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Integration of Conventional PLC with HMI and Industrial IoT

Understanding PLC

Programmable Logic Controller (PLC), is well tested hardware-based control system that has been in industrial automation for decades. It is a reliable compute unit that controls processes & parameters in various industries and manufacturing plants.

PLC Challenges

  1. Data analytics: PLCs concentrate a massive amount of operational data, which unfortunately ends up unprocessed for data analytics within machine. Even most modern PLCs are not designed for remote communications, device management and control parameters updates.

  2. PLC without HMI: It is difficult to monitor and operate PLC without HMI on machines. No method to select multiple programs and modify them as per control parameters of the process on macchine itlsef.

  3. Programming Issues: Incorrect encodings, code errors, and communication faults are some problems PLCs experience. It can lead to improper control of machinery, resulting in reduced productivity.

  4. No isolations and protections: Conventional PLCs doesn't have propoer power supply and IO isolations creatss circuit hardware failure when there's power surge & module interference from within compoenents or external parts. It also lacks ESD protections to external connectors which may cause hardware failure due to static charge.

  5. Memory corruption: Electrical interference and power disruptions can corrupt the memory of a PLC. When this happens, the data within the PLC may become unreachable, or the PLC may not be able to boot up from an unintentional shut down.

Industrial IoT

Internet of Things (IoT) can capture, save, processes information from sensors & control systems and send it via MQTT, HTTPS, XMPP, COAP, REST, etc protcol and so forth that is controlled by on-request adaptability.

  • IIoT prioritizes robust security measures due to its involvement in critical infrastructure and sensitive industrial data.

  • The essential objective of Industrial IoT (IIoT) is to normalize sensor networks, data gathering, and conglomeration.

  •  It aims to maximize efficiency, reduce costs, and improve overall performance in industries.

  • It brings more intelligence to OT and unlock insights,

  • It helps in predictive maintenance and problem resolution.

  • Communication protocols: 4G LTE, 3G, 2G GSM, LPWA), BLE, LAN, Ethernet, Wi-Fi, LORA, RF.

HMI - Display and UI

Industrial automation is demanding greater connectivity, efficiency, added-value integrated function, and cost-effectiveness.

Here are some benefits of exploring a Human Machine Interface (HMI) for process monitor and control.

  • HMI is widely known for its ability to present live data, and store for record.

  • You can configure control parameters for the processes via HMI.

  • It has easy-to-use displays, workers don’t need to spend much time on training to operate.

  • All the above benefits can result in increased productivity and efficiency of human resources because utilising an HMI can automate tasks.


PLC Functions

Added Features with HMI and Industrial IoT


Process binary input signals in Control Sequential

Visual representations of the condition of a machine


Performs programming and time critical tasks

Open architectures that allow for various off-the-shelf UI tools and interface software


Monitors a sensors and machine parameters and take necessary action with a controlled process

Include built-in integration tools to allow for quick connections to networks


Controls inputs and outputs, motors and drives, and communications

Wireless 4G LTE fall back 2G, BLE communication


It has five common PLC programming languages

Tracking via GPS and triangulation


Role based access and authentication


Device management, live health monitoring


OS and Firmware version management


OTA for screen and firmware update & parameters config


Issue, ticket management for change request (CR)

Conclusion: For industrial automation, as technology continues to advance, staying informed about the strengths and considerations of PLC and IIoT is crucial for making strategic decisions that will drive your industrial automation system toward success in the modern era. It is clear that IoT is the upcoming technology over PLC. Obviously, our future technological advancement is going to be IIoT or Industry 5.0. A next-generation HMI IIoT such as Inditronics HMI_IoT-124 is capable of bridging the gap between IT and OT. Please visit inditronics for more information.

How does Inditronics support in this technology evolution?

Inditronics is one of the globally leading custom IoT product development company in India, providing embedded engineering servicesfor automation & process control that drives customer's growth.

We have integrated the IoT with ECU and PLCs globally. As we are involved in real-time projects, we make use of our own hardware boards, sensors & customized software. Our recent project, “Smart TRP Meter” has been designed, developed and manufactured in-house for 25,000 IoT devices and 50,000 display units. Industrial IoT will help for better industrialization and company growth.


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