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Allen Bradley vs Mitsubishi PLC: A Comparative Guide for Engineers

by Bryan Hellman




Programmable Logic Controllers (PLCs) are the backbone of industrial automation, controlling everything from simple machine operations to complex production lines. Two of the most well-known PLC brands in the market are Allen-Bradley (AB) and Mitsubishi Electric. Both companies offer robust automation solutions but cater to different needs, industries, and budgets.

In this guide, we will compare Allen-Bradley vs Mitsubishi PLCs in terms of performance, programming environment, communication protocols, scalability, pricing, and industry applications to help engineers make an informed decision.

1. Overview of Allen-Bradley and Mitsubishi PLCs

Allen Bradley PLCs (Rockwell Automation)

Allen-Bradley, a brand owned by Rockwell Automation, is widely used in North America and other high-end industrial sectors. Known for its reliability, scalability, and extensive ecosystem, AB PLCs are a top choice for industries requiringΒ high-performance automation.

Popular Allen Bradley PLC Series:

  • πŸ”Ή Micro800 Series – Ideal for small-scale applications
  • πŸ”Ή CompactLogix – Mid-range PLC for scalable solutions
  • πŸ”Ή ControlLogix – High-end PLC for large automation systems

Strengths:

  • βœ… Strong presence in North America and Europe
  • βœ… Highly reliable and robust for critical industries
  • βœ… Seamless integration with Rockwell Automation ecosystem
  • βœ… Extensive support and documentation

Mitsubishi PLCs

Mitsubishi Electric is a global leader in automation, with a strong presence in Asia and Europe. Their PLCs are known for being cost-effective, compact, and energy-efficient, making them ideal for OEMs (Original Equipment Manufacturers) and small-to-mid-scale automation projects.

Popular Mitsubishi PLC Series:

  • πŸ”Ή FX Series – Compact and cost-effective for small automation
  • πŸ”Ή L Series – Mid-range PLC with flexible capabilities
  • πŸ”Ή Q Series – High-end PLC with advanced processing power

Strengths:

  • βœ… Strong market presence in Asia and cost-sensitive industries
  • βœ… Competitive pricing and lower cost of ownership
  • βœ… Efficient energy management and compact designs
  • βœ… Ideal for machine automation and mass production industries

2. Programming and Software Environment

Allen Bradley: Studio 5000 & Connected Components Workbench (CCW)

Allen Bradley PLCs are programmed using Studio 5000 Logix Designer (for CompactLogix and ControlLogix) and CCW (for Micro800 series).

Software Usability & Features:

  • βœ… Studio 5000 is a powerful development environment with:
    • πŸ”Ή Tag-based addressing, simplifying modular programming
    • πŸ”Ή Advanced debugging tools like online editing and trend analysis
    • πŸ”Ή Seamless integration with Rockwell products
  • βœ… CCW is simpler but lacks the robustness of Studio 5000

Debugging & Diagnostics:

  • πŸ”Ή Real-time diagnostics and live monitoring
  • πŸ”Ή Emulation tools (RSLogix Emulate 5000) for offline testing

Licensing & Cost:

  • πŸ”Ή Studio 5000 licenses are expensive and have additional fees for advanced tools
  • πŸ”Ή CCW is free but has limitations

Mitsubishi: GX Works2 & GX Works3

Software Usability & Features:

  • βœ… GX Works3 offers:
    • πŸ”Ή Graphical function block programming
    • πŸ”Ή Pre-configured function blocks for motion control
    • πŸ”Ή Automatic device labeling
  • βœ… GX Works2, while older, is still widely used for FX and Q series PLCs

Debugging & Diagnostics:

  • πŸ”Ή Built-in simulation toolsΒ allow engineers to test logic without needing hardware.
  • πŸ”Ή Integrated maintenance functions monitor system health, helping to reduce downtime.

Licensing & Cost:

  • πŸ”Ή GX Works3 is more affordable than Studio 5000
  • πŸ”Ή Some basic versions are included for free with certain Mitsubishi PLCs

6. Industry Applications: Where Do They Fit Best?

Industry Allen Bradley PLCs Mitsubishi PLCs
Automotive βœ… Widely used πŸ”Ή Some adoption
Food & Beverage βœ… Strong presence βœ… Common in packaging
Oil & Gas βœ… Preferred choice ❌ Less common
Pharmaceuticals βœ… High reliability πŸ”Ή Some applications
Manufacturing βœ… Large factories βœ… Small to mid-size machines
Electronics πŸ”Ή Some use βœ… Very common

πŸ”Ή = Moderate usage, βœ… = Preferred choice, ❌ = Not commonly used

Conclusion: Which PLC Should You Choose?

  • πŸ”Ή Allen Bradley: Best for large-scale, high-budget, and mission-critical applications.
  • πŸ”Ή Mitsubishi: Best for cost-effective, compact, and OEM-focused automation.
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