The combination of OpenPLC, Node-RED, BLRAT, and FUXA enables a lightweight, open-source, end-to-end automation solution. It covers hardware control, logic orchestration, data processing, visualization, and remote maintenance—all without commercial software licensing. This makes the solution ideal for small and medium automation projects, remote operations, education, and secondary development.
Goal: Real-time device monitoring, remote control, and automated alarms.
Use Cases: Conveyors, motors, temperature/humidity regulation, auxiliary machine control.
Workflow:
OpenPLC: Collects sensor data (temperature, current) and drives actuators (relays, VFDs).
Node-RED: Implements logic such as “If temperature exceeds limit → shut down device → trigger alarm.”
BLRAT: Provides secure remote access and maintenance.
FUXA: Displays real-time charts, device status, alarms, and manual control buttons.
Goal: Low-cost automation and environment control without commercial smart-home platforms.
Use Cases: Lighting control, HVAC, smart curtains, incubators, irrigation systems.
Workflow:
OpenPLC: Using ARMxy X23 (RS485), Y24 (relays), Y01 (DI/DO) to connect sensors and actuators.
Node-RED: Example logic: “Humidity < 40% → start humidifier” or “After 7 PM → open-door triggers auto-light.”
BLRAT: Remote device access.
FUXA: Mobile/PC interface for real-time values and manual control.
Goal: Capture production counts, runtime, and generate real-time and historical reports.
Use Cases: Packaging lines, small assembly machines, product counters.
Workflow:
OpenPLC: Reads count pulses and equipment runtime.
Node-RED: Stores data to MySQL/InfluxDB and calculates metrics (hourly output, failure rate).
BLRAT: Ensures remote maintenance.
FUXA: Displays daily/weekly trends and supports historical queries.
A standard three-layer structure ensures modularity, flexibility, and easy expansion.
| Layer | Component | Role | Protocols |
|---|---|---|---|
| Hardware Control | OpenPLC | I/O control and sensor acquisition | Modbus TCP, MQTT |
| Logic Layer | Node-RED | Automation logic, event handling, DB integration | MQTT, HTTP, DB connectors |
| Visualization Layer | FUXA | HMI dashboard, data display, manual control, reporting | MQTT, WebSocket |
| Remote Maintenance | BLRAT | Secure remote access for all modules | Encrypted tunnel |
