17th IFAC Conference on Technology, Culture and International

October
17th IFAC26-28, 2016. Durrs,
Conference Albania Culture and International
on Technology,
Stability
Stability
17th IFAC26-28,
October Conference on Technology,
2016. Durrs, Culture and
Albania Available International
online at www.sciencedirect.com
October
Stability 26-28, 2016. Durrs, Albania
October 26-28, 2016. Durrs, Albania
ScienceDirect
Cost-Oriented Open Source Automation Potential Application in
IFAC-PapersOnLine 49-29 (2016) 212214
Cost-Oriented Open
Open Source
Cost-Oriented IndustrialSource Automation
Control Potential
Potential Application
Applications
Automation Application in
in
Cost-Oriented Industrial
Open SourceControl Applications
Automation
Industrial Control Applications Potential Application in
Industrial Control Applications
Valmir Hoxha, Ines Bula,
Muzafer
Valmir Shala,
Hoxha,Edmond Hajrizi
Ines Bula,
Valmir Hoxha, Ines Bula,
Muzafer Shala, Edmond Hajrizi
Faculty ofMuzaferValmir
Mechatronics Hoxha,
Shala, Ines Bula,
Edmond
Management, Hajrizi
UBT, Pristina,
Kosovo Muzafer
(Tel:00377 44 Shala,
77 11 31;Edmond
e-mail: Hajrizi
valmir.hoxha@ubt-uni.net;
Faculty of Mechatronics Management, UBT, Pristina,
Faculty of Mechatronics
ines.bula@ubt-uni.net; Management, UBT,ehajrizi@ubt-uni.net
muzafer.shala@ubt-uni.net; Pristina, )
Kosovo (Tel:00377 44 77 11 31; e-mail: valmir.hoxha@ubt-uni.net;
Faculty
Kosovo of Mechatronics
(Tel:00377 44 77 11 31;Management, UBT, Pristina,
e-mail: valmir.hoxha@ubt-uni.net;
ines.bula@ubt-uni.net; muzafer.shala@ubt-uni.net; ehajrizi@ubt-uni.net )
Kosovo (Tel:00377 44
ines.bula@ubt-uni.net; 77 11 31; e-mail: valmir.hoxha@ubt-uni.net;
muzafer.shala@ubt-uni.net; ehajrizi@ubt-uni.net )
Abstract: One of theines.bula@ubt-uni.net;
most cost effective ways muzafer.shala@ubt-uni.net;
to make system control ehajrizi@ubt-uni.net
(automation) is by using ) open source
hardware and
Abstract: Onesoftware,
of the mostin order to be costways
cost effective oriented besides
to make the price
system controlthe(automation)
systems need to be
is by implemented
using in
open source
Abstract:
reasonableandOne of the most
timesoftware,
frame and cost effective beways to makesafe.
systemthis
control (automation) is by justify
using open source
hardware in also
orderneeds
to betocost reliable
orientedand
besides In
the price paper
the we will treat
systems needand the cases
to be implemented of
in
Abstract:
hardware
using Onesoftware,
the and
Open ofSource
the most cost effective
in order to be cost ways to make
oriented system
besides control
the price the(automation)
systems is by
need to using
be open source
implemented in
reasonable time frame andHardware
also needsandto beSoftware,
reliable in
andcomparison
safe. In thistopaper
industry standard
we will treat andProgrammable Logic
justify the cases of
hardware
reasonable
Controllers and
timesoftware,
frame
(PLC).Source in
and
Also we order
also to
needsbe
will discusstocost
be oriented
reliable besides
and safe. the
In price
this the
paper systems
we will need
treat to
and be implemented
justify the cases in
of
using the Open Hardware and about the point
Software, of system complexity
in comparison to industrywhere the cost
standard reduction will
Programmable not
Logic
reasonable
using
justify the
the timespend
Open
time frame
Source and
to alsothe
Hardware
build needs to be
and reliable
Software,
interfacing of andcomparison
in
sensors, safe. Inand
digital thisanalog
topaper we for
industry
I/O will treat
standard
the and
open justifyHardware.
the cases
Programmable
source of
Logic
Controllers (PLC). Also we will discuss about the point of system complexity where the cost reduction will not
using the Open
Controllers (PLC).Source
Also weHardware and about
will discuss Software, in comparison
the point to industrywhere
of system complexity standard Programmable
the cost Logic
reduction will not

justify the
2016,the
Keywords:
Controllers
justify
time
IFAC spend
(PLC).
time spend
to build
(International
Open Source,
Also weCost
theOriented
will
to build
interfacing
Federation
thediscuss ofabout
interfacing
of sensors,
Automatic
Automation,
ofthe point
sensors,
digitalMicro-controllers,
Control)
PLC, and analog
Hosting
of system
digital andcomplexity
analog
I/O forSensors,
by Elsevier the open
Ltd.
where
I/O for the the
open
sourcereserved.
Allcost
rights
Industry, Hardware.
Developing
reduction
source will not
Hardware.
countries.
Keywords: Open
justify the time Source,
spend Cost
to build Oriented
theOriented
interfacingAutomation, PLC,
of sensors,PLC, Micro-controllers,
digitalMicro-controllers, Sensors,
and analog I/O forSensors, Industry,
the openIndustry, Developing
source Hardware.
Keywords: Open Source, Cost Automation, Developing
countries.
Keywords: Open Source, Cost Oriented Automation, PLC, Micro-controllers, Sensors, Industry, Developing
countries.
countries. 1. INTRODUCTION The main advantages of the PLC compared to the Open source
1. INTRODUCTION Hardware and Software
The main advantages using
of the PLC Open Sourcetomicro-controllers
compared the Open source
Open source applications 1. INTRODUCTION
are gaining popularity in applications The
is main
that PLCadvantages
support ofindustry
the PLCstandard
comparedvoltageto the Open source
and current
Hardware and Software using Open Source micro-controllers
mainlysource
in hobby, 1. INTRODUCTION
amongst The main
Hardware advantages
and Software of the
usingPLC Opencompared
Source to the Open source
micro-controllers
Open applications are the programmers
gaining popularityand electronics
in applications ratings
is that PLC of different
support sensors, including voltage
industry standard Analogand to current
digital
Open sourcebut
enthusiasts, applications
there is a are gaining popularity
great in applications Hardware
is that PLC and Software
support using
industry Open
standardSource micro-controllers
voltage and current
mainly in hobby, amongst the potential
programmersof usingandopen source
electronics Converters (ADC) for interfacing with
ratings of different sensors, including Analog to digital sensors producing
Open
mainly source applications
ininhobby, amongst are the
gaining
too.popularity
programmers in applications
and electronics is that PLC support industry standard voltage
hardware
enthusiasts, Industrial
but there is applications
a great potential of using open source ratings
standard
Converters
of different
values
(ADC)
sensors,
like 0-10V, including
4-20mA,
for interfacing 0-20mA,
with alsoand
Analog
sensors
to current
we digital
should
producing
mainly in hobby,
enthusiasts, but there amongst
is a greatthe potential
programmersof usingandopenelectronics
source ratings
Converters of different
(ADC) forsensors, including
interfacing with Analog
sensors to digital
producing
hardware in Industrial applications too. take in account
standard values the
like digital
0-10V,inputs4-20mA, that 0-20mA,
in the industry
also weareshould
used
enthusiasts,
hardware
"Open hardware,"but there
in Industrial is a great
or applications
"open source potential
too.hardware," refers source
of using open to the Converters
standard (ADC)
values like for
0-10V, interfacing
4-20mA, with
0-20mA, sensors
also producing
we should
as 24VDC,
take that the
in account is supported
digital inputsfromthatPLCinand the the other are
industry modular
used
hardware
design in Industrialof
specifications applications
a physical too.
object which are licensed in standard
take values the
in account like 0-10V,
digital 4-20mA,
inputs that 0-20mA, alsogages
in the strain
industry weareshould
used
"Open hardware," or "open source hardware," refers to the extensions
as 24VDC, that cansupported
that is support sensors
from PLC using
and the other (e.g.
modular
"Open
such a hardware,"
way that or "open
object can be source
studied,hardware,"
modified, refers
created, to and
the take
as inCell),
24VDC,
Load account
that the digital inputs
is supported
Thermocouples fromthat
etc. PLCinand the the
industry
other are used
modular
design specifications of a physical object which are licensed in extensions that can support sensors using strain gages (e.g.
"Open
design hardware,"
specifications
distributed orof"open source
a physical hardware,"
object which are refers to the
licensed in as 24VDC, that
extensions that is
cansupported
support from sensors PLC and strain
using the other modular
gages (e.g.
such a waybythat anyone.
object can be studied, modified, created, and Load Cell), Thermocouples etc.
design
such a specifications
way that object of can
a physical objectmodified,
be studied, which arecreated,
licensedand in extensions
distributed by anyone. On the other hand, all this advantages of the PLC come (e.g.
Load Cell), that can
Thermocouplessupport sensors
etc. using strain gages with
such a way
distributed by that object
anyone. can be studied,
In 1997 Eric S. Raymond, Tim O'Reilly and Larry Augustin modified, created, and Load Cell), Thermocouples etc.
great disadvantage of high price, for the
On the other hand, all this advantages of the PLC come with Hardware and also
distributed by anyone. On
established
In 1997 Eric "open source" asTim
S. Raymond, an alternative
O'Reilly and expression to "free
Larry Augustin highthe
great
other
price forhand,
disadvantage
all this advantages
the software
of high license
price, for
of the PLC come
for the
programming
Hardware and which withis
also
In 1997 Eric
software," S. Raymond, Tim O'Reilly and the
Larry Augustin On
greatthedisadvantage
other hand, of all thisOriented
high advantages
price, for the of the PLC
Hardware come
and with
also
established "open source" as an alternative expression toSource
and in 1997 Bruce Perens published Open "free not very
high price suitable
for thefor Cost
software license Automation
for programming (COA). which is
In 1997 Eric
established
Definition. "open
In S. Raymond,
late source"
1998Bruce Tim
Dr.asSepehr O'Reilly(aand
an alternative Larrymechanical
expression Augustin
to "free great disadvantage
high price of high license
for the software price, for for the Hardware and
programming which also
is
software," and in 1997 PerensKiani
published PhDtheinOpen Source not very suitable for Cost Oriented Automation (COA).
established
software," "open
and in 1997source"
MIT)Bruce as Perens
an alternative
published expression
Opentobenefit
thecould "free
Source high price for the software license Automation
forof programming
engineering
Definition. Infrom late 1998 realized
Dr. Sepehrthat designers
Kiani (a PhD in mechanical
not
On very
the suitable
other for
hand, Cost
the Oriented
advantages Openwhich
using(COA). Source is
software,"
Definition.
from and
In
open source in
late 1997
1998 Bruce
Dr. Perens
Sepehr published
Kiani (a PhDtheinOpen Source
mechanical not very suitable for Cost Oriented Automation (COA).
engineering from policies,
MIT) realizedand in that
earlydesigners
1999 he convinced
could benefit Dr. Hardware
On the other and Software
hand, theis advantages
that it comes of with
usinga fraction of the
Open Source
Definition.
engineering
Ryan VallanceInfrom
late
and 1998
MIT)
Dr. Dr.
Samir Sepehr
realized
Nayfeh Kiani
thatof the(apotential
PhD in
designers mechanical
could benefit
benefits of On the other hand, the advantages of source
using there
OpenisSource
from open source policies, and in early 1999 he convinced Dr. price of the PLC, because of being open
Hardware and Software is that it comes with a fraction of the plenty
engineering
from
open open
design from
source MIT) realized
policies,
inandmachine and in that
design early designers
applications. could benefit
1999 he Together
convinced Dr.
they On the other
Hardware hand,
andforSoftware theis advantages
that it comes of with
using Open
a fraction Source
of the
Ryan Vallance Dr. Samir Nayfeh of the potential benefits of of examples
price of the PLC, certain
becauseapplication
of being open and also
sourcegreat
therenumber
is plentyof
from
Ryan open
established source
Vallance andpolicies,
Dr.Design
Samir and in early
Nayfeh 1999
of the he as
convinced
potential a benefits Dr.
of Hardware
price of theand Software
PLC, because is that
of it
being comes
open with
sourcea fraction
there is of the
plenty
open designtheinOpen machine Foundation
design (ODF)
applications. non-profit
Together they forums supporting.
of examples for certain application and also great number of
Ryan
open Vallance
design and
corporation, inandset Dr.
machine
out Samir
to Nayfeh
design
develop anofOpen
the potential
applications.Design benefits
Together
Definition. of
they price
of of the PLC,
examples becauseapplication
for certain of being open and source there
also great is plenty
number of
established the Open Design Foundation (ODF) as a non-profit forums supporting.
open design
established
(Vallance, 2000)in machine design applications.
the Open Design Foundation (ODF) as a non-profit Together they of examples
forums for
supporting. certain application and also great number of
corporation, and set out to develop an Open Design Definition. The main disadvantage is that requires interfacing for the
established
corporation,the andOpenset outDesign Foundation
to develop an Open(ODF) as a Definition.
Design non-profit forums supporting.
(Vallance, 2000) industry standard voltage ratings for inputs,
The main disadvantage is that requires interfacing for the outputs, sensors
corporation,
(Vallance, and
2000) set out to develop an Open
This popularity of using open source Hardware and Software is Design Definition. The mainhardware.
disadvantage is that requires interfacing for the
and other
industry standard voltage ratings for inputs, outputs, sensors
(Vallance, 2000)
developed even offurther The mainstandard
industry disadvantage
voltageisratingsthat requires
for inputs, interfacing for the
outputs, sensors
This popularity using with
open the useHardware
source of micro-controllers,
and Softwareby is and other hardware.
This popularity
opening a differentof using open source
perspective Hardware
especially and Software of
with development is industry
and other standard
hardware. voltage ratings for inputs,
Digital input voltage needs to step down to 0-5 V, and the outputs, sensors
developed even further with the use of micro-controllers, by
This popularity
developed
prototyping even of using
further open
with
platformperspective
on easy to source
the use Hardware
of and Software
micro-controllers,
use hardware and software. is
by and otherneed hardware.
opening a different especially with development of outputs
Digital input to be interfaced
voltage needs to with transistors
step down to 0-5 to V,
be and
able the
to
developed
opening a even
different further with
perspective the use of
especially micro-controllers,
with development by
of Digital input voltageand needs
Arduino is one
prototyping of the on
platform most popular
easy to use open source Hardware
hardware and software. and command
outputs the relays
need to be interfacedothertoindustrial
step down to 0-5 V, and the
parts.
with transistors to be able to
opening
prototyping
Software a different
platformperspective
on easy to especially
use (Atmel)with that
hardware development
andaresoftware. of Digital input
outputs need voltage needs to with
to be interfaced step down to 0-5
transistors to V,
be and
able the
to
Arduino isthat oneusesof the micro-controllers
most popular open source Hardware ableandto command the relays and other industrial parts.
prototyping
Arduino is platform
one of the on
most easy to
popular use hardware
open source and software.
Hardware and
read inputs and turn ON the outputs by
Software that uses micro-controllers (Atmel) that are able to sending a set of Programming with open source Hardware and Software to
outputs
command need
the to be
relays interfaced
and other with
industrial transistors
parts. to be able is
Arduino
Software isthat
oneusesof the most popular by
micro-controllers open source
(Atmel) Hardware
that are able and
to command
instructions
read inputs toand the micro-controller
turn ON the outputsusing by Open
sending source
a set(freeof much morethedifficult
Programming
relays and
with open
other of
because industrial
sourcethe lackparts.
Hardware of customer
and Softwaresupport is
Software
read
of inputsthat
charge) to uses
and
Arduino micro-controllers
turn ON the
programming by outputs(Atmel)
by
language, that
sending
based area able
set
on (free to
of
java Programming with open source Hardware and Software is
instructions the micro-controller using Open source and
much themore
programming language
difficult because ofisthe
muchlackmore difficult
of customer than the
support
read inputs
instructions
programming toandthe turn ON
languageprogramming the
micro-controller outputs
by by
using sending
Open
Processing. language, based on java a
source set of
(free Programming
much more with
difficult open
because source
of Hardware
the lack of and Software
customer support is
of charge) Arduino PLC
and theprogramming
programming language
language Ladder
is much Logic.more difficult than the
instructions
of charge) to the micro-controller
Arduino programming by using Open
language, basedsource
on (free
java much
and themore difficult because
programming languageofisthe muchlackmoreof customer support
difficult than the
programming language Processing. PLC programming language Ladder Logic.
of charge)
programming Arduino
language programming
Processing.
2. ADVANTAGES AND DISADVANTAGES language, based on java and
PLC the programming
programming language
language isismuch
Ladder Logic.more difficulttimethan and
the
Another aspect of disadvantage the programming
programming language Processing. PLC programming language Ladder Logic.
2. ADVANTAGES AND DISADVANTAGES capacity, aspect
Another micro-controllers
of disadvantage usually have 256 kbytes
is the programming time and of
2. ADVANTAGES AND DISADVANTAGES Another aspect of disadvantage is the programming time and
2. ADVANTAGES AND DISADVANTAGES capacity, micro-controllers usually have 256 kbytes of
Copyright 2016 IFAC 212 Another
capacity, aspect of disadvantage
micro-controllers is the programming
usually have 256 kbytes time and of
capacity, micro-controllers usually have 256 kbytes of
Copyright
2405-8963 2016,
2016 IFAC 212Hosting by Elsevier Ltd. All rights reserved.
IFAC (International Federation of Automatic Control)
Copyright
Peer reviewunder
2016 responsibility
IFAC 212Control.
of International Federation of Automatic
Copyright 2016 IFAC
10.1016/j.ifacol.2016.11.105 212
 2017 IFAC TECIS
October 26-28, 2016. Durrs, Albania
Valmir Hoxha et al. / IFAC-PapersOnLine 49-29 (2016) 212214 213
memory for the instruction and this is enough for simple
applications but as the system increase in complexity there is
always need for more memory.
Reliability is an issue, what if just one of the Cost oriented
micro-controllers malfunctions which is a very obvious
possibility because we need to reset once in a while and after
reset it works perfect, but this is not tolerable when you are
controlling expensive industrial machines and also human lives
are in jeopardy. PLC always have a standby CPU that takes over
when primary CPU fails or starts misbehaving
3. OPEN SOURCE JUSTIFICATION OF USE
The aim of this paper is to compare and justify the use of Open
Source Hardware and Software in industrial Control application
taking in account the price and complexity of the system.
The most widespread Control of Industrial processes is by using
industry standard Programmable Logic Controllers (PLC),
which are proven for reliability and longevity in industrial
applications.
The use of PLC has the reliability but it comes with a very high
price of hardware and most of the PLC producers charge for the
licenses of the Software used for programming.
The comparison is made between price and the system
complexity for PLC and Open Source Hardware
Implementation.
Labour hours for I/O
400.00
Labor working hours
300.00
200.00
100.00
0.00
100 ( 300 ( 500 ( 700 ( 900 (
I/O ) I/O ) I/O ) I/O ) I/O )
Open Source PLC
Fig. 1. Labor working hours compared to System complexity
measured with the number of Inputs and Outputs I/O
In Fig1. we present the Labor working hours compared to
System complexity measured with the number of Inputs and
Outputs, (I/O). By I/O we mean the digital and analog input
and outputs.
As we can see the labor time for the Open Source applications is
very high and after a certain working hours for making the
interface the time will increase and the open source
implementation will no longer be feasible to even start to
implement it, for this reason, the best way is to find the balance
between the price and time needed for the interface-ing between
different components in the open source method.
On the other hand, the already good established PLC solution is
reliable, quick setup no industrial interfacing problem but it is
expensive.
4. CASE STUDY
For the study we took an old weighing and packaging machine
from a local factory in Kosovo, the machine was built in early
1980, which had the old control system (Shala, 2015) we
replaced the old control system and build the new control
system with industry standard PLC and modules for readings
of the weighing sensors (Load Cells).
The total amount of time required for the implementation took
48 hours of labor including wiring, programming and
manufacturing, we managed to finish in this short time due to
advantages on programming with ladder logic (PLC
programming Language) and also the interfacing with other
electrical and electronic components was easy to realize
thanks to the PLC hardware.
The materials cost in total 2100 euro including the PLC (CPU,
display, modules), Weighing sensor (Load Cell) and other
unspecified materials (e.g. cables).
The same functionality by using open source Hardware and
Software in this case using Arduino Uno for control that cost
dramatically less than PLC.
The open source HW and Software implementation will cost
around 550 euro.
Cost
2,750
2,200
1,650 2,100
1,100
550 550
0
Open Source PLC
Fig. 2. Comparison of cost for Open Source and PLC
In order to be able to use this control process of the weighing
and packaging machine with open source hardware and
software we need to develop interfacing electronics for inputs,
outputs and also we must develop transmitters to amplify the
output of values for the Load Cell which gives around 2mV/V.
But we also need to take in account that Load Cell readings
form the PLC are with up to 24bit of Resolution for 0-5V DC,
and the Arduino Uno uses only 8bit of resolution for 0-5V
DC, to solve this issue we need to use ADC converters with at
least 10bit resolution to be able to have accurate reading from
the weighing sensors, but this will increase the labor time, cost
and requires more research time to develop the interface.
For the Open Source the total amount of time required for the
implementation would be at least 95 hours.
2017 IFAC TECIS
October 26-28, 2016. Durrs, Albania
214 Valmir Hoxha et al. / IFAC-PapersOnLine 49-29 (2016) 212214

Labor Hours their products and meet internatioanl standards and also
increase the production capacity.
100
75 95 And also there is a great potential to train young technicians to
50 build open source applications which will contribute in
25 48 professional development and have impact on employment.
0 7. FURTHER STUDY
Open Source PLC
In further studys we need to find ways of building more time
Fig. 3. Comparison of labor hours for Open Source and PLC efficient systems that are more reliable for cost oriented
applications always giving priority to human safety in work.
5. MAINTENANCE

According to (Morell, 2001) maintenance should

keep a systems facilities functioning in order to contribute to the
enterprise target. Maintenance should fulfil the right CRAMP
parameters (Cost, Reliability, Availability, Maintainability, and
Productivity) for any automation system (Erbe, 2002).
In order to cover all the aspects of the maintenance we need to
cover the hardware and software maintenance.
Open source software that are used to program cannot guarantee
that software will run properly for a long time, because they
dont apply industry standard quality assurance, and for this
reason the maintenance cost can go up.
On the other hand, the PLC software maintenance is almost not
an issue because they are reliable, and in most PLC producers
the instructions are stored in SD cards.
REFERENCES
Erbe, H., (2002). Low Cost Intelligent Automation in
Manufacturing. Barcelona, Spain, IFAC 15 th Tirennial World
Congress .
Morell, G., (2001). Maintenance Holistic Framework for
optimizing the Cost/Availability Compromise of MS. Elsevier,
On Cost Oriented Automation(6th IFAC Symposium).
Shala, M., Hajrizi , E., Hoxha, V. & Stapleton, L., (2015).
Cost Oriented Agile Innovation for Mechatronics
Management in Less Developed Region. Sozopol. Bulgaria,
16th IFAC - TECIS Conference, Elsevier, Science LTD,
Oxford.
Vallance, R., (2000). Bazaar Design of Nano and Micro
Manufacturing Equipment, Kentucky USA, Presentation at:
University of Kentucky to Namotechnology Workshop.

Open Source hardware maintenance is also very hard because of

the industrial standard that are not applied and also there is the
issue of harsh industrial environments that can affect in normal
working of the machine, to the Open Source Hardware that are
not designed for that purpose, compared to the PLC that are
designed to withstand this harsh industrial environment
including temperature, dust, moisture etc.

6. CONCLUSION

Open source micro-controller based application should be used

only in simple applications, where there is reasonable time for
building the system and only in systems and machines where
human lives are not in danger.

After a certain point of system complexity, the cost reduction

will not justify the time spend to build the interfacing of sensors
and digital and analog I/O.

In our case study the conditions were perfect to use Open

Source of Hardware and Software because the machine will not
put in danger human lives in any case of malfunction and the
system is not so complex and the time to build the system is
reasonable, taking in account the savings from the cheaper
Hardware.

Kosovo as developing country there are many factories that

have old machines that can be upgraded with open source
aplication which will contribute on improving the quality of