Can an Arduino Be Used for Industrial Automation and Control Systems?

Can you use an Arduino board for industrial automation and control systems? The answer is complex and depends on several factors. In this article, we will explore the capabilities and limitations of Arduinos in industrial settings, providing insights into how they can successfully be used in industrial environments.

The Limitations of Arduino Boards

Firstly, the classic Arduino boards such as Arduino Nano or Arduino Uno are not designed for industrial environments. These boards are not built to withstand the harsh conditions of industrial applications, which can include extreme temperatures, high voltages, and electromagnetic interference (EMI). As a result, they may reset frequently and have a short lifespan, often not lasting more than a few weeks or months. This makes them unsuitable for critical industrial applications where reliability is paramount.

Using Arduino within Industrial Grade Systems

However, the situation changes drastically when you design an industrial-grade PCB that uses the same microcontroller (MCU) as found in Arduino boards but with enhanced features such as a robust power system, high-quality isolation circuits for GPIO, and proper shielding. These custom-designed systems often perform exceptionally well and can even outperform the PLCs they replace. This is because these boards are built with the specific requirements of industrial automation in mind, ensuring long-term reliability.

Moreover, it is possible to integrate advanced programming environments such as ladder logic, which is commonly used in PLCs, into Arduino systems. OpenPLC is an example of such a project that supports ladder programming on Arduino boards, making them a viable alternative for industrial automation.

Real-World Applications

Consider a case where a team needed to replace a broken PLC in an industrial setting. This setting involved 10 hydraulic motors feeding cutting, bending, and welding thick rebar wire. The operation required a significant amount of power consumption, and the EMI was so strong that it caused Android phones to reboot. The team designed an STM32-based board that was used to control the system. Although it was not a traditional Arduino board, it was built using the same STM32 MCU found in Arduino boards but with a more robust power system and a higher-quality design. The firmware was written in GCC, but it could have been an Arduino environment without any issues. The team had more experience using native Atollic Studio and STM32CubeStudio for similar projects, but the STM32 MCU is fully supported by Arduino as well.

Another example involves replacing a PLC in a clean room in a glass factory where a temperature and humidity controller was needed. The environment was highly controlled, both physically and electrically, making it a suitable place to use an Arduino-based system. A person designed a robust enclosure for an Arduino Nano, added sensors, and optoisolated outputs to drive 24V relays. This system worked reliably for years without any issues, often outperforming the original PLC.

Conclusion

While Arduino boards have limitations, they can be effectively used in industrial automation and control systems given proper design and implementation. The key is to understand the specific requirements of the application and build a system that can withstand the industrial environment. Whether it is through custom PCB design or by integrating advanced programming environments, Arduino boards can be a cost-effective and reliable solution for many industrial projects.

Key Takeaways

Classic Arduino boards are not suitable for industrial environments due to their lack of durability. Industrial-grade systems designed with the right components and features can perform reliably in industrial settings. Programming environments like ladder logic can be integrated into Arduino boards to support industrial automation. Custom design and robust construction are critical for successful Arduino-based industrial automation systems. While initial investment in custom designs may be higher, long-term reliability and performance can make them a cost-effective solution.

By following these guidelines and understanding the specific needs of your industrial automation project, you can leverage the power and flexibility of Arduino boards to create robust and reliable systems.