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var(--bs-navbar-toggler-padding-x);font-size:var(--bs-navbar-toggler-font-size);line-height:1;color:var(--bs-navbar-color);background-color:transparent;border:var(--bs-border-width) solid var(--bs-navbar-toggler-border-color);border-radius:var(--bs-navbar-toggler-border-radius)}@media (min-width:576px){.navbar-expand-sm{flex-wrap:nowrap;justify-content:flex-start}.navbar-expand-sm .navbar-nav{flex-direction:row}.navbar-expand-sm .navbar-nav .nav-link{padding-right:var(--bs-navbar-nav-link-padding-x);padding-left:var(--bs-navbar-nav-link-padding-x)}.navbar-expand-sm .navbar-collapse{display:flex!important;flex-basis:auto}.navbar-expand-sm .navbar-toggler{display:none}}body:before{display:none}.navbar-dark{--bs-navbar-color:rgba(255, 255, 255, 0.85);--bs-navbar-hover-color:rgba(255, 255, 255, 0.5);--bs-navbar-disabled-color:rgba(255, 255, 255, 0.25);--bs-navbar-active-color:#ffffff;--bs-navbar-brand-color:#ffffff;--bs-navbar-brand-hover-color:#ffffff;--bs-navbar-toggler-border-color:transparent;--bs-navbar-toggler-icon-bg:none}.card{--bs-card-spacer-y:1rem;--bs-card-spacer-x:1rem;--bs-card-title-spacer-y:0.5rem;--bs-card-border-width:1px;--bs-card-border-color:var(--bs-border-color-translucent);--bs-card-border-radius:0.375rem;--bs-card-inner-border-radius:calc(0.375rem - 1px);--bs-card-cap-padding-y:0.5rem;--bs-card-cap-padding-x:1rem;--bs-card-cap-bg:rgba(0, 0, 0, 0.03);--bs-card-bg:#f8f9fa;--bs-card-img-overlay-padding:1rem;--bs-card-group-margin:0.75rem;position:relative;display:flex;flex-direction:column;min-width:0;height:var(--bs-card-height);word-wrap:break-word;background-color:var(--bs-card-bg);background-clip:border-box;border:var(--bs-card-border-width) solid var(--bs-card-border-color);border-radius:var(--bs-card-border-radius);box-shadow:var(--bs-card-box-shadow)}.card-body{flex:1 1 auto;padding:var(--bs-card-spacer-y) var(--bs-card-spacer-x);color:var(--bs-card-color)}.breadcrumb{display:flex;list-style:none;--bs-breadcrumb-padding-x:0;--bs-breadcrumb-padding-y:0.5rem;--bs-breadcrumb-margin-bottom:0;--bs-breadcrumb-font-size:0.75rem;--bs-breadcrumb-bg:transparent;--bs-breadcrumb-divider-color:#6c757d;--bs-breadcrumb-item-padding-x:0.5rem;--bs-breadcrumb-item-active-color:#6c757d;flex-wrap:wrap;padding:var(--bs-breadcrumb-padding-y) var(--bs-breadcrumb-padding-x);margin-bottom:var(--bs-breadcrumb-margin-bottom);font-size:var(--bs-breadcrumb-font-size);background-color:var(--bs-breadcrumb-bg);border-radius:var(--bs-breadcrumb-border-radius)}.breadcrumb-item+.breadcrumb-item{padding-left:var(--bs-breadcrumb-item-padding-x)}.breadcrumb-item+.breadcrumb-item::before{float:left;padding-right:var(--bs-breadcrumb-item-padding-x);color:var(--bs-breadcrumb-divider-color);content:var(--bs-breadcrumb-divider, "|")}.breadcrumb-item.active{color:var(--bs-breadcrumb-item-active-color)}.alert{--bs-alert-bg:transparent;--bs-alert-padding-x:1rem;--bs-alert-padding-y:1rem;--bs-alert-margin-bottom:1rem;--bs-alert-color:inherit;--bs-alert-border-color:transparent;--bs-alert-border:1px solid var(--bs-alert-border-color);--bs-alert-border-radius:0.375rem;position:relative;padding:var(--bs-alert-padding-y) var(--bs-alert-padding-x);margin-bottom:var(--bs-alert-margin-bottom);color:var(--bs-alert-color);background-color:var(--bs-alert-bg);border:var(--bs-alert-border);border-radius:var(--bs-alert-border-radius)}.alert-heading{color:inherit}.alert-link{font-weight:700}.alert-dismissible{padding-right:3rem}.alert-dismissible .btn-close{position:absolute;top:0;right:0;z-index:2;padding:1.25rem 1rem}.alert-primary,.alert-secondary{background-image:var(--bs-gradient)}.alert-primary{--bs-alert-color:rgb(30, 44.4, 91.2);--bs-alert-bg:rgb(214, 218.8, 234.4);--bs-alert-border-color:rgb(193.5, 200.7, 224.1)}.alert-primary .alert-link{color:#182449}.alert-secondary{--bs-alert-color:rgb(64.8, 70.2, 75);--bs-alert-bg:rgb(225.6, 227.4, 229);--bs-alert-border-color:rgb(210.9, 213.6, 216)}.alert-secondary .alert-link{color:#34383c}.alert-native,.alert-success,.alert-validation{--bs-alert-color:rgb(15, 81, 50.4);--bs-alert-bg:rgb(209, 231, 220.8);--bs-alert-border-color:rgb(186, 219, 203.7);background-image:var(--bs-gradient)}.alert-native .alert-link,.alert-success .alert-link,.alert-validation .alert-link{color:#0c4128}.alert-info,.alert-warning{background-image:var(--bs-gradient)}.alert-info{--bs-alert-color:rgb(5.2, 80.8, 96);--bs-alert-bg:rgb(206.6, 244.4, 252);--bs-alert-border-color:rgb(182.4, 239.1, 250.5)}.alert-info .alert-link{color:#04414d}.alert-warning{--bs-alert-color:rgb(102, 77.2, 2.8);--bs-alert-bg:rgb(255, 242.6, 205.4);--bs-alert-border-color:rgb(255, 236.4, 180.6)}.alert-warning 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.alert-link,.alert-notice .alert-link{color:#04414d}.alert-color-blue,.alert-criticalcss{--bs-alert-color:rgb(7.8, 66, 151.8);--bs-alert-bg:rgb(206.6, 226, 254.6);--bs-alert-border-color:rgb(182.4, 211.5, 254.4);background-image:var(--bs-gradient)}.alert-color-blue .alert-link,.alert-criticalcss .alert-link{color:#063579}.alert-cache,.alert-color-orange{--bs-alert-color:rgb(151.8, 75.6, 12);--bs-alert-bg:rgb(254.6, 229.2, 208);--bs-alert-border-color:rgb(254.4, 216.3, 184.5);background-image:var(--bs-gradient)}.alert-cache .alert-link,.alert-color-orange .alert-link{color:#793c0a}.alert-color-red{--bs-alert-color:rgb(132, 31.8, 41.4);--bs-alert-bg:rgb(248, 214.6, 217.8);--bs-alert-border-color:rgb(244.5, 194.4, 199.2);background-image:var(--bs-gradient)}.alert-color-red .alert-link{color:#6a1921}.alert-cdnjs,.alert-color-yellow{--bs-alert-color:rgb(102, 77.2, 2.8);--bs-alert-bg:rgb(255, 242.6, 205.4);--bs-alert-border-color:rgb(255, 236.4, 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var(--bs-list-group-border-color)}.list-group-item:first-child{border-top-left-radius:inherit;border-top-right-radius:inherit}.list-group-item:last-child{border-bottom-right-radius:inherit;border-bottom-left-radius:inherit}.list-group-item+.list-group-item{border-top-width:0}.btn-close{box-sizing:content-box;width:1em;height:1em;padding:.25em;color:#000;background:url("data:image/svg+xml,%3csvg xmlns='http://www.w3.org/2000/svg' viewBox='0 0 16 16' fill='%23000000'%3e%3cpath d='M.293.293a1 1 0 0 1 1.414 0L8 6.586 14.293.293a1 1 0 1 1 1.414 1.414L9.414 8l6.293 6.293a1 1 0 0 1-1.414 1.414L8 9.414l-6.293 6.293a1 1 0 0 1-1.414-1.414L6.586 8 .293 1.707a1 1 0 0 1 0-1.414z'/%3e%3c/svg%3e") center/1em auto 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0.15)}.modal-dialog{max-width:var(--bs-modal-width);margin-right:auto;margin-left:auto}.modal-sm{--bs-modal-width:300px}}.offcanvas{--bs-offcanvas-zindex:1045;--bs-offcanvas-width:400px;--bs-offcanvas-height:30vh;--bs-offcanvas-padding-x:1rem;--bs-offcanvas-padding-y:1rem;--bs-offcanvas-bg:#ffffff;--bs-offcanvas-border-width:1px;--bs-offcanvas-border-color:var(--bs-border-color-translucent);--bs-offcanvas-box-shadow:0 0.125rem 0.25rem rgba(0, 0, 0, 0.075);position:fixed;bottom:0;z-index:var(--bs-offcanvas-zindex);display:flex;flex-direction:column;max-width:100%;color:var(--bs-offcanvas-color);visibility:hidden;background-color:var(--bs-offcanvas-bg);background-clip:padding-box;outline:0;box-shadow:var(--bs-offcanvas-box-shadow)}.offcanvas.offcanvas-start{top:0;left:0;width:var(--bs-offcanvas-width);border-right:var(--bs-offcanvas-border-width) solid 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itemprop="headline">The Industrial Nervous System: IIoT and PLCs</h1></div></div> <div class="row" itemprop="articleBody"><aside class="article-social text-center col-md-1 col-12"> <ul class="list-group list-group-horizontal-down-md"> <li class="d-block list-group-item border-0"> <a href="https://www.shareaholic.com/api/share/?apikey=65befd2e10310fbce11aee6ee90bf582&apitype=1&v=1&service=facebook&link=https://www.techbriefs.com/component/content/article/51718-the-industrial-nervous-system-iiot-and-plcs?r=905&title=The+Industrial+Nervous+System%3A+IIoT+and+PLCs" rel="nofollow" target="_blank"><i class="fa-brands fa-facebook fa-lg"></i></a></li> <li class="d-block list-group-item border-0"> <a href="https://www.shareaholic.com/api/share/?apikey=65befd2e10310fbce11aee6ee90bf582&apitype=1&v=1&service=twitter&link=https://www.techbriefs.com/component/content/article/51718-the-industrial-nervous-system-iiot-and-plcs?r=905&title=The+Industrial+Nervous+System%3A+IIoT+and+PLCs" rel="nofollow" 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src='data:image/svg+xml;base64,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' data-src='https://res.cloudinary.com/tbmg/c_scale,w_auto,f_auto,q_auto/v1728054085/sites/tb/articles/sup/ST/2024/applications/ST-1024-p11_fig1.jpg' class=' w-100 cld-responsive' alt='' /> <figcaption>Figure 1. PLCs are the synapses of the industrial internet of things. (Image: xmentoys/Adobe Stock)</figcaption></figure> <p>The industrial internet of things (IIoT) is the nervous system in manufacturing facilities worldwide, with programmable logic controllers (PLCs) serving as its vital synapses. This digital neural network is transforming isolated machines into interconnected ecosystems of unprecedented intelligence and efficiency. PLCs have evolved from simple control devices into sophisticated nodes in a vast, responsive network.</p> <p>If PLCs are the synapses of this system, then backup and recovery systems provide its long-term memory. The importance of a robust backup and recovery strategy cannot be overstated. The vast amounts of data generated by PLCs and other IIoT devices are not just operational byproducts — they are critical assets for maintaining continuity and driving ongoing optimization.</p> <h4>Backup and Recovery</h4> <p>Backup and recovery systems come in all shapes and sizes, from improvised collections of simple text documents to modern Industrial DevOps Platforms with Git-based source control and automated back-up solutions, such as Copia’s DeviceLink<sup>™</sup>, that enable factories to quickly recover from system failures, cyberattacks, or unforeseen disasters, with minimal data loss. Together, these tools provide a robust framework for developing and maintaining the automation code for large manufacturing environments. A DevOps platform is a comprehensive suite of tools that integrates and automates software development and IT operations, streamlining the entire software lifecycle from coding to deployment and monitoring.</p> <h4>IIoT Integration: Creating a Seamless Industrial Ecosystem</h4> <figure title="Figure 2"><img src='data:image/svg+xml;base64,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' data-src='https://res.cloudinary.com/tbmg/c_scale,w_auto,f_auto,q_auto/v1728054085/sites/tb/articles/sup/ST/2024/applications/ST-1024-p11_fig2.jpg' class=' w-100 cld-responsive' alt='' /> <figcaption>Figure 2. Intelligent monitoring, quality control, and production optimization can keep a factory in motion for the long-term. (Image: Gorodenkoff/Adobe Stock)</figcaption></figure> <p>The true power of IIoT lies in its ability to create a seamless, interconnected industrial ecosystem. PLCs, as the primary data generators and control units, form the foundation of this ecosystem. They interact with a multitude of IIoT devices — from smart sensors and actuators to edge computing devices and cloud platforms. This integration allows for extensive levels of data-sharing and coordinated decision-making across the entire production chain. For instance, in a smart factory, PLCs controlling individual production lines can communicate in real time with inventory management systems, supply chain logistics, and even customer order platforms. This level of integration enables dynamic production scheduling, where manufacturing priorities can be adjusted on the fly based on real-time market demand, inventory levels, or supply chain disruptions. The result is a highly responsive and efficient manufacturing system that can adapt to changes almost instantaneously, minimizing waste and maximizing productivity.</p> <h4>Predictive Maintenance: From Reactive to Proactive</h4> <p>Imagine a world where machines never break down unexpectedly. While we’re not quite there, predictive maintenance is bringing us tantalizingly close. By harnessing the power of machine learning and the treasure trove of data that PLCs collect, downtime for maintenance can be planned in advance.</p> <p>For example, Siemens’ Insights Hub system has been implemented in large-scale manufacturing plants. By analyzing the subtle changes in vibration patterns and energy consumption on the production line, customers can use it to better predict the likelihood of a problem so they can reduce downtime. It’s like giving machines a health checkup every millisecond.</p> <p>But why stop there? Picture a steel mill where thermal cameras connected to PLCs keep a vigilant eye on roller bearings in continuous casting machines. With the right algorithms, you could potentially predict bearing failures weeks in advance.</p> <h4>The Cloud, the Edge, and Everything in Between</h4> <figure title="Figure 3"><img src='data:image/svg+xml;base64,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' data-src='https://res.cloudinary.com/tbmg/c_scale,w_auto,f_auto,q_auto/v1728054085/sites/tb/articles/sup/ST/2024/applications/ST-1024-p12_fig1.jpg' class=' w-100 cld-responsive' alt='' /> <figcaption>Figure 3. According to the Copia Automation Inaugural State of Industrial DevOps 2024 Report, cybersecurity breaches are the leading cause of unplanned downtime, accounting for 47 percent of such incidents. (Image: Copia Automation)</figcaption></figure> <p>The marriage of PLCs with IIoT and cloud systems is a union of technologies that is reshaping how we think about data in manufacturing. Rockwell Automation’s FactoryTalk line, for example, is a group of products that incorporates analytics, machine learning, IIoT, and augmented reality (AR) into industrial operations, and is just one example of how intelligent monitoring, quality control, and production optimization can keep a factory in motion for the long-term.</p> <p>But the cloud isn’t always the answer. Sometimes, you need to think closer to home — or closer to the machine. Deploying edge computing systems in proximity to manufacturing facilities can reduce the likelihood of latency issues. Edge computing also provides an opportunity to safely secure assets within a well-protected border. The Emerson PACSystems<sup>™</sup> RX3i CPL410 PLC brings computing power right to the factory floor, enabling split-second decisions based on real-time sensor data for reduced reaction time.</p><div class="ad-position g-0 row mb-3 "> <div class="col-12 align-content-center mx-auto"> <script tb-donotmove>window.ntb_google_ad_manager_items=window.ntb_google_ad_manager_items||[];ntb_google_ad_manager_items.push({display_sizes:['xs','sm'],slot_ad_unit:'techbriefs.com_450x450_300x300',slot_code:'21835072403',slot:'/21835072403/techbriefs.com_450x450_300x300',slot_ad_sizes:['fluid',[450,450],[300,300]],div_id:'GAM_pos_22_modid_365',target_pos:'22',size_mapping:[],slot_ad_empty:'default'});</script> <div id='GAM_pos_22_modid_365' class=""></div></div></div><p>Imagine an automotive company where PLCs controlling battery production lines feed real-time data to cloud-based AI. This digital oversight system could analyze process parameters across multiple facilities, tweaking manufacturing protocols on the fly to optimize efficiency and quality. In competitive environments where every minute and resource counts, this kind of micro-management of the production cycle could be the key to maximizing profits.</p> <h4>Securing the Digital Factory</h4> <p>As our factories get smarter, they also become more vulnerable. Cybersecurity for PLCs isn’t just about protecting data — it’s about ensuring that a hacker can’t take control of potentially dangerous machinery. It is a fast-growing problem that all businesses need to consider. According to the <a href="https://www.copia.io/blog/press-release-the-state-of-industrial-devops" target="_blank" rel="noopener" rel="noopener noreferrer">Copia Automation Inaugural State of Industrial DevOps 2024 Report <i class="fad fa-external-link fa-sm"></i></a> , cybersecurity breaches are the leading cause of unplanned downtime, accounting for 47 percent of such incidents.</p> <p>Applying blockchain technology to PLC firmware updates is one possible approach to solving this problem. By creating an unbreakable chain of trust in software, manufacturers can eliminate the risk of a supply chain attack that might compromise production line safety or quality. It would be like assigning each line of code its own digital fingerprint for ultimate traceability and accountability.</p> <h4>X-ray Vision on the Plant Floor</h4> <p>As Industrial OT becomes more and more complex, having clear visibility into your code — both production code and code change history — is crucial for optimizing operations and troubleshooting issues. A modern version-control system for PLC code will allow teams to track changes over time, understand why specific modifications were made, and quickly roll back to previous versions if needed. This historical perspective is invaluable when diagnosing intermittent issues or optimizing processes. Furthermore, the ability to easily compare different versions of code across multiple PLCs in a facility can highlight discrepancies that might otherwise go unnoticed, ensuring consistency in operations.</p> <p>Advanced visualization tools, such as the Git-based source control found in the Copia Industrial DevOps platform, can even map code changes to specific performance metrics, allowing engineers to directly correlate code updates with improvements or regressions in efficiency, quality, or energy consumption. In essence, comprehensive code visibility transforms PLC programming from a black box into a transparent, manageable asset, empowering teams to make data-driven decisions and continuously refine their industrial processes.</p> <h4>The Human Touch in a Digital World</h4> <p>The best technology in the world is useless if operators can’t work with it effectively. The design of human-machine interfaces (HMIs) continues to improve, with the addition of touch screens, customizable interfaces, and gesture controls. But beyond flat screens, the future of HMIs will no doubt be three-dimensional. With the advent of virtual reality (VR) and augmented reality (AR) the smart factory of tomorrow will be led by operators wearing AR glasses to view real-time process data overlaid on the equipment they’re monitoring. The addition of enhanced computer vision and real-time operations data will elevate efficiency and safety across the manufacturing landscape.</p> <h4>The Road Ahead</h4> <p>As we embrace Industry 4.0, PLCs are evolving from simple control devices into the linchpins of our smartest factories. By embracing advanced algorithms, edge computing, AI, and seamless human-machine interfaces, we’re not just improving efficiency — we’re reimagining what’s possible in manufacturing.</p> <p>Moving forward, the lines between PLCs, edge devices, and cloud systems will continue to blur. The most successful manufacturers will be those who can seamlessly integrate these technologies, creating a unified system that’s greater than the sum of its parts.</p> <p><em>This article was written by Adam Gluck, Co-founder and CEO, Copia Automation. For more information, go <a href="https://www.copia.io/" target="_blank" rel="noopener" rel="noopener noreferrer">here <i class="fad fa-external-link fa-sm"></i></a> .</em></p> <hr> <div class="ntb_tagsbot"> <div class="taglist"> <strong class="sans-serif text-small">Topics:</strong><br> <a class="badge bg-secondary link-white fw-light sans-serif text-small fst-normal" href="/component/ntb_tags/topic/149/1961/tb/*?start=0"> <i class="fa-duotone fa-people-roof"></i> Anatomy</a> <a class="badge bg-secondary link-white fw-light sans-serif text-small fst-normal" href="/component/ntb_tags/topic/116/1450/tb/*?start=0"> <i class="fa-duotone fa-bolt"></i> Architecture</a> <a class="badge bg-primary link-white fw-light sans-serif text-small fst-normal" href="/component/ntb_tags/topic/ar_ai/artificial_intelligence/tb/*?start=0"> <i class="fa-duotone fa-head-side-goggles"></i> Artificial Intelligence</a> <a class="badge bg-primary link-white fw-light sans-serif text-small fst-normal" 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