Choosing a control platform is an important decision for OEM machine builders. The PLC, HMI, communication network, motion system, and engineering software all affect machine performance, development time, maintenance, and long-term support.
Two platforms frequently considered by OEMs are B&R Automation and Allen-Bradley (Rockwell Automation). Both offer comprehensive automation solutions, but their hardware architecture, communication ecosystems, programming environments, and motion-control capabilities can lead to different considerations for machine builders.
B&R Automation and Allen-Bradley are both established industrial automation platforms, but they have traditionally developed around somewhat different ecosystems.
Allen-Bradley is widely used in North American manufacturing and has a large EtherNet/IP-based ecosystem with extensive third-party device support.
B&R, part of ABB, is particularly well known for integrated automation and motion-control solutions. Its platform is often considered for applications where coordinated motion, servo integration, and compact machine architectures are important.
For OEMs, the right choice depends less on a simple brand comparison and more on the machine's requirements, existing components, engineering resources, and target market.
Communication compatibility is one of the first factors an OEM should evaluate.
Allen-Bradley's EtherNet/IP ecosystem provides access to a large range of third-party sensors, drives, I/O modules, HMIs, and other industrial devices.
B&R's POWERLINK technology was designed for deterministic, real-time industrial communication and is particularly suited to tightly integrated automation and motion-control applications.
When designing a machine with components from multiple suppliers, OEMs should verify communication compatibility before selecting the control platform.
HMI hardware is another important consideration for machine builders.
B&R offers integrated automation hardware and larger-format operator interfaces that can be attractive for applications requiring a relatively large display.
Some B&R hardware platforms also use industrial solid-state storage rather than conventional mechanical hard drives, which can be beneficial in demanding industrial environments.
Other potential considerations include:
Long-term hardware availability
Industrial-grade components
Integrated controller and HMI architectures
Display size and resolution
Mounting requirements
Storage technology
Replacement and service availability
For an OEM, the initial hardware price should not be considered in isolation. The total cost of ownership also includes engineering, commissioning, spare parts, software, training, and long-term support.
The engineering environment can have a significant impact on OEM development time.
B&R uses Automation Studio as its engineering platform. It supports multiple programming languages and is designed to integrate PLC programming, motion control, visualization, and other automation functions within a common environment.
Allen-Bradley systems are commonly programmed using Studio 5000 Logix Designer, which is widely used in North American industrial automation.
For OEMs, important questions include:
Which programming languages are supported?
How easily can engineers troubleshoot the machine?
Can programs be backed up and restored efficiently?
How easy is online editing?
How familiar is the engineering team with the platform?
How easy is it to maintain machines in the field?
B&R supports IEC-based programming approaches, including Ladder Diagram and Structured Text. In practice, the programming method used can vary depending on the application and engineering team.
Legacy equipment can introduce additional challenges.
Older B&R automation systems may use earlier generations of programming software and hardware, requiring attention to firmware compatibility between CPUs, communication modules, and memory devices.
When maintaining older machines, OEMs and end users should check:
Controller generation
Firmware versions
Programming software compatibility
Replacement hardware availability
Backup and restoration procedures
Availability of obsolete components
These considerations are not unique to B&R. Any long-running industrial machine can eventually face challenges related to discontinued hardware, legacy software, and component obsolescence.
For new machine projects, it is therefore important to evaluate the current-generation platform rather than making a decision based primarily on the limitations of older systems.
Motion control is one of the areas where B&R has traditionally positioned its automation platform strongly.
For machines involving multiple coordinated axes, servo drives, electronic gearing, synchronization, and high-speed positioning, an integrated automation and motion-control architecture can simplify system design.
Typical applications include:
Packaging machines
Pick-and-place systems
High-speed material handling
Filling and labeling equipment
CNC-related applications
Multi-axis positioning systems
B&R's close integration between controllers, drives, and motion functions can be particularly relevant to OEMs building machines where coordinated motion is a core requirement.
Allen-Bradley also provides extensive motion-control capabilities through its Logix and Kinetix product families. The appropriate solution should therefore be evaluated based on the specific machine architecture rather than the controller brand alone.
Software licensing and technical support can have a substantial impact on the long-term cost of an OEM machine.
Before selecting a platform, machine builders should consider:
Software licensing models
Version compatibility
Upgrade requirements
Local technical support
Availability of trained engineers
Training requirements
Spare-parts availability
Support in the machine's target market
A control platform that is technically suitable but unfamiliar to the OEM's engineering team may require additional training and development time.
Likewise, a platform that is already widely used by a machine's end users can simplify commissioning, service, and troubleshooting.
Rather than selecting a universal winner, OEMs should evaluate the platform against the machine's actual requirements.
Advanced motion control is a major requirement.
Servo integration is central to the machine design.
A highly integrated automation architecture is preferred.
Large HMI solutions are required.
The engineering team is experienced with B&R Automation Studio.
The machine can operate effectively within the B&R communication ecosystem.
The machine is primarily targeted at the North American market.
The customer already operates an EtherNet/IP-based automation network.
Integration with a wide range of third-party industrial devices is important.
The customer's maintenance team is already familiar with Rockwell Automation products.
Existing Allen-Bradley equipment needs to be integrated into the new machine.
Before committing to B&R or Allen-Bradley, an OEM should answer several practical questions:
What is the target market?The preferred automation platform can vary significantly between North America, Europe, and other regions.
What communication protocols are already used?Existing drives, I/O, sensors, safety devices, and other equipment may influence the controller choice.
How important is motion control?Machines with demanding multi-axis motion requirements may benefit from a highly integrated motion-control architecture.
Who will maintain the machine?The customer's existing engineering and maintenance capabilities should be considered.
What is the expected machine life?Long-life equipment requires careful consideration of hardware availability, software support, and replacement strategy.
How much third-party equipment needs to be integrated?Communication compatibility should be confirmed before the machine architecture is finalized.
There is no single automation platform that is ideal for every OEM application.
B&R offers a strong integrated automation approach, particularly for machines where motion control and close integration between controllers, drives, and visualization are important.
Allen-Bradley provides a mature automation ecosystem with broad adoption in North America and extensive EtherNet/IP-based integration options.
For OEM machine builders, the most practical approach is to compare the two platforms based on the complete project:
machine requirements + target market + communication architecture + motion requirements + engineering resources + service strategy + total cost of ownership.
Evaluating these factors early in the design process can help OEMs select a control platform that is not only suitable for the initial machine build but also practical to support throughout the machine's service life.