Back in 2010, when I first took over a project to upgrade an automotive parts production line, the client insisted on obtaining real-time operational data from each piece of equipment. At that time, I was baffled: “Brother, your PLC only has 4K of memory, and it can’t even fit extra timers, yet you want real-time analysis?” More than a decade later, edge computing systems based on PLCs have become the “new standard” in industrial sites, turning once impossible demands into everyday operations.
What is Edge Computing Based on PLC?
Edge computing essentially moves computing power to the location where data is generated. Imagine your smart speaker can recognize and respond to your voice commands locally without sending them to a distant server—that’s a daily version of edge computing.
In industrial settings, modern PLCs are no longer just simple replacements for relays; they have evolved into edge nodes that integrate communication, computation, and storage functions. They can:
- • Collect and preprocess massive amounts of industrial data on-site
- • Execute complex algorithms without relying on cloud systems
- • Make autonomous decisions based on real-time conditions
- • Communicate high-value information to upper-level systems after filtering
Starting with a Failure
Last summer, I received an urgent call—there was a mysterious small measurement error occurring every day around 3 PM on a packaging line at a food factory, but all equipment parameters checked out fine. The traditional approach would require us to monitor the site 24/7 to record data, which was not only painful but also unlikely to catch the “culprit.”
We deployed an edge computing module on the critical PLC and set up algorithms for capturing and analyzing abnormal data. Three days later, the system automatically identified that whenever the outdoor temperature exceeded 32°C, direct sunlight would cause a specific sensor to heat up, resulting in a small but cumulative error.Without the edge computing system, this “invisible enemy” could have consumed months of troubleshooting time.
Core Advantages of Edge Computing PLC Systems
1. Enhanced Real-Time Performance
In traditional architectures, data needs to be uploaded layer by layer to the MES or cloud platform, analyzed, and then commands issued, with delays typically in seconds or even minutes. Edge computing compresses this process to milliseconds.On high-speed production lines, this difference can determine whether a product is scrapped.
2. Data Reduction
A client once proudly told me that their injection molding machine could collect 200 parameter points per second. I asked, “Are you really using all this data?” The reality is that 90% of the raw data is of limited value.
Edge computing PLCs can performlocal data filtering and preprocessing, transmitting only valuable information to upper-level systems, saving bandwidth resources and reducing storage costs.
3. Enhanced Security
Network security issues in industrial settings are becoming increasingly severe. I remember helping a factory troubleshoot a network failure and discovered that their PLC was directly exposed to the public internet! Edge computing architectures allow PLCs to operate ina limited and controlled network communication environment, significantly reducing security risks.
Recommendations for Implementing Edge Computing PLC Systems
- 1. Start Small: Choose a critical but low-risk production line for a pilot project
- 2. Define Objectives: Is it for predictive maintenance or quality traceability? Different goals require different system architectures
- 3. Choose the Right Partners: Major manufacturers like Siemens and AB have launched PLC product lines that support edge computing
- 4. Focus on Talent Development: Edge computing PLCs require a combination of traditional PLC engineers and data analysis skills
Future Trends
Currently, edge computing PLC systems are evolving in two directions: one issmarter analytical algorithms, such as machine learning models that can be directly deployed to PLCs; the other iscloser OT-IT integration, allowing production data to be more seamlessly integrated into enterprise decision-making.
I have personally experienced the entire evolution from relays to early PLCs, and now to intelligent edge systems. It is hard not to marvel at the fact thatthe core of technological change has never been the technology itself, but how it changes the way humans solve problems. Edge computing allows PLCs to upgrade from mere “controllers” to “thinkers,” which may be the most exciting transformation in the field of industrial automation.
Remember, choosing the right technological path is more important than blindly pursuing the cutting edge. After all, in industrial settings, stability is always the top priority.