Beckhoff opinion: Operating systems for industrial automation starts with people, not tech

When people talk about operating systems (OS) in industrial automation, it’s easy to jump straight into performance stats, software capabilities or the technical specs.

But the real question most engineers and operations teams are asking themselves is much simpler: “Can our team actually use this?”

Windows or Linux?

In this exclusive article, Beth Ragdale, software business manager at industrial automation and control specialist Beckhoff UK, explains the practical differences between Windows and Linux to help you choose the best OS for your industrial automation.

Within the automation and controls sector many companies rely heavily on Windows. It’s familiar, the user interface is intuitive, it boots to a desktop and it’s easy to install software and get up and running.

For many teams, especially those without a dedicated IT department embedded on the factory floor, that simplicity matters. However, automation systems have historically been stand-alone. They are now becoming more networked, connected and integrated, the OS sitting underneath starts to create a bigger decision for companies.

Open source

This is where Linux enters the conversation. Unlike Windows, which is a proprietary operating system owned and controlled by Microsoft, Linux is open source. That means its source code is freely available and developers can inspect, modify and tailor it to suit specific needs.

This flexibility is what makes Linux so appealing in industrial settings. It’s a lean, modular platform that can be customised to include only the components you need – nothing more.

For developers and system architects, that’s a dream, but for teams used to plug-and-play software environments, Linux can feel a bit like stepping into the deep end.

Much of that comes down to how Linux is traditionally managed. Instead of a graphical interface by default, you’re often working with a command line. It’s powerful, but it requires a different skillset.

That steeper learning curve has historically kept Linux in the background of industrial automation, until recently.

One of the major challenges has been the phasing out of Windows Embedded Compact (Windows CE), Microsoft’s lightweight operating system designed specifically for embedded and industrial devices. For years, CE was the go-to for lightweight, embedded applications.

However, with its end-of-life status, companies have been pushed to research what operating systems they use for things like soft PLCs and industrial PCs.

Newer Windows options like Windows 10 IoT help to fill this space, but they tend to come with default features than many embedded applications don’t need. This includes features like printer services or desktop tools that may not be required for all applications.

This is where Linux differs. With the right setup, you can build an operating system that includes only what you need like the runtime, a user interface and just the tools required to get everything connected – no unnecessary extras. That slimmed-down approach means systems can boot up faster and use less processing power.

Security factor

Windows has a vast install base which makes it a constant target. However, it also has one of the largest technology companies fighting and patching security risks as they arise, and as a well-known entity, there is a lot of knowledge on how to make the system safe.

Whereas Linux is built from the ground up to be more selective. You can strip out anything unnecessary, lock down your system with highly configurable security rules and sandbox different processes using a technique called containerisation.

Containerisation involves packaging software so that each application runs inside its own isolated environment, or container. Think of containers like separate boxes inside a warehouse (your computer), each holding everything an app needs to function – its code, libraries and settings without interfering with others.

Such isolation can help improve security and stability because if one container crashes or is compromised, the rest keep running smoothly.

In Linux, tools like Docker allow you to isolate different functions – say, process control, data logging or the Human-Machine Interface (HMI) – into separate containers, all running on the same hardware.

This separation on a Windows system would be achieved using virtual machines, tailored to the software requirement.

Windows’ role

Windows is still the frontrunner as it offers a user-friendly environment and extensive support. For many businesses, especially those with existing investment in Windows-based systems, it’s the right choice.

As industrial environments scale, across factories, logistics hubs and multi-site networks, Linux can offer customisation, control and efficiency at scale.

One of the reasons Linux is now a viable choice in automation is thanks to developments in the real-time performance space.

Innovations like the PREEMPT_RT patch have changed the game. This patch is a special modification to the Linux kernel that adds real-time capabilities, allowing Linux to handle time-sensitive tasks with the precision required in industrial automation.

This isn’t as accurate as the Windows systems allow, but it is starting to bridge the gap. That includes Beckhoff, whose TwinCAT software traditionally ran on Windows and, more recently, on Berkeley Software Distribution (BSD).

This is the foundation of TwinCAT/BSD, a scalable, industrial-grade operating system that combines the flexibility of open-source FreeBSD with real-time machine control.

As an alternative choice to Windows, TwinCAT/BSD also allows Beckhoff Industrial PCs to run compact, secure, high-performance automation environments.

Building on that, Beckhoff has been able to bring TwinCAT to its own Linux platform too. That means users can now take advantage of containerised architectures, including running different TwinCAT functions in their own containers, lightweight Linux distributions and real-time responsiveness while running the same high-performance automation software they already trust.

At the end of the day, there’s no one-size-fits-all answer when it comes to operating systems in automation. The right choice depends on your team’s experience, your infrastructure, your security needs and how your systems will grow over time.

However, as the industry moves toward more open, connected and software-driven operations, the flexibility of platforms like Linux is becoming harder to ignore.

To discover how Beckhoff’s TwinCAT Runtime for Beckhoff’s Linux distribution can enhance your automation projects, connect with experts who can help tailor these technologies to your needs here.

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