Can Arduino Be Practically Used in Industrial Automation?

Yes, Arduino can be practically used in industrial automation, but the effectiveness depends on the context and how well you understand the industrial environment. Whether you can use a classic Arduino board in place of a Programmable Logic Controller (PLC) is a little more nuanced. Let's break it down:

Classic Arduino vs Industrial Environment

If you ask if you can simply take a classic Arduino Nano or Arduino Uno and use it in an industrial setting, the answer is a qualified yes. However, it is not ideal. These boards are not designed to withstand the industrial environment. They may reset frequently and might only last for a few weeks or months. The harsh conditions, such as high power consumption, electromagnetic interference (EMI), and physical stress, can lead to frequent resets and even failure.

Designing Industrial-grade Arduino Boards

If you design an Arduino-compatible board using the same microcontroller (MCU) as found on Arduino boards but with an industrial-grade design, the situation changes. Higher-quality power systems, isolation circuits for GPIO, proper shielding, and other robust components can significantly enhance the board's performance and longevity. In many industries, Arduino-based boards have successfully replaced PLCs and have performed reliably for years.

Examples of Successful Arduino Integration

For example, in a complex industrial setup with multiple hydraulic motors responsible for cutting, bending, and welding thick rebar, we replaced an outdated PLC with a custom-designed STM32-based board. The firmware was written in GCC but could have easily used the Arduino environment without issues. The team had more experience with Atollic Studio and STM32CubeStudio, but it is important to note that the same MCU is supported by Arduino boards. This custom board has performed remarkably well over the years, often surpassing the functions of the PLC it replaced.

Arduino in Clean Environments

Another example involves a clean room in a glass factory where laminates are manufactured. The environment is physically quiet and electrically clean, making it an ideal setting for an Arduino-based solution. A simple Arduino Nano with added sensors and optoisolated outputs to drive 24V relays was encased in a metal box and worked flawlessly for years, even outperforming the original PLC.

Limitations and Practical Considerations

While Arduino can be effectively used in industrial automation, it is crucial to be aware of the limitations. The board you choose must be engineered to withstand the industrial environment. If not, it might not last long under actual industrial use. However, if you understand the limitations and how to mitigate them, the integration of Arduino in industrial systems can be highly successful.

Conclusion

Ultimately, yes, it is possible to use Arduino in industrial automation, but it requires careful planning and the right design to ensure long-term reliability. While the initial investment and design process might be more expensive, the long-term benefits and flexibility often outweigh the costs. Check out projects like OpenPLC for ladder programming capabilities that can further enhance the functionalities of Arduino boards.

Utilizing Arduino in industrial automation is not only possible but can also lead to innovative and cost-effective solutions in many industrial settings.