Factories run PLCs from Siemens, Mitsubishi, Omron, Delta, and others — alongside Modbus, BACnet, and IEC104. Without unified data, higher-level intelligence is impossible.
BL110 protocol conversion gateway solves this. It collects mainstream PLC protocols and industrial protocols downstream, then forwards to OPC UA, MQTT, or Modbus TCP upstream. It connects directly to Alibaba Cloud IoT, Huawei Cloud IoT, and ThingsBoard — without replacing existing equipment. This moves smart manufacturing maturity from Level 2 (Standardized) to Level 3 (Integrated).
2.Edge-Side Control and AI ConvergenceIf all data goes to the cloud and instructions come back, latency and bandwidth cannot support a truly intelligent line. Level 4 (Optimized) maturity requires AI inference at the edge.
EdgePLC integrates CODESYS real-time control (five IEC 61131-3 languages), EtherCAT, up to 6 TOPS AI compute, and up to 1024 I/O points in a single DIN-rail device. It supports natural-language-driven AI for predictive maintenance and anomaly diagnosis.
EA Series handles heavier edge AI inference:
How they work together: EdgePLC handles the deterministic control loop at millisecond cycles and passes vibration, temperature, and current signals to the EA Series for AI inference. The EA Series runs visual inspection or equipment health models and feeds results back to EdgePLC via digital output or RS485. Control and intelligence close the loop at the edge — not on two separate systems.
3.Flexible, Scalable Field ArchitectureProduction lines must adapt quickly to product changeovers and capacity shifts. Hardware must be modular.
ARMxy Series uses a “main control platform + X board + Y board” architecture. Users swap Y boards (digital, analog, temperature, pulse, serial) to match field signals — no custom redesign. In a filling and capping machine upgrade, ARMxy (RK3562j) used an IgH EtherCAT master to synchronize conveyor servo, filling pump, and capping servo.
EdgeIO pushes flexibility to the I/O layer. BL192Pro integrates Modbus TCP, OPC UA, and MQTT in one device — replacing “PLC + I/O + protocol gateway + cloud gateway.” For legacy lines, it emulates original PLC address mapping so HMI remains compatible with zero changes, while adding OPC UA and MQTT cloud connectivity.
How Products Fill the Gaps
|
Smart Manufacturing Need |
Capability Gap |
Solution |
|
Equipment connectivity |
Multi-brand PLCs, multiple protocols |
BL110 converts to OPC UA/MQTT |
|
Real-time control + AI |
PLCs lack AI; industrial PCs lack real-time |
EdgePLC (CODESYS + 6 TOPS); EA Series up to 275 TOPS |
|
Integrated HMI + edge computing |
HMI, controller, compute are separate |
TPC touch panel integrates HMI, CODESYS, AI inference, IP66 |
|
Flexible field I/O |
Fixed interfaces; rewiring for changeovers |
ARMxy X/Y boards; EdgeIO pluggable I/O |
|
Low-cost legacy intelligence |
Cannot replace PLC or modify HMI |
EdgeIO emulates PLC addresses; adds OPC UA/MQTT |
Conclusion
Smart manufacturing does not replace old systems. It overlays data connectivity and edge intelligence on existing assets.
Together, they form the complete path from digitalization to intelligence.
