BL245 EdgePLC with CODESYS: A New Integrated Control and Computing Solution for Process Control

In the context of the rapid advancement of Industry 4.0 and smart manufacturing, traditional PLCs face the challenge of balancing real-time control with edge intelligence. The BL245 EdgePLC Industrial AI Edge Controller launched by BLIIoT Technology uses a high-performance RK3588 processor as its core, perfectly integrating real-time PLC control, edge computing, and AI acceleration capabilities. It provides an efficient and open "all-in-one" solution for process control applications. Pairing it with the industry-leading CODESYS runtime system enables process control projects to upgrade from traditional automation to intelligent and predictive optimization.

BL245 EdgePLC: A Powerful Hardware Platform Designed for Industrial Process Control

The BL245 series adopts the Rockchip RK3588J/RK3588 high-performance SoC, featuring an 8-core ARM architecture (4× Cortex-A76 + 4× Cortex-A55, up to 2.4 GHz), an integrated 6 TOPS NPU supporting multiple AI inference precisions (INT4/8/16, FP16, etc.), and a Mali-G610 GPU, delivering strong computing power for complex process optimization and vision applications.

Key hardware highlights include:

• Memory and Storage: Up to 16 GB LPDDR4X + 128 GB eMMC, with M.2 NVMe SSD expansion support to meet big data acquisition and model deployment needs.
• Rich I/O Expansion: Supports up to 32 N-series I/O modules, covering digital (DI/DO), analog (AI/AO), temperature (RTD/thermocouple), PWM, and more—precisely suited for collecting and actuating critical parameters such as temperature, pressure, flow, and pH in process control.
• Industrial-Grade Reliability: Wide temperature design (-40°C to +85°C for RK3588J industrial version), DIN rail mounting, vibration/shock/humidity resistance, and compliance with IEC 61000-4 standards, making it suitable for harsh environments in chemical, pharmaceutical, and energy storage applications.
• Communication Interfaces: Dual Gigabit Ethernet, RS485, CAN-FD, Mini PCIe (supporting 4G/5G/WiFi), USB 3.1, and HDMI output for easy interconnection of field devices and local visualization.

These features make the BL245 not just a PLC controller, but an industrial edge node integrating control, computing, and AI.

Enhanced by CODESYS: Perfect Combination of Standardization, Real-Time Performance, and Openness

The BL245 Professional Edition natively supports CODESYS Runtime, fully compatible with IEC 61131-3 standard programming languages (LD ladder diagram, FBD function block, ST structured text, SFC sequential function chart, etc.). Optional SoftMotion/CNC and EtherCAT master station functions enable deterministic real-time control cycles at the millisecond or even sub-millisecond level.

Core advantages in process control:

• Standardized Programming: Engineers can reuse existing CODESYS projects without learning vendor-specific languages, significantly reducing training and migration costs.
• High Real-Time Performance: Combined with the Linux-RT kernel, it ensures stable execution of critical tasks such as PID regulation, sequential control, interlock protection, and safety logic.
• Rich Protocols: Native support for Modbus TCP/RTU, OPC UA, EtherCAT, PROFINET, etc., enabling seamless integration with field instruments, actuators, SCADA, and MES systems.
• Visualization and Expansion: Built-in WebVisu or HMI development support for operator monitoring of process curves, alarms, and trends.

The open ecosystem of CODESYS also allows AI inference results to be fed directly into control logic via shared variables, shared memory, or external interfaces, forming a true "control-computing closed loop."

Typical Applications of Integrated Control and Computing in Process Control

BL245 + CODESYS is particularly suitable for scenarios requiring high-precision process control alongside intelligent optimization, such as:

• Chemical/Pharmaceutical Reaction Process Optimization Real-time collection of reactor temperature, pressure, pH, and online analysis data via analog modules. CODESYS handles basic PID control, valve/pump interlocks, and recipe management. AI models (running YOLO, TensorFlow Lite, or custom optimization models on the NPU) analyze historical and real-time parameters to predict product performance trends and dynamically adjust heating power, feed rate, or stirring parameters—achieving "proactive optimization of reaction endpoints." Electronic batch records compliant with GMP requirements can be automatically generated after production.
• Energy Storage Systems (EMS/BMS) and PV Inverter Control CODESYS manages battery charge/discharge strategies, balancing control, and safety protection, while AI performs energy optimization scheduling based on load forecasting and weather data to improve system efficiency and extend equipment life.
• Intelligent Manufacturing Unit Process Closed Loop Combined with industrial cameras for AI vision quality inspection, defect features are correlated with process parameters and fed back to CODESYS to adjust upstream parameters (such as temperature curves or holding time), reducing defect rates and generating optimization reports.

In addition, BL245 supports Docker containerized deployment, Node-RED flow orchestration, and Python secondary development, allowing engineers to easily integrate third-party AI algorithms or cloud platforms (such as MQTT and OPC UA to the cloud) for edge-to-cloud collaboration.

Significant Advantages Over Traditional Solutions

Traditional process control often uses a separated architecture of "PLC + industrial PC/edge gateway," which suffers from complex integration, high costs, multiple failure points, and difficulty in unifying real-time and intelligent performance.

The advantages of BL245 + CODESYS lie in:

• All-in-One Functionality: Control, edge computing, AI acceleration, and gateway functions are integrated into a single device, reducing hardware costs and maintenance complexity.
• Balance of Performance and Openness: 6 TOPS AI computing power + CODESYS deterministic control, avoiding the limitations of insufficient computing power or closed systems in traditional PLCs.
• Flexible Expansion: Smooth upgrade path from Lite Edition (OpenPLC) to Professional Edition (full-featured CODESYS), allowing projects to gradually introduce AI according to needs.
• Long-Term Value: Based on the ARM Linux platform, it offers strong software-defined capabilities and high code portability, suitable for large-scale deployment and continuous iteration.

Conclusion and Outlook

The BL245 EdgePLC paired with CODESYS provides an efficient, open, and intelligent modern path for the process control field. It not only retains the familiar programming habits of PLC engineers but also empowers the system with predictive optimization and autonomous decision-making capabilities through AI edge computing, helping enterprises achieve cost reduction, efficiency improvement, green production, and digital transformation.

In industries such as chemical, energy, pharmaceutical, and intelligent manufacturing, the BL245 is becoming a powerful tool for implementing "integrated control and computing."

As AI models continue to lighten and the CODESYS ecosystem deepens, industrial AI edge controllers like the BL245 will surely become the mainstream choice for process control.