PLCs are standard designed to interface with industrial grade sensors, actuators, and

communication modules and are thus given current and voltage ratings which are often
incompatible with microcontrollers without extra hardware.

PLCs usually use Ethernet, and several variations of the RS- serial series like RS-232,
RS-485 for communication. The advent of the industrial internet of things nowadays, is
creating a surge in the number of connected PLC devices capable of transmitting data
over wireless communication interfaces.

3. Performance, Sturdiness and Reliability

This is by far the point under which the PLC distinguishes itself the most. As
mentioned initially, the PLC was designed for use in industrial setups and was thus
fortified to be able to withstand several adverse conditions associated with that
environment like, extreme temperature ranges, electrical noise, rough handling and high
amount of vibration. PLCs are also a good example of real time operation system due to
their ability to produce outputs within the shortest time possible after evaluating an input.
This is very important in industrial system as timing is a huge part of the manufacturing
plant/process.

Microcontrollers however are less sturdy. By design they were not designed to serve as
standalone devices like PLCs. They were designed to be embedded in a system. This
provides an explanation for their less sturdy look compared to PLCs. For these reasons,
microcontrollers may fail when deployed in certain scenarios as the chips are fragile and
can easily be damaged

4. Skill Requirement for Use

One of the key attributes of the PLC is the low technical knowledge required for
programming, and generally operating it. The PLC was designed to be use by both the
highly skilled automation experts and factory technicians who have little or no formal
training. It is relatively easy to troubleshoot and diagnose faults. Modern PLC devices
usually come with a display screen that makes things easier to monitor without
sophisticated tools.

Microcontrollers on the other hand however, require skilful handling. Designers

need to have a good knowledge of electrical engineering principles and programming to
be able to design complementary circuits for the microcontroller. Microcontrollers also
require special tools (e.g Oscilloscope) for fault diagnosis and firmware trouble shooting.
Although several simplified platforms like the Arduino currently exists, it is still a lot
more complex than the plug and play PLCs both from connection stand point,
programming standpoint, and ease of use.

6. Applications
PLCs are the primary control elements used in industrial control systems. They find
application in the control of industrial machines, conveyors, robots and other production
line machineries. They are also used in SCADA based systems and in systems that
require a high level of reliability and ability to withstand extreme conditions. They are
used in industries including;

1. Continuous bottle filling system

2.Batch mixing system
3.stage air conditioning system
4.Traffic control

Microcontrollers on the other hand find application in everyday electronic devices. They
are the major building blocks of several consumer electronics and smart devices.

While the answer can be found from the points already mentioned within this article, it is
sufficient to highlight two key points.
1. Microcontrollers are not designed with the ruggedness and ability to withstand extreme
conditions like PLCs. This makes them not ready for industrial applications.

2. Industrial sensors and actuators are usually designed according to the IEC standard
which is usually at a range of current/voltage and interfaces which may not be directly
compatible with microcontrollers and will require some sort of supporting hardware
which increases cost.