software in industrial control.

Fortunately, hardware advancements have kept pace with the demands of sophisticated software. Beckhoff’s IPC portfolio spans cost‑effective, ultra‑compact Intel‑powered units in the C60xx range to IP65‑rated, multi‑core processors in the C70xx range designed for harsh environments. Each series offers multiple processor options, enabling manufacturers to match the right IPC to their data intensity and software needs.

Moreover, every IPC is engineered for flexibility—whether mounted in a control cabinet or directly on a machine—accommodating a wide range of form factors. This adaptability allows legacy machines to upgrade their control systems without extensive redesign or costly delays.

Perhaps it’s time to reframe the IIoT narrative as advanced automation, giving due emphasis to the hardware that keeps data flowing seamlessly through operations. Doing so will help manufacturers fully grasp how these technologies add tangible value and transform the intangible concept of the IIoT into a concrete, operational advantage.

Author: Stephen Hayes, Managing Director, Beckhoff UK.