Open-Source Industrial Automation

The industrial automation landscape is undergoing a significant transformation, driven by the growing demand for interoperability, interchangeability, and portability. At the forefront of this revolution is the adoption of open-source technologies, ranging from Raspberry Pi-based industrial controllers to Linux edge devices. This shift reshapes how industries approach automation, offering unprecedented flexibility and innovation potential.

The Rise of Open-Source in Industrial Settings

Open-source solutions are gaining traction in industrial environments because they can be customized for specific needs. This adaptability is particularly valuable in complex manufacturing processes where off-the-shelf solutions may fall short. The community-driven nature of open-source projects accelerates innovation, allowing for faster development cycles and collective problem-solving.

One of the most compelling advantages of open-source automation is its cost-effectiveness. By reducing dependency on proprietary systems, companies can significantly lower their initial investment and ongoing maintenance costs.^[1] This accessibility democratizes access to advanced automation technologies, which is particularly beneficial for smaller enterprises or those with limited budgets.

Benefits of Open-Source Automation

Open-source automation tools provide numerous advantages that make them ideal for complex industrial environments. From enhanced interoperability to greater vendor independence, these benefits have transformed how companies approach automation.

Enhanced Interoperability

Open-source solutions excel in promoting seamless communication across diverse devices and protocols. This interoperability is crucial in modern industrial settings, where equipment from various manufacturers must work in harmony. By adhering to open standards, these solutions ensure that different components of an automation system can effectively “speak” to each other, regardless of their origin.

Improved Security Through Transparency

Contrary to the misconception that open-source software is less secure, the transparency inherent in open-source projects often leads to more robust security. The community’s ability to scrutinize code allows for quicker identification and resolution of vulnerabilities. This collaborative approach to security is precious in industrial settings where system integrity is paramount.

Vendor Independence

One of the most significant advantages of open-source automation is the freedom from vendor lock-in. Traditional proprietary systems often tie users to specific vendors for upgrades, maintenance, and support. Open-source alternatives provide the flexibility to choose from a wide range of service providers or even develop in-house expertise, ensuring long-term support and adaptability.

Open-Source Hardware Solutions

A range of open-source hardware platforms are helping to drive the revolution in industrial automation. These solutions offer scalability, flexibility, and support for widely used industrial protocols, making them invaluable to engineers and manufacturers.

KUNBUS Revolution Pi

Revolution Pi (RevPi) is a modular industrial PC based on the Raspberry Pi Compute Module. This innovative platform offers exceptional flexibility for expansion and supports a wide array of industrial protocols, including Open Platform Communications Unified Architecture (OPC UA), Message Queuing Telemetry Transport (MQTT), Modbus, and EtherNet/IP.^[2]

In practice, RevPi has found applications in diverse manufacturing environments. For instance, it can serve as a central controller in a smart factory, coordinating various production processes and collecting real-time data for analysis. Its modular nature allows for easy scaling and adaptation as production needs evolve.

Arduino Opta

Arduino, known for its user-friendly development boards, has entered the industrial automation space with the Arduino Opta. This programmable logic controller (PLC) maintains compatibility with the Arduino ecosystem while meeting the rigorous demands of industrial applications.

The Opta’s strength lies in its ease of programming and compatibility with industrial protocols.^[3] It’s particularly well-suited for small-scale automation projects and rapid prototyping. For example, a small manufacturing facility might use Opta to automate a packaging line, leveraging its intuitive programming interface to implement and iterate on control logic quickly.

Other Notable Options

While RevPi and Arduino Opta are at the forefront, other open-source hardware platforms like BeagleBoard and Olimex are also making inroads in industrial automation.^[4],[5] These platforms offer unique features and capabilities, further expanding the options available to automation engineers.

Open-Source Operating Systems for Industrial Applications

Open-source software plays a critical role in managing and controlling industrial processes. Highly customizable and scalable, these software platforms can handle diverse applications, from monitoring to automation control.

Zephyr RTOS

Zephyr is a lightweight, scalable, real-time operating system (RTOS) for embedded devices. Its low memory footprint and high configurability make it ideal for resource-constrained industrial applications.

Zephyr excels in tasks requiring precise timing and rapid response in automation contexts. For instance, it could be employed in a high-speed sorting system where millisecond-level accuracy is crucial for proper operation.

FreeRTOS

FreeRTOS has become a popular choice for microcontroller-based automation tasks. Its extensive ecosystem and ease of use have made it a favorite solution for many industrial applications.

A practical application of FreeRTOS might be in a distributed control system, where multiple microcontrollers work together to manage different aspects of a complex manufacturing process. FreeRTOS’s robust task scheduling capabilities ensure that critical operations are executed promptly and predictably.

Real-Time Linux

Real-time Linux offers a compelling solution for more complex automation systems requiring the power of a full operating system. Modifying the standard Linux kernel to support real-time operations provides the benefits of Linux's extensive software ecosystem with the deterministic performance required in industrial settings.

Real-time Linux finds applications in scenarios demanding both high-performance computing and low-latency control. For example, it could power a vision-based quality control system in a high-speed production line, processing real-time image data to identify defects.

Open-Source Software Solutions

As automation advances, open-source control software provides cost-effective alternatives to traditional hardware-based solutions. These projects empower industries to develop flexible, hardware-independent control systems.

Rapid SCADA

Rapid SCADA is an open-source industrial control and monitoring system that offers extensive customization options. Its modular design allows it to be adapted to various industrial applications.

In practice, Rapid SCADA might be employed to create a comprehensive monitoring and control interface for an application like a water treatment plant. Its data logging capabilities could track water quality parameters over time, while its control functions manage treatment processes based on real-time data.

ROS-Industrial

ROS-Industrial extends the capabilities of the Robot Operating System (ROS) to industrial applications. This open-source framework provides robust tools for programming and controlling industrial robots.

An example application of ROS-Industrial is an automotive manufacturing plant using the OS to program and coordinate a series of robotic arms performing complex assembly tasks. The framework's flexibility allows for rapid reconfiguration of robotic tasks as production needs change.

Open-Source PLC Projects

Several open-source projects aim to provide software-based alternatives to traditional hardware PLCs. Notable examples include:

• Autonomy OpenPLC, which offers a flexible, open-source PLC platform with strong community support.
• KPA Automation SoftPLC, a software-based PLC solution that provides hardware-independent automation capabilities.

These open-source PLCs can be particularly valuable in educational settings or for small-scale automation projects where the cost of traditional hardware PLCs might be prohibitive.

Open-Source Communication Protocols

Seamless communication between devices is key in modern industrial environments. Open-source communication protocols allow for interoperability and real-time data exchange, ensuring smooth operations across diverse equipment.

OPC UA

OPC UA has emerged as a standard protocol for secure and reliable data exchange in industrial automation. Its vendor-agnostic nature and broad compatibility make it an ideal choice for creating interoperable systems.

In a smart factory setting, OPC UA might serve as the backbone for data communication, enabling seamless information flow between diverse equipment, from CNC machines to environmental sensors.

MQTT

MQTT’s lightweight design makes it particularly well-suited for Internet of Things (IoT) applications in industrial environments. Its efficiency in handling high-latency or unreliable networks makes it ideal for connecting remote sensors or equipment.

An example application might be in a large-scale agricultural operation, where MQTT could collect and transmit data from widely dispersed soil sensors, enabling precise irrigation control.

Other Protocols

Protocols like Modbus, EtherNet/IP, and EtherCAT, while not inherently open-source, have open-source implementations that play crucial roles in industrial automation.^[6],[7] These protocols enable communication between diverse industrial devices, forming the foundation of many automation systems.

The Future of Open-Source Automation

As we look to the future, the role of open-source in industrial automation is set to expand further. Advancements in IoT and artificial intelligence (AI) technologies will likely drive innovations in open-source automation solutions, offering even greater flexibility and intelligence in industrial processes.

The adoption of open-source technologies in industrial automation represents more than just a technological shift—it's a fundamental change in how industries approach control and optimization. By embracing openness and collaboration, the industrial sector is positioning itself for a future of unprecedented innovation and efficiency.

Sources

[1]https://www.rinf.tech/open-source-vs-proprietary-solutions-in-embedded-development/
[2]https://ecosystem.cumulocity.com/product/revolution-pi-core-3/
[3]https://docs.arduino.cc/hardware/opta
[4]https://www.beagleboard.org/boards/beaglebone-black
[5]https://www.olimex.com/Products/Duino/AVR/OLIMEXINO-328/open-source-hardware
[6]https://www.modbus.org/tech.php
[7]https://www.ethercat.org/default.htm