Industrial SBC for Automation Control Panel
Project Overview
A manufacturing company in Chennai, India, was using outdated PLC-based control systems in its production line. The client sought a cost-effective, programmable, and compact alternative to replace legacy hardware, while maintaining flexibility, remote accessibility, and long-term reliability.
The client needed a compact, reliable, and cost-effective embedded computing solution to replace bulky PLCs in their control panels. Their goal was to upgrade to a more flexible system capable of:
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Existing PLCs were bulky, expensive, and limited in custom programming.
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System lacked real-time monitoring or remote diagnostics capabilities.
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Integration with modern interfaces (touchscreens, Ethernet, USB, etc.) was not feasible.
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The client required a custom Single Board Computer (SBC) that could operate reliably in industrial environments with minimal maintenance.
The Rennologic engineering team proposed a custom ARM-based SBC designed from the ground up, tailored to the factory's automation workflow and environmental conditions.
Key Development Milestones:
Requirement Analysis
- GPIO mapping for relay control
- Serial (RS232/RS485) support for legacy device compatibility
- Ethernet and USB ports for interfacing and data transfer
- 7” touchscreen interface for on-site monitoring
Hardware Design
- ARM Cortex-A7 based processor
- 4-layer custom PCB with thermal optimization
- Industrial-grade connectors and protection circuits (TVS, ESD, power filtering)
- Wide input voltage range (9–36V DC)
Software Stack
- Embedded Linux OS (Yocto-based)
- Custom bootloader and secure firmware
- Device drivers for display, I/O, and communication modules
- Remote SSH & OTA firmware update support
Testing & Validation
- Continuous operation under 55°C ambient temp
- Vibration and EMI/EMC pre-compliance testing
- Ethernet and USB ports for interfacing and data transferI/O stress testing under load
After successful deployment:
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Reduced hardware cost by 45% compared to commercial PLCs
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Improved visibility with touchscreen-based diagnostics and logging
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Enabled remote maintenance via SSH and web interface
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Increased system uptime due to reliable hardware and optimized OS
The custom SBC now runs 24/7 inside the automation panel of the facility, controlling relays, monitoring sensors, and reporting system health in real-time.
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Custom SBC Prototype Units
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Complete PCB Gerber & BoM
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Software Image + SDK for app development
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Integration Guide and API Documentation
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Post-deployment AMC for 12 months
Recent Caestudies
Key Features of the SBC
Compact Size:
100mm x 100mm board footprint
I/O Ports:
24 GPIOs, 2x UART, CAN, SPI, I2C
Connectivity:
Ethernet, USB 2.0, HDMI, SD Card
HMI Support:
Capacitive touchscreen (via LVDS or HDMI)
Security:
Secure boot & remote firmware upgrade features
Storage:
8GB eMMC + microSD card slot
Industrial Protocols Supported:
Modbus, CANopen, and MQTT