Thanks to the growing integration of open-source technologies, the industrial automation sector is experiencing a remarkable transformation. This shift is the result of increasing demand for more flexible, scalable, and cost-effective solutions that can adapt to the evolving needs of modern manufacturing and production processes. By moving away from proprietary, rigid systems, industries are discovering the many benefits of open-source platforms. In this blog, we’ll explore how open-source solutions are reshaping automation and why they are becoming a cornerstone of industrial progress.
New Tools, New Advantages in Industry
Unlike traditional solutions, open-source tools allow for greater flexibility, enabling engineers and manufacturers to build systems that cater to their unique requirements. Open-source technology is particularly advantageous in industries where off-the-shelf products often fail to meet the complexity and specificity of certain applications.
Perhaps the most notable advantage of open-source is the significant reduction in costs. By eliminating the need for expensive licensing fees and support contracts, companies can not only lower their upfront investment but also decrease long-term maintenance expenses. As a result, even smaller businesses with limited budgets can now access advanced automation technologies, leveling the playing field in industries that were once reliant on high-cost proprietary systems.
Open-source automation solutions offer seamless integration across diverse systems by supporting various industry-standard protocols, enhancing interoperability, ensuring smoother operations, and preventing costly silos. Contrary to common belief, open-source platforms often enhance security through transparency, enabling faster identification and resolution of vulnerabilities. Additionally, they eliminate vendor lock-in, providing businesses with the flexibility to choose service providers and adapt solutions without being tied to a single vendor.
Modern Hardware for Modern Automation
Alongside software, open-source hardware platforms are gaining traction in the industrial automation space. These devices offer flexibility and scalability, enabling companies to tailor their automation systems without being constrained by exclusive designs.
KUNBUS Revolution Pi
The Revolution Pi (RevPi) is an innovative industrial PC built on the Raspberry Pi Compute Module. This open-source hardware platform offers outstanding adaptability with support for a wide variety of industrial communication protocols, including MQTT, Modbus, OPC UA, and EtherNet/IP. The modular nature of the RevPi allows it to be easily customized and expanded to suit the specific needs of different production environments. For example, a manufacturer could use it as the central controller for managing multiple production lines or gathering data from various sensors.
Arduino Opta
The Arduino Opta is a compact programmable logic controller (PLC) designed for automation applications. With Arduino already renowned for its user-friendly development boards, this open-source solution comes as natural solution for various industrial automation needs. The Opta combines the simplicity of the Arduino ecosystem with the ruggedness required for industrial environments. It’s particularly useful for small-scale automation projects and is perfect for quickly prototyping solutions, such as automating a conveyor belt or controlling a packaging line in a small factory.
Open-Source Software in Automation Control
Software has long-played a key role in managing industrial automation systems, and open-source options are making it easier than ever to implement highly customizable control systems. Here are several key open-source software solutions for automation control in industrial settings:
- Zephyr RTOS: A lightweight, real-time operating system (RTOS) designed for embedded devices with limited resources. Zephyr’s small footprint and highly configurable nature make it ideal for industrial applications where millisecond-level accuracy is essential, such as in high-speed sorting systems or precision-controlled machinery.
- FreeRTOS: Widely used in microcontroller-based automation, FreeRTOS is an open-source RTOS known for its ease of use and extensive ecosystem. It is particularly suitable for distributed control systems, where multiple microcontrollers work together to manage complex processes across a factory or production facility.
- Real-Time Linux: For more demanding industrial tasks, real-time Linux provides the power of a full operating system combined with the deterministic performance required for real-time applications. By modifying the Linux kernel, this version of Linux ensures low-latency performance while maintaining the flexibility and robustness of the standard Linux environment. It is especially valuable in applications like vision-based quality control or robotics, where real-time data processing is critical.
Open-source software also extends to control systems themselves. Compared to traditional supervisory control and data acquisition (SCADA) systems, platforms like Rapid SCADA are providing a flexible, versatile alternative. Rapid SCADA’s open architecture is particularly valuable in industries where customization is key, such as water treatment plants, energy management systems, and environmental monitoring.
Another significant advancement in industrial automation software is the rise of ROS-Industrial, an open-source framework derived from the Robot Operating System (ROS). ROS-Industrial brings ROS into industrial settings by offering a powerful platform for controlling and programming robotic arms, automated conveyors, and other robotic systems on the factory floor.
Communication Protocols to Ensure Smooth Data Flow
In any automated system, seamless communication between devices is essential. Open-source communication protocols, such as OPC UA and MQTT, are helping make this possible by providing robust, standardized methods for devices to exchange data in real time. OPC UA is a popular protocol for industrial automation because of its security and compatibility with a wide range of devices. MQTT, a lightweight protocol, is especially useful in Internet of Things (IoT) applications, where devices are distributed over large areas or where network reliability may be a concern.
Conclusion
As the industrial sector continues to evolve, the role of open-source technologies is only set to grow. With the continued development of IoT, AI, and machine learning, open-source platforms will become even more capable, providing the flexibility and intelligence needed for next-generation industrial automation systems. The open-source movement is not just a trend—it’s reshaping the way industries think about control, optimization, and innovation.
Source: Mouser Blog
