Omron vs. Allen Bradley vs. Johnson Controls

Introduction

As the demand for cutting-edge, safe, and reliable automation solutions continues to rise rapidly, companies across the globe are developing innovative and highly advanced automation hardware and software solutions to usher in the new age of autonomous buildings, smart manufacturing, automated transit systems, etc.

In this article, we’ll look at three popular industrial automation companies – Allen Bradley, Omron Corporation, and Johnson Controls– whose automation solutions are greatly transforming our workplaces.

Allen Bradley Overview

Founded in 1903 by Dr. Stanton Allen and Lynde Bradley originally as the Compression Rheostat Company, Allen Bradley is an American manufacturer of industrial automation products such as programmable controllers, Variable Frequency Drives (VFDs), sensors, servo motors, encoders, servo drives, power supplies, circuit breakers, etc. At present, Allen Bradley is owned by Rockwell Automation – a multinational factory automation company headquartered in Milwaukee, Wisconsin, United States.

In a nutshell, Rockwell Automation develops and deploys highly specific automation technologies for smart manufacturing in a wide array of industries. The Allen‑Bradley automation components, integrated controls, and information solutions are particularly built for demanding industrial applications, such as the automation of newspaper printing presses to increase efficiency and improve printing quality.

Outlined below are some of the Allen‑Bradley hardware products being used in most workspaces for automation purposes.

Programmable Controllers

Allen Bradley offers different types and sizes of Programmable Automation Controllers (PACs) and Programmable Logic Controllers (PLCs), ideal for large to small and even micro industrial applications. Available Allen‑Bradley programmable controllers include:

• Large Control Systems: ControlLogix and GuardLogix 5580 controllers, CompactLogix and Compact GuardLogix 5380 process controllers, and ControlLogix5570 Controllers.
• Small Control Systems: SLC 500 controllers, SmartGuard600 Controllers enhanced with safety features, CompactLogix 5480 controllers, etc.
• Micro Control Systems: Micro850 PLCs, MicroLogix 1400 PLCs, Micro810 PLCs, Micro830 controllers, Micro820PLCs, Micro800 PLC Plug-in Modules and Accessories, and Micro870PLCs.

Variable Frequency Drives (VFDs)

Allen-Bradley’s PowerFlex family of Variable Frequency Drives is designed and built for ease of use, scalability, flexibility, and productivity. They offer a comprehensive range of drive options, control modes, features, power ratings, and global voltages for improved system connectivity and productivity. The available PowerFlex drives are classified as follows:

• Low Voltage VFDs: PowerFlex 523, PowerFlex 525, PowerFlex 753, PowerFlex 4M, PowerFlex 755TS, PowerFlex40P, PowerFlex 755T VFD, PowerFlex 700L, PowerFlex 400 AC Drives, etc.
• Medium Voltage VFDs: PowerFlex 6000 AC Drives, PowerFlex 7000 VFDs, and PowerFlex7000 medium-voltage VFD with ArcShield technology.
• PowerFlex DC Digital Drives

Servo Drives

Rockwell Automation’s comprehensive range of servo drives is designed to simplify control architectures and machine designs, improve system flexibility, extend machine capabilities, and enhance overall performance. Some of the available Allen‑Bradley servo drives include:

• Multi-axis Control Servo Drives: Kinetix 5700, Kinetix 5500, ArmorKinetix Distributed servo drives, Kinetix6500, Kinetix 6000, and Kinetix 2000.
• Single-axis Control Servo Drives: Kinetix5500, Kinetix350, Kinetix 5300, and Kinetix 7000.
• Standalone Control Servo Drives: Kinetix5100, Kinetix300, Kinetix Ultra 3000, and Kinetix3 Component servo drives.
• Decentralized Control Kinetix Servo Drives: The ArmorKinetix Distributed servo drives provide compact, high-performance, On-Machine motion control that enables production machines to become more flexible, efficient, and cost-effective.

Human Machine Interface

Allen Bradley’s computing and HMI solutions provide enhanced visualization of critical processes, information exchange, and plant data across various types of industrial applications and workspaces. These solutions include:

• Graphic Terminals: OptixPanel terminals, PanelView 5000 terminals, PanelView Plus 7 terminals (Bulletin 2711P), PanelView 800 (Bulletin 2711R) Graphic Terminals, etc.
• MobileViewTethered Operator Terminals
• Industrial Computers and Monitors

Omron Overview

Founded in 1933 by Kazuma Tateisi, originally as the Tateisi Electric Manufacturing Co., Omron is a Japanese electronics company headquartered in Kyoto, Japan. The company provides a broad spectrum of innovative solutions and advanced technologies, ranging from electronic and industrial automation components to social automation systems, including automated healthcare systems, solar power conditioners, and ticket gates. Omron primarily focuses on the manufacture and deployment of automated systems and equipment.

The main products provided by Omron Corporation are:

• Automated Systems: The automation systems manufactured by Omron include Machine Automation Controllers, Industrial PC Platforms, Multi-Axis Controllers that support machine control, Safety Controllers, Programmable Terminals, Software & Network products that facilitate seamless information exchange with host systems, RFID Systems, Human Machine Interfaces (HMI), Remote Access Solutions, Input and Output (I/O) modules, and Peripheral Devices.
• Control Components: Omron’s Control Components provide ideal control at manufacturing facilities through Digital Temperature Controllers, Programmable Relays, Timers, Counters, Timer Switches, Cam Positioners, Digital Panel Indicators, and other input, control, and output elements.
• Switches: Omron provides a variety of basic switching components, including Limit Switches, Level Switches, Push Buttons, and Thumbwheel Switches.
• Sensors: The sensing components manufactured by Omron are widely used to detect, analyze, measure, and process varying changes that occur in manufacturing facilities, such as changes in displacement, position, height, appearance, and length. Available Omron’s sensors include Fiber Sensors, Displacement Sensors, Code Readers, Photoelectric Sensors, Flow Sensors, Vision Sensors, Condition Monitoring Sensors, Contact Sensors, Rotary Encoders, Photomicro Sensors, etc.
• Relays: Available Relays from Omron include Solid-state Relays, Low Voltage Switching Gears, Safety Relays, I/O Relay Terminals, Power Controllers, Terminal Relays, and General Purpose Relays. These relays are used to make or break electric circuits by their output section that is driven by an electric input signal often controlled by a switching device.
• Motion Control & Drives: Omron provides a wide range of Machine Automation Controllers, Servo motors, Inverters, Variable Speed Drives (VSDs), and Servo Drives ideal for positioning, torque, and speed controls in various machine control applications.   
• Robotics: Omron develops and deploys Fixed Robots, Mobile Robots, Vision Systems, Robotic Arms, Collaborative Robots, and Robotics Integrated Controllers in manufacturing industries to achieve more flexible production lines.
• Industrial Safety Components: Omron’s Safety Components are widely used for building safety circuits, detecting shut-out of mechanical guards in industrial equipment, and checking intrusion into hazardous areas. They include Safety Light Curtains, Safety Laser Scanners, Safety Controllers, Safety Multi-Light Beams, Safety Door Switches, Single-beam Safety Sensors, Safety Limit Switches, Safety Mats, Safety Edges, Emergency Stop and Control Devices, Safety Key Selector Switches, Safety Relay Units, Enabling Grip Switches, Safety Drives, Safety Outputs, and Safety Logic Control Systems.

Johnson Controls Overview

Founded in 1885 by Professor Warren Johnson, Johnson Controls is an American, Irish-domiciled multi-industrial company headquartered in Cork, Ireland. For nearly 140 years, this multinational conglomerate has continued to provide the world’s largest portfolio of building automation technology, software, and services.

For instance, through its OpenBlue enterprise–a comprehensive suite of connected automation solutions– Johnson Controls is delivering the blueprint of future automation across different industries such as manufacturing, healthcare, data centers, schools, sports and entertainment, global marine and navy, transportation, and beyond, making it a world leader in creating smart, safe, and sustainable workspaces.

Some of the main products provided by Johnson Controls include:

HVAC Equipment

Johnson Controls provides a broad portfolio of efficient and reliable HVAC (Heating, Cooling, Air Handling, and Controls) equipment, including the following:

• Water-Cooled Chillers: YZ Magnetic Bearing Centrifugal Chiller, YK Centrifugal Chiller,YMC2 Centrifugal Magnetic Drive Chiller, YK-EP Centrifugal Chiller with Economizer, CYK Compound Centrifugal Chiller, etc.
• Air-Cooled Chillers: YVAA Air-cooled Variable Speed Drive (VSD) Screw Chiller, YMAE-X Full DC inverter Modular Chiller, YLAA Air-Cooled Scroll Chiller, YVAG-HR Full DC inverter Mini-Chiller, etc.
• Air Handling Units: YORK Custom AHU, YORKSolution Air Handling Units, and Johnson Controls AMI Modular Air Handling Units
• Air Distribution Solutions: Energy Recovery Ventilators, Gravity Ventilators, Utility Centrifugal and Radial Blowers, Roof Mounted Fans, Ceiling Fans, etc.

Building Automation and Controls

Johnson Controls offers industry-leading configurable building controls that integrate seamlessly with various smart equipment in buildings to achieve smart and autonomous buildings. These control systems are designed to keep occupants safe, comfortable, and productive in any workspace or environment. Available Building Automation solutions from Johnson Controls include:

• Metasys Building Automation System: An intelligent, world-class building automation technology system that connects commercial HVAC, security & protection, and lighting systems from Johnson Controls to allow seamless communication on a single platform, allowing occupants to make smarter, savvier decisions that enhance their safety, comfort, and productivity.
• Facility Explorer: A cutting-edge building automation system from Johnson Controls that delivers exceptional automation capabilities and scalability when combined with next-generation FX equipment controllers and networking topologies. 
• BACnet/IP Equipment Controllers: State-of-the-art FX equipment controller models from Johnson Controls use BACnet/IP protocol, with support for daisy chain, ring, and star network topologies. Also, their updated firmware and embedded software align with industrial-grade cybersecurity standards and protocols. 

Security Products

Johnson Controls offers a broad set of innovative security products and services, from access controls to video surveillance to intruder prevention to cyber security. Some of the available security products include:

• Access Control Products: Featured solutions include: Hosted Electronic Access Control, Managed Access Control, Electronic Access Control, and Physical Access Control solutions.
• Intrusion Detection Products: Powered with innovative technology, these products provide real-time alerts of probable security incidents, enabling prompt response to mitigate any risks. Featured solutions include Burglar Alarm Systems,  PowerG-enabled Wireless Devices, Panic Devices and Protection Solutions, Mobile Security Management, Smart Perimeter Protection Solutions, etc.
• Video Surveillance: In an effort to create a safer and smarter world, Johnson Controls offers the following video-based security solutions: Video Monitoring Systems, Video Surveillance Systems, Video Analytics, and value-added Managed Video Services.

Industrial Refrigeration Solutions

FRICK Industrial Refrigeration solutions from Johnson Controls are designed to deliver efficient and reliable means of keeping food fresh through refrigeration.

Fire Detection Systems

Fire safety, which is a fundamental mandate for every business, begins with fire detection. Available fire detection products and technologies from Johnson Controls include Sensors and Initiating Devices, Emergency Communications Systems (ECS) with advanced technology, Notification Appliances and Audio Devices, Fire Alarm Control Panels, and next-generation Networks and Workstations that enable centralized fire detection management.

Fire Suppression Systems

Johnson Controls offers an unmatched range of fire suppression products, including Fire Sprinklers, Fire Valves and Devices, Fire Extinguishers and Agents, Water Mist Fire Protection Solutions, Special Hazards Systems, SPRAYSAFE Autonomous Fire Suppression (AFS), as well as Related Components and Fittings.

Omron vs. Allen Bradley vs. Johnson Controls

To answer the question: which automation giant among the three ­–Omron, Allen Bradley, and   Jonson Controls – reigns supreme in our workspaces? Let’s take a look at a few comparison factors.

Global Reach

Currently, Omron Corporation is providing its automation products and services in about 120 countries and regions across the globe, with over 35,000 employees worldwide. It has also established a global support network in Asia, the Americas, Oceania, Europe, and Africa.

Similarly, Rockwell Automation is currently providing Allen‑Bradleyautomation software & hardware components and LifecycleIQ services in more than 100 countries around the world, with approximately 26,000 employees worldwide. The company has also established a global support network for its customers, with offices located in more than 80 countries across the globe.

On the other hand, Johnson Controls, together with a set of global partners, is presently providing comprehensive and holistic HVAC equipment, fire, and security solutions for smart buildings in more than 150 countries across six continents. And by the end of 2022, the company had a total of 102,000 dedicated employees in around 2,000 locations worldwide.

Therefore, in terms of global reach, we can say that the automation solutions provided by Johnson Controls reign supreme in most workspaces, as the company has customers and established locations in more countries across the globe compared to Omron and Allen-Bradley. Also, among the three automation giants, Johnson Controls has the highest number of employees worldwide.

Global Revenue

Rockwell Automation’s global revenue, inclusive of its Allen‑Bradley product line, was $8.351 billion USD for the 12 months ending March 31^st, 2023, which was a 14.07% increase year-over-year. For 2022, the company’s annual revenue was $7.76 billion USD, a 10.9% increase from the previous year (2021). While in 2021, the company had a total annual revenue of $6.997 billion USD, a 10.55% increase from 2020’s revenue.

Omron’s global annual revenue for the year 2023 was $6.483 billion USD, which was a 4.52% decline from the previous year (2022). For 2022, the company’s annual revenue was $6.79 billion USD, a 10.19% increase year-over-year. While its annual revenue for the year 2021 was $6.162 billion USD, a 1.21% decline from the year 2020.

For the 12 months ending March 31^st, 2023, the global annual revenue for Johnson Controls was $26.093 billion USD, a 5.67% increase year-over-year. The company’s annual revenue for the 2022 financial year was $25.299 billion USD, a 6.89% increase from the previous year (2021). And for the year 2021, its annual revenue was $23.668 billion USD, a 6.05% increase year-over-year.

From the statistics outlined above, we can deduce that Johnson Controls’ global annual revenue topped the list for the financial period 2021-2023, with the company’s average revenue during this period being $25.02 billion USD. And since revenue refers to the total amount of money a business receives from the sale of its products and services, it thus appears that automation solutions and products from Johnson Controls dominated most workspaces across the globe in the 2021-2023 period.

Automation Products and Solutions

Omron Corporation operates in six business segments, namely: Healthcare, Social Systems and Services, Electronic & Mechanical Components, Industrial Automation, Automotive Electronic Components, and Development Group. The company’s product portfolio includes Automation Systems, Robotics, Sensors, Switches, Safety Components, Software Tools, Quality control & Inspection Systems, Motion & Drives, Control Components, Relays, Electric Power Monitoring Equipment, and Power Supplies.

Similarly, Allen Bradley offers a wide range of innovative products and solutions, including Programmable Controllers, Power Supplies, Network Security & Infrastructure Solutions, Motor Control Products, Signaling Devices, Safety Products, Relays & Timers, Push Buttons, Variable Frequency Drives (VFDs), Sensors, Signal Interface Products, Input/Output Modules, Industrial Control Products, Lighting Control Products, Motion Control Solutions, Independent Cart Technology, Human Machine Interface Solutions, Switches,  Condition Monitoring Products, Connection Devices, Circuit and Load Protection Products, Industrial Computers & Monitors, Energy Monitoring Products, Distributed Control Systems, Manufacturing Execution System, and  Design & Operations Software.

Likewise, Johnson Controls provides a broad set of products and solutions to meet the specific needs of customers globally. The company’s product portfolio includes HVAC Equipment and Controls, Fire Detection Products, Industrial Refrigeration Solutions, Security Products and Services, Fire Suppression Systems, Building Automation Systems and Controls, Residential and Smart Home Solutions, Security Systems, Retail Solutions, Digital Solutions, and OpenBlue Solutions.

Essentially, all three companies (Omron, Allen Bradley, & Johnson Controls) do provide a broad portfolio of automation products and services for diverse applications across different industries, including Manufacturing, Healthcare, Infrastructure, Entertainment, Aerospace, Automotive, Marine, Government, etc. It’s also worth noting that the three automation giants leverage the latest technologies to develop and deploy leading-edge automation products and solutions built on a foundation of expertise and innovation.

This entry was posted on July 3rd, 2023 and is filed under Uncategorized. Both comments and pings are currently closed.