Intelligent Local Control? Discover CODESYS on Zenith Gateways

2024-07-20•Eduardo Vieira, Zenith Industrial Cloud

The Traditional Dilemma: Gateway vs. PLC

Historically, in industrial automation, there was a clear separation of duties:

  • PLC (Programmable Logic Controller): The robust, deterministic brain responsible for executing machine or process control logic in real-time (reading inputs, executing logic, writing outputs).
  • Gateway/HMI/SCADA: Separate devices or systems responsible for visualization, collecting data from the PLC, and more recently, connecting to higher-level networks or the cloud.

This separation works, but often involves more hardware, more wiring, more points of failure, and complex communication configurations between the PLC and the gateway. What if we could combine the intelligence of the IIoT gateway with the control capability of a PLC?

The Modern Solution: Soft PLC with CODESYS at the Edge

Thanks to advancements in hardware (more powerful processors like those in RPi Compute Modules) and software, it's now possible to run a full PLC runtime directly on the Edge Gateway. This is known as a Soft PLC.

CODESYS is the world-leading development environment (IDE) and runtime system for PLC programming according to the IEC 61131-3 standard. It's used by hundreds of hardware manufacturers globally.

Zenith Industrial Cloud leverages this technology: Several of our advanced Edge Gateways and Industrial HMIs (specifically models based on compatible hardware, like those using RPi CM4/CM5) are prepared to run the official CODESYS runtime (requires purchasing a per-device license).

What Does This Mean for You? Benefits of CODESYS on a Zenith Gateway

Integrating CODESYS into our gateways offers significant advantages:

  1. Hardware Consolidation: In many applications (small/medium machine control, local sequences), the gateway can act simultaneously as a data collector, cloud communicator, AND the primary logic controller. Fewer boxes, less wiring, reduced complexity.
  2. Robust & Deterministic Local Control: CODESYS is a proven system designed for real-time control. Logic executes locally on the gateway, ensuring continuous process operation even if the cloud connection is lost.
  3. Standard Programming (IEC 61131-3): Your maintenance or engineering staff familiar with standard PLC languages (Ladder Diagram - LD, Structured Text - ST, Function Block Diagram - FBD, etc.) can understand and potentially modify the logic. Zenith can develop the entire CODESYS application for you.
  4. Seamless Cloud-Control Integration: Data generated or used by the CODESYS logic on the gateway can be easily exposed to the Zenith cloud platform via MQTT (through our agent software running alongside CODESYS). Likewise, commands or setpoints from the cloud can be securely sent for the CODESYS logic to use.
  5. Flexibility: Use the gateway purely for data, or add CODESYS control capability when needed, only paying for the license if that functionality is required.
  6. Processing Power: The modern processors in our gateways allow running both the communication/gateway tasks and the CODESYS logic efficiently.

Ideal Use Cases for CODESYS on a Zenith Gateway

  • Small/Medium OEM Machine Control: Replace a separate micro-PLC + Gateway with a single Zenith HMI+Control+Gateway unit.
  • Localized Process Automation: Control specific sequences, pumps, valves, etc., directly from the edge, but with cloud supervision and parameterization.
  • Systems with Local Fallback: Implement basic control logic on the gateway that activates if communication with a main PLC or the cloud is lost.
  • Rapid Prototyping: Develop and test control logic and cloud connectivity on a single platform.

Zenith Industrial Cloud: Your Partner for Integrated Control & Connectivity

We offer the flexibility you need:

  • CODESYS-Ready Gateways: Our advanced hardware is prepared to run the runtime.
  • CODESYS Programming Service: Our expert team can develop the complete PLC application based on your functional requirements.
  • Full Integration: We ensure the CODESYS logic communicates seamlessly with our cloud platform and your dashboards/HMIs.
  • Simplified Licensing: We handle the CODESYS license procurement as part of the project if you choose to use this feature.

Conclusion: One Gateway, Double the Potential

The ability to run standard PLC control logic (CODESYS) directly on our IIoT Edge Gateways opens up new possibilities for distributed, intelligent, and connected automation. You no longer have to choose between a powerful data gateway and a reliable local controller; with Zenith Industrial Cloud and CODESYS, you can have both integrated into an efficient, managed solution.

Interested in exploring how integrated CODESYS local control on our gateways can benefit your application?

Contact Us About Control Capabilities or Learn More About Zenith Industrial Cloud