Automating your wind tunnel isn’t just about convenience—it’s about repeatability. But choosing between PLC and SCADA for equipment integration can feel overwhelming. Let’s simplify.

PLC (Programmable Logic Controller) is the workhorse for:

Real-time control (e.g., adjusting fan speed when pressure hits a threshold).

Hardwired devices (motors, valves, probes) with simple on/off or setpoint commands.

It’s fast (response times <10ms) and rugged, ideal for harsh environments (dust, vibration in industrial tunnels). Programming is straightforward with ladder logic—great for technicians familiar with electrical diagrams.

Best for: Small to mid-sized tunnels focused on single processes (e.g., fixed-speed tests for automotive parts).

SCADA (Supervisory Control and Data Acquisition) excels at:

Centralized monitoring of multiple systems (e.g., fan, heater, data logger).

Complex data visualization (trend charts, alerts on a dashboard).

Remote access (viewing/adjusting tests via desktop/mobile).

It’s better for large tunnels with diverse equipment (e.g., hypersonic tunnels with temperature control, pressure scanners, and motion stages). SCADA integrates with databases, making it easy to track test history for audits.

When to combine them: Use PLCs for low-level control (e.g., opening/closing valves) and SCADA for oversight (e.g., logging valve positions and triggering alerts if they stick). This hybrid setup balances speed and visibility.

Cost breakdown:

PLC: $5k–$20k (hardware + basic programming).

SCADA: $15k–$50k (software licenses + integration with existing tools).

Pro tip: For academic labs on a budget, open-source SCADA (e.g., Ignition Community Edition) pairs well with affordable PLCs (Allen-Bradley Micro800 series).

Testing a PLC/SCADA setup? Start with a simple loop: Program the PLC to adjust fan speed, then have SCADA log the change. If the system lags, check for network congestion—PLCs need dedicated Ethernet ports, not shared Wi-Fi.

What’s your tunnel’s primary use (aerospace, automotive, education)? Tell us, and we’ll recommend the best fit.