30+ Applications of OpenPLC+ARMxy Progammable Logic Controller

The ARMxy is a compact industrial ARM Based PC，provides A7~8*A76 Cores，with flexible I/O，OpenPLC is an open source PLC，BLRAT is a remote access tool, BLIoTLink is an edge IoT Gateway software, using ARMxy+OpenPLC+BLIoTLink+BLRAT，can create innovative Smart factory.

Below is 30+ applications for reference.

1. Automotive Welding Production Line Control Station

Scenario

Welding workstation for a vehicle manufacturer's body-in-white assembly, requiring coordination of six welding robots for synchronous operation.

Configuration

• ARMxy main controller
• X-DI board (detects workpiece fixture clamping signals)
• X-DO board (controls welding gun start/stop and cooling water valve)
• Y-AO board (adjusts welding current from 0-500A)

Implementation

• The DI board receives the fixture-ready signal and triggers the welding sequence via the OpenPLC program.
• The AO board outputs a 4-20mA signal to the welding power supply to automatically adjust the current based on steel plate thickness.
• The DO board activates the cooling system after welding is completed.

Advantages

• Remote modification of welding parameters (e.g., current/time) via BLRAT to accommodate new vehicle models. Remote uploading of PLC programs facilitates parameter adjustments.
• X/Y board cards feature hot-swappable design, enabling quick IO configuration changes when switching welding gun types. 

2. Photovoltaic Power Station Smart Combiner Box

Scenario

String monitoring for a 100MW photovoltaic power station.

Configuration

• ARMxy main controller
• X-RS485 board (connects multiple string monitoring units)
• Y-AI board (monitors combiner box temperature/humidity)

Implementation

• RS485 polls and collects string voltage/current (Modbus RTU protocol).
• The AI board monitors environmental parameters in real-time, activating cooling fans when thresholds are exceeded. The OpenPLC program implements logic for automatic alarms and cooling.
• Data is uploaded to the cloud platform via a 4G module.

Advantages

• Maintenance personnel can view string attenuation curves via a mobile app to pinpoint faults accurately.
• The Y-series AI board supports direct temperature sensor connections, eliminating the need for transmitters.

3. Smart Greenhouse Cluster Control

Scenario

Environmental regulation for a 50-acre interconnected tomato greenhouse.

Configuration

• ARMxy main controller
• Y-AI board (collects CO₂/light/temperature/humidity data)
• X-DO board (controls roof vents/fans/grow lights/drip irrigation)

Implementation

• The AI board collects environmental data every 5 minutes, and OpenPLC executes PID control algorithms.
• The DO board coordinates equipment based on strategies (e.g., opening roof vents when CO₂ exceeds 1000ppm).
• Remote network integration (MQTT or cloud platform APIs) with weather station data enables predictive adjustments.

Advantages

• Farmers can manually intervene remotely via mobile devices (e.g., forcing vents closed before heavy rain).
• The Y-series AI board supports mixed 0-20mA/-10-10V inputs, compatible with various sensors.

4. Lithium Battery Formation and Capacity Testing System

Scenario

Charge/discharge testing for power batteries.

Configuration

• ARMxy main controller
• Y-AI board (monitors individual cell voltages)
• X-DO board (controls charge/discharge circuits)

Implementation

• The AI board scans cell voltages (-10-10V range).
• OpenPLC compares voltage differences and automatically balances charging.
• The DO board cuts off the corresponding circuit in case of abnormal voltage.

Advantages

• Test data is automatically generated into Excel reports for remote download and analysis.
• The Y-series high-density AI board saves 90% of wiring space.

5. Vertical Parking Lift Control

Scenario

12-layer vertical lifting parking garage.

Configuration

• ARMxy main controller
• Y-high-speed pulse board (controls lifting motor)
• X-DI board (detects leveling/anti-drop signals)

Implementation

• The pulse board outputs AB-phase pulses to drive the servo (100kHz frequency).
• The DI board verifies position signals in real-time for closed-loop control.
• Data interaction with the billing system via RS485.

Advantages

• Equipment vendors can remotely debug pulse parameters to adapt to different lifting heights, enabled by OpenPLC and BLRAT for remote control.
• The X-series DI board supports mixed voltage inputs.

6. Wastewater Treatment Plant Dosing Control System

Scenario

Municipal wastewater treatment PAC dosing.

Configuration

• ARMxy main controller
• Y-AI board (monitors turbidity/pH)
• Y-AO board (controls dosing pump frequency)

Implementation

• The AI board collects signals from online water quality meters (0-20mA).
• OpenPLC adjusts AO output (-10-10V corresponding to 0-50Hz) based on turbidity changes.
• Automatic generation of daily dosing reports.

Advantages

• Data can be stored and remotely audited by environmental authorities.
• The Y-series AO board supports voltage/current output switching.

7. Stage Machinery Lifting Point Synchronization Control

Scenario

Multi-point synchronization for theater lifting stages.

Configuration

• ARMxy main controller
• Y-axis pulse board (controls servo hoists)
• X-DI board (detects limit positions)

Implementation

• The pulse board synchronously outputs four pulse channels (max 100kHz).
• The DI board monitors mechanical limits for each lifting point in real-time.

Advantages

• Pre-programming of motion trajectories remotely before performances.
• OpenPLC supports linear/circular interpolation algorithms (requires custom implementation).

8. Smart Parcel Locker Master Control

Scenario

Community parcel delivery terminal.

Configuration

• ARMxy main controller
• X-DI board (detects locker door status)
• X-RS232 board (connects to touchscreen)

Implementation

• The DI board scans all compartment states (normally open/closed contacts).
• Interaction with the display via RS232 (custom protocol), with logic implemented by OpenPLC.
• Real-time data synchronization with the cloud via a 4G module.

Advantages

• Maintenance personnel can remotely reset faulty compartments.
• The X-series DI board supports dry/wet contacts.

9. Subway Platform Screen Door Safety Control System

Scenario

Interlocking control for urban rail transit platform screen doors.

Configuration

• ARMxy main controller
• X-DI board (detects door position/obstacles)
• X-DO board (controls drive motors/alarms)

Implementation

• The DI board monitors "fully open," "fully closed," and "obstacle" signals for each door (dry contact input).
• The OpenPLC program implements hardwired interlocking with train signals (SIL2 safety level).
• The DO board outputs control for:

Advantages

• The operations center can remotely force open specific doors (emergency mode).
• The X/Y-series DO board supports hybrid relay/transistor outputs for different loads.

10. Pharmaceutical Cold Chain Transport Monitoring Terminal

Scenario

Real-time temperature/humidity monitoring for vaccine transport vehicles.

Configuration

• ARMxy main controller
• Y-AI board (collects data from four temperature/humidity sensors)
• 4G communication board (uploads data to the cloud)

Implementation

• The AI board collects sensor data every 30 seconds (4-20mA output probes).
• OpenPLC triggers local alarms (via digital output to a buzzer) when temperature thresholds are exceeded.
• Generates GSP-compliant records (including GPS coordinates), uploaded via MQTT to regulatory platforms.

Advantages

• Regulators can view transport routes and temperature/humidity curves in real-time via a mobile app.
• The Y-series AI board supports sensor disconnection detection.

11. Rocket Fuel Loading Control System

Scenario

Cryogenic propellant loading at a space launch site.

Configuration

• ARMxy main controller (explosion-proof)
• Y-AI board (monitors level/pressure/temperature)
• X-CAN board (communicates with safety interlock systems)

Implementation

• The AI board collects:
• CAN bus receives loading commands from the launch control center (CANopen protocol).
• Automatically triggers emergency shutoff valves (hardwired safety circuit) in critical situations.

Advantages

• The space command center can remotely abort the loading process.
• Complies with GB3836.1-2010 explosion-proof standards.

12. Coal Mine Drainage Automation System

Scenario

Intelligent control for underground main drainage pump rooms.

Configuration

• ARMxy main controller (intrinsically safe)
• X-DI board (detects water level switch status)
• Y-AO board (controls pump frequency converters)

Implementation

• The DI board monitors:
• The AO board outputs 0-10V signals to adjust pump speed (corresponding to 0-50Hz). OpenPLC monitors voltage values to control pump speed.
• Optimizes start/stop times based on electricity price periods.

Advantages

• The ground dispatch room can remotely switch between manual/auto modes.
• Industrial-grade X and Y boards ensure stable and reliable performance.

13. SPF-Level Laboratory Animal Room Monitoring System

Scenario

Environmental assurance for biomedical laboratories.

Configuration

• ARMxy main controller
• Y-AI board (monitors NH₃/CO₂/temperature/humidity)
• X-DO board (controls fresh air units/UV lamps)

Implementation

• The AI board collects:
• OpenPLC:
• Generates daily reports compliant with standards.

Advantages

• Lab managers can remotely view real-time environmental parameters.
• The Y-series AI board supports automatic sensor calibration.

14. Smart Waste Sorting and Recycling Station

Scenario

Community intelligent waste sorting.

Configuration

• ARMxy main controller
• X-DI board (detects door status)
• X-RS485 board (connects to weighing instruments)

Implementation

• The DI board monitors:
• RS485 reads weight data (Modbus RTU protocol).
• OpenPLC implements control logic.
• Data is uploaded to municipal management platforms via a 4G module.

Advantages

• Sanitation departments can remotely adjust sorting rules (e.g., adding plastic subcategories).
• The X/Y-series DI boards support various input types like photoelectric/magnetic sensors.

15. Ship Ballast Water Treatment System

Scenario

Ballast tank balancing control for ocean freighters.

Configuration

• ARMxy main controller (marine-grade)
• Y-AI board (monitors draft depth)
• X-DO board (controls ballast pumps/valves)

Implementation

• The AI board collects:
• Automatically calculates balancing solutions based on load.
• OpenPLC implements control logic.
• Operational reports are sent via satellite communication.

Advantages

• Shipping companies can remotely monitor global fleet status.
• Complies with IMO BWMS certification requirements.

16. Semiconductor Cleanroom FFU Control System

Scenario

Class 10 cleanroom for wafer fabrication.

Configuration

• ARMxy main controller
• Y-AI board (monitors particle counters)
• X-DO board (controls FFU fan arrays)

Implementation

• The AI board collects:
• Dynamically adjusts FFU speed to maintain unidirectional airflow.
• OpenPLC implements logic.

Advantages

• Engineers can remotely adjust cleanliness levels (e.g., Class 10 to Class 100).
• The Y-series AI board supports ±0.1% high-precision measurements.

17. Beer Fermentation Process Control System

Scenario

Precise temperature control for large fermentation tanks.

Configuration

• ARMxy main controller
• Y-AI board (monitors temperature/sugar content)
• Y-AO board (controls coolant valves)

Implementation

• The AI board collects:
• Executes staged cooling curves (from 12°C to -1°C).
• Automatically generates fermentation process graphs.
• Detects fermentation parameters like time, with new OpenPLC programs remotely updated via BLRAT.

Advantages

• Brewers can adjust process parameters remotely via a mobile app.
• The Y-series AO board supports valve position feedback.

18. Airport Baggage Sorting Robot Control

Scenario

Automatic baggage sorting at terminal buildings.

Configuration

• ARMxy main controller
• Y-high-speed counter board (reads barcode information)
• X-DO board (controls diverting arms)

Implementation

• The high-speed counter board interfaces with laser scanners (5000 items/hour).
• OpenPLC implements control operations.
• The DO board drives pneumatic sorting devices (24V DC solenoid valves).

Advantages

• Ground staff can remotely modify sorting destinations.
• Supports rapid deployment and secondary development.

19. Smart Substation Relay Protection System

Scenario

Equipment monitoring for 110kV substations.

Configuration

• ARMxy main controller
• X-DI board (collects circuit breaker/disconnector status)
• X-RS485 board (connects to protective relays)

Implementation

• The DI board monitors:
• Data is uploaded to the dispatch master station via protocol.
• Fault recording data is stored locally.

Advantages

• Power dispatch centers can remotely view real-time status.
• The X-series DI board supports -10-10V wide voltage input.

20. Medical Waste Incineration Control System

Scenario

Special waste treatment center for hospitals.

Configuration

• ARMxy main controller
• X-DI board (detects incinerator door status)
• Y-AO board (controls secondary combustion temperature)

Implementation

• The DI board implements:
• The AO board adjusts gas flow valves (4-20mA output).
• OpenPLC enables rapid deployment and programming control.
• Automatically generates operational logs required by environmental authorities.

Advantages

• Health departments can remotely review incineration temperature curves.
• Complies with "Medical Waste Treatment Regulations" technical requirements.

21. Steel Plant Continuous Caster Mold Level Control

Scenario

Precise mold level maintenance during steel casting.

Configuration

• ARMxy main controller
• Y-AI board (collects radioactive level gauge signals)
• X-DO board (controls stopper rod servo mechanism)

Implementation

• The AI board collects level gauge signals (4-20mA, range 0-300mm) in real-time.
• OpenPLC executes PID algorithms, outputting PWM signals to servo drives.
• The DO board activates emergency gates (hardwired safety circuit).

Advantages

• Engineers can remotely adjust PID parameters for different steel grades.
• The Y-series AI board supports signal isolation, resisting electromagnetic interference.

22. Chemical Plant Reactor Pressure Protection System

Scenario

Safety interlocking for high-pressure polymerization reactors.

Configuration

• ARMxy explosion-proof controller
• X-DI board (detects pressure switches/emergency stops)
• X-DO board (controls pressure relief solenoid valves)

Implementation

• The DI board monitors:
• Triggers three-stage pressure relief via the DO board when thresholds are reached.
• Event logs are uploaded to DCS via RS485.

Advantages

• Safety departments can remotely review interlock action records.
• Complies with IEC 61511 SIL3 safety requirements.
• BLRAT with OpenPLC enables remote control to prevent on-site hazards.

23. Paper Machine Drying Section Steam Regulation System

Scenario

Temperature control for paper drying sections.

Configuration

• ARMxy main controller
• Y-AI board (collects dryer surface temperatures)
• Y-AO board (adjusts steam valves)

Implementation

• The AI board connects to infrared thermometers (0-10V output, range 0-200°C).
• Automatically calculates dryer temperature setpoints based on paper speed.
• The AO board outputs 4-20mA to control pneumatic valve openings.

Advantages

• Process engineers can remotely modify temperature curves via ALRAT+OpenPLC for different paper weights.
• The Y-series AO board supports closed-loop control with valve position feedback.

24. Tire Factory Vulcanizer Control System

Scenario

Automation of tire vulcanization processes.

Configuration

• ARMxy main controller
• X-DI board (detects mold locking signals)
• Y-AI board (collects temperature/pressure data)

Implementation

• The DI board verifies:
• The AI board monitors:
• Automatically generates vulcanization process curves.

Advantages

• Equipment vendors can remotely diagnose temperature control anomalies.
• The X-series DI board supports LED status indicators for input signals.
• BLRAT enables remote monitoring and updating of OpenPLC programs for optimization.

25. Cement Plant Raw Mill Load Control

Scenario

Load optimization for raw material vertical mills.

Configuration

• ARMxy main controller
• Y-AI board (collects motor current/vibration data)
• X-DO board (controls feed belt frequency converters)

Implementation

• The AI board monitors:
• Automatically adjusts feed rates based on load characteristics.
• Data interacts with DCS via Modbus TCP.

Advantages

• Process engineers can remotely set load thresholds and quickly upload PLC programs.
• The Y-series AI board supports direct current transformer connections.

26. Glass Factory Tin Bath Temperature Balance Control

Scenario

Lateral temperature control for float glass production tin baths.

Configuration

• ARMxy main controller
• Y-AI board (collects 40 thermocouple points)
• Y-AO board (controls heater power)

Implementation

• The AI board collects temperatures via thermocouple amplifiers (K-type, 0-800°C).
• Uses fuzzy control algorithms to balance lateral temperature differences (±1°C).
• The AO board outputs 0-10V to adjust solid-state relay conduction angles.

Advantages

• Technical experts can remotely analyze temperature field distributions.
• The Y-series AI board supports thermocouple disconnection detection.
• OpenPLC enables rapid implementation of control logic.

27. Chemical Fiber Plant Spinning Box Temperature Control

Scenario

Multi-zone temperature control for polyester filament spinning boxes.

Configuration

• ARMxy main controller
• Y-AI board (collects multi-point temperatures)
• X-DO board (controls heater contactors)

Implementation

• The AI board connects to PT100 3-wire temperature sensors.
• Implements zone-based PID control (12 independent loops).
• The DO board switches heater groups (220V AC output).

Advantages

• Supports remote downloading of process recipes for different products.
• OpenPLC with Y-series AI boards implements 3-wire RTD auto-compensation algorithms.

28. Food Plant Sterilization Retort Automatic Control

Scenario

High-temperature sterilization for canned products.

Configuration

• ARMxy main controller
• Y-AI board (collects temperature/pressure data)
• X-DO board (controls steam/drain valves)

Implementation

• The AI board monitors:
• Automatically adjusts sterilization time based on preset F-values.
• Generates FDA-compliant sterilization reports.

Advantages

• Quality control departments can remotely review historical sterilization curves.
• Electronic records are certified for compliance.

29. Automotive Paint Shop Oven Control

Scenario

Temperature curve control for electrophoretic paint drying.

Configuration

• ARMxy main controller
• Y-AI board (collects zone temperatures)
• X-DO board (controls burner start/stop)

Implementation

• The AI board connects to K-type thermocouples (0-300°C).
• Automatically selects drying curves (10-30 minutes) based on vehicle models.
• The DO board controls natural gas solenoid valve groups.

Advantages

• Process engineers can remotely update drying parameters for new colors.
• Oven temperature uniformity reaches ±2°C.
• BLRAT+OpenPLC enables remote operation and control.