The control system is one of the most important parts of modern mobile machinery.Construction equipment, agricultural machines, mining vehicles, and industrial vehicles require reliable controllers to manage sensors, actuators, communication networks, and machine functions.For many years, traditional PLCs have been widely used in industrial automation applications. However, as mobile machinery becomes more intelligent and connected, OEM manufacturers are increasingly adopting CODESYS-based control platforms for machine control applications.
But what are the differences between CODESYS and traditional PLC systems?
This article explains how CODESYS-based controllers compare with traditional PLCs and why CODESYS is becoming an attractive solution for modern mobile machinery.
CODESYS is a software development environment based on the international IEC 61131-3 programming standard.
It allows engineers to program industrial controllers using common programming languages, including:
Structured Text (ST)
Function Block Diagram (FBD)
Ladder Diagram (LD)
Sequential Function Chart (SFC)
Unlike traditional PLC systems that are often tied to specific hardware platforms, CODESYS provides a flexible software environment that can run on different types of industrial controllers.
CODESYS-based systems are widely used in:
Mobile machinery
Industrial automation
Robotics
Special-purpose equipment
A traditional PLC (Programmable Logic Controller) is a dedicated industrial controller designed mainly for factory automation.
Traditional PLC systems are commonly used in:
Production lines
Packaging machines
Manufacturing equipment
Process control systems
A typical PLC architecture includes:
CPU module
Communication modules
Programming software
PLCs are known for:
High reliability
Long service life
Simple programming
Industrial compatibility
| Feature | CODESYS-Based Controller | Traditional PLC |
|---|---|---|
| Programming standard | IEC 61131-3 | IEC 61131-3 |
| Hardware flexibility | High | Usually manufacturer-specific |
| Mobile machinery support | Excellent | Limited |
| CAN Bus integration | Native support | Requires additional modules |
| Software scalability | High | Medium |
| Custom applications | Flexible | More restricted |
| Development ecosystem | Open | Vendor-dependent |
Mobile machinery has different requirements compared with factory automation.
A machine such as a wheel loader or agricultural vehicle must operate under:
Vibration
Temperature changes
Outdoor environments
Limited installation space
Variable operating conditions
The control system must handle:
Hydraulic control
Motor management
Sensor inputs
CAN communication
HMI integration
Diagnostic functions
Traditional PLCs were mainly designed for fixed industrial environments, while mobile controllers are specifically designed for dynamic machine applications.
One of the biggest advantages of CODESYS is software flexibility.
Engineers can develop machine functions using standardized programming languages.
This allows OEM manufacturers to:
Create customized control logic
Reuse software modules
Develop different machine models faster
For manufacturers producing multiple machine variants, software scalability is extremely valuable.
Mobile machinery relies heavily on CAN-based communication.
Examples include:
CANopen devices
J1939 systems
Remote I/O modules
Motor controllers
Sensors
CODESYS provides strong support for CAN communication, allowing engineers to integrate different electronic components more efficiently.
This is especially important for modern machines with distributed electronic architectures.
Modern mobile machines require more than simple logic control.
They need functions such as:
Motion control
Data processing
Diagnostics
Communication management
Automation features
CODESYS provides tools for developing advanced applications beyond traditional PLC logic.
Machine requirements often change during product development.
Manufacturers may need to add:
New sensors
Additional I/O modules
New communication interfaces
Intelligent functions
A flexible CODESYS-based platform makes future expansion easier without completely redesigning the control system.
Traditional PLCs remain reliable solutions, but they may have limitations in mobile applications.
Many traditional PLCs are designed for cabinet installation in factories.
Mobile machinery requires:
Compact design
High protection rating
Resistance to vibration
Wide temperature operation
Dedicated mobile controllers are often better suited for these conditions.
Modern mobile machines require communication with many devices:
Sensors
Displays
Hydraulic controllers
Battery systems
Motor controllers
Mobile machinery often requires native support for CAN Bus protocols, which may require additional hardware in traditional PLC systems.
Using industrial PLC systems in mobile machinery may increase:
Hardware costs
Installation complexity
System size
A dedicated mobile controller with CODESYS support can provide a more optimized solution.
CODESYS-based controllers are suitable for:
Examples:
Wheel loaders
Excavators
Cranes
Concrete machinery
Applications:
Hydraulic control
Machine monitoring
Operator interface
Examples:
Harvesters
Balers
Tractors
Applications:
Automated functions
Sensor integration
Precision control
Electric machines require advanced control of:
Battery systems
Motor controllers
Energy management
CODESYS provides a flexible platform for developing these intelligent functions.
OEM manufacturers should consider:
Evaluate:
Temperature range
Vibration
Protection requirements
Installation conditions
Consider:
CANopen
J1939
Ethernet
Remote diagnostics
A good control platform should support:
Software updates
New functions
Machine connectivity
Intelligent features
As mobile machinery becomes more intelligent, control systems are moving toward:
Software-defined machines
Connected equipment
Autonomous functions
Remote diagnostics
AI-assisted operation
Flexible software platforms like CODESYS will play an increasingly important role because they allow manufacturers to develop smarter and more adaptable machines.
Both traditional PLCs and CODESYS-based controllers have important roles in industrial control.
However, for modern mobile machinery, CODESYS-based controllers provide advantages in flexibility, communication integration, and software scalability.
For OEM manufacturers developing construction equipment, agricultural machines, mining vehicles, and electric mobile machinery, choosing the right control platform is essential for building reliable and future-ready machines.
SonnePower provides CODESYS-compatible electronic control solutions for mobile machinery, including:
Programmable mobile controllers
Remote I/O modules
CAN communication solutions
Customized control systems
Our solutions help OEM manufacturers create scalable and intelligent control architectures for next-generation mobile machines.
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