On the Chinese CNC drilling machine that I am controlling with a BRX instead of a CNC controller I suddenly realized I could save a lot of cabling by using 3 BRX PLCs instead of one with expansion modules. So I am going to have one BRX in the motor controller cabinet controlling the 3 servo drives and 8 VFDs. Then an ethernet cable through the energy chain to the X axis with a BRX controlling 12 solenoid valves and about 12 proximity sensors. Finally a BRX in the base to control another 12 solenoid valves, door interlocks, product detection proximity and photoeyes.
The cost per I/O point is low and having all the same PLCs reduces spares inventory. If my scheme for automating this machine works the labor savings and reduction in mistakes will be truly huge for this company that has been doing it the same way for 40 years.