An automotive assembly line required real-time monitoring and control of safety doors, pneumatic systems, and robotic arm movement. The system needed to ensure that any unsafe condition — such as an open door or low air pressure — would immediately halt robotic operation and activate alarms, while continuously reporting system data to the central IIoT platform.
Challenges
Integrate digital, analog, and pulse signals from multiple field devices.
Implement fast local response to safety events without relying on a PLC.
Enable real-time data transmission to the central monitoring dashboard.
Solution
The solution adopted the BLIIOT BL192Pro Edge I/O Module with a modular configuration of:
Y01 – 4DI + 4DO for safety door inputs and alarm control
Y31 – 4AI for pneumatic pressure sensor inputs
Y41 – 4AO for robotic arm speed control outputs
The BL192Pro supports MQTT, Modbus TCP, and OPC UA, allowing seamless data integration with upper systems such as SCADA or cloud dashboards.
Logic Control Implementation
Using the built-in edge logic function, the following conditions were configured directly on the BL192Pro web interface:
Logic 1:
IF DI1 = 0 (safety door open) OR AI1 < 0.6 MPa
→ DO1 = 1 (alarm ON), DO2 = 0 (robot power OFF)
Logic 2:
IF pulse count > 10000
→ AO1 = 4mA (robot slowdown output)
Emergency Stop:
IF DI2 (E-stop) = 1
→ All DO outputs OFF
Results
The system achieved:
Instant shutdown of the robotic arm and alarm activation during unsafe conditions.
Automatic slowdown when motion exceeded preset thresholds.
Real-time data upload to the central monitoring system via MQTT.
Enhanced production safety and equipment reliability without needing an external PLC.
Device Advantages
All-in-one Protocols: MQTT + Modbus TCP + OPC UA for flexible integration.
Edge Computing: Local logic and arithmetic control reduce latency.
Modular I/O: Y-series boards adapt to diverse input/output needs.
Industrial Reliability: EMC-tested, -40~85°C operating range, 24V DC supply.
Learn more:https://bliiot.com/products/mqtt-opcua-modbustcp-edge-io-module-bl192pro
