Control Intelligence

Balancing safety and throughput

The space shuttle had three computers and needed a two-of-three voting system to determine if a sensed variable was real or phantom. This would be a good thing regarding a leaking door seal on the capsule. Safety sensing isn’t a new technology, but it seems that understanding what a safety system function is might be lacking a bit.

In this episode of Control Intelligence, written by contributing editor Jeremy Pollard, editor in chief Mike Bacidore talks about safety systems.

How to choose between Ethernet industrial protocol and synchronous serial interface

Controls engineers are surrounded by protocols. Proprietary protocols are less common today than before, but they are still around.

In this episode, written by contributing editor Tobey Strauch, Editor-in-Chief Mike Bacidore discusses how to choose between Ethernet IP and SSI.

Choosing the right enclosure material for fanless industrial PCs

In most factory lines, the soft PLC and PAC are commonly based on Industrial PC hardware. It is this hardware platform that has quietly become one of the most important components of a factory line’s control hardware.

In this episode of Control Intelligence, written by contributing editor Joey Stubbs, editor in chief Mike Bacidore discusses fanless controller housings.

PACs vs. PLCs: What’s the difference?

In this episode of Control Intelligence, written by contributing editor Tobey Strauch and originally aired in March 2025, editor in chief Mike Bacidore discusses the similarities and differences between PLCs and PACs.

When is it time to upgrade your control system?

It’s the beginning of the new year, and everyone’s capital budget is going to be reset and revised. People will come out with their five-year and 10-year and 20-year plans, and once again plant management will ask the question: “Can we upgrade the control systems?”

In this episode of Control Intelligence, written by contributing editor Tobey Strauch, editor in chief Mike Bacidore discusses when to upgrade control systems.

On-machine sensing: How is it implemented?

In this episode of Control Intelligence, written by contributing editor Tobey Strauch, editor in chief Mike Bacidore discusses on-machine sensing and IIoT implementation.

Once you’ve finished listening to the podcast, take Control Design's quiz about on-machine sensing and IIoT implementation.

How to monitor and manage the health of hydraulic systems

Many electrical engineers will ignore mechanical properties of a machine because it’s not their specialty. Control systems engineers cannot do that. Controls require an understanding of the electrical and mechanical interface.

In this episode of Control Intelligence, written by contributing editor Tobey Strauch, editor in chief Mike Bacidore discusses how to monitor and manage the health of hydraulic systems.

The 4 cornerstones of effective I/O checkout

During commissioning and after, if you hear three definitions of I/O checkout and then get residual failures after a down and an install because no one is going off a commissioning plan, writing up a test plan or adhering to a commissioning plan, then there is a problem.

In this episode of Control Intelligence, written by contributing editor Tobey Strauch, editor in chief Mike Bacidore discusses machine commissioning and I/O checkout.

The impact of I/O on the interoperability trend

With the advent of common communication platforms, new layers of automation devices became available to control systems on the plant floor.

In this episode of Control Intelligence, written by contributing editor Jeremy Pollard, editor in chief Mike Bacidore discusses the impact of I/O on the interoperability trend.

Safety integrity level: What is it and why it matters

In factory automation, safety systems are no longer the peripheral add-ons of the past. They are integral to the design, operation and long-term viability of production lines. As automation increases and machinery becomes more interconnected, engineers are routinely tasked with specifying safety controllers, networks, sensors and safety I/O devices that carry a defined safety integrity level (SIL).

In this episode of Control Intelligence, written by contributing editor Joey Stubbs, editor in chief Mike Bacidore shares why SIL matters.