If you like to listen to those “deep focus” soundtracks that are all ambient and relaxing, then you’ve heard a tongue drum in action. A tongue drum, or tank drum, is a unique percussion instrument traditionally made from an empty propane cylinder — though purpose-built models are now common. Several tongues are cut into one end cap and weighted to produce specific notes when struck. As with all instruments, playing a tongue drum is an art. To simplify that, Jeremy Cook built a robot capable of playing a small tongue drum.
When robotizing a percussion instrument, it is common to use solenoids and that is what Cook did here. Solenoid actuators like these move linearly and can strike with pretty decent force, which makes them a good choice. Cook’s drum has eight tongues, so his robot has eight solenoids held by flexible friction arms mounted onto a C-shaped laser-cut MDF frame. PVC pipes actual as the vertical structural supports on that frame.
To tell the robot what tunes to play, Cook added a MIDI input that comes through an Opta-compatible I2C and serial adapter of his own design. That adapter is available for sale on Tindie if you want one.
The MIDI input can come from a something like a keyboard for real-time manual control, or it can come from a PC for playing pre-written (or algorithm-generated) ambient hits. If you attended the Orlando Maker Faire last year, you may have had a chance to try this robotic tongue drummer for yourself.
The silk industry has a rich history in Italy, but modern challenges have brought this centuries-old tradition to the brink of decline. Once a cornerstone of the rural economy in Italy, with a strong presence in Zagarolo, Rome, silk production has dwindled in the country due to industrial developments, synthetic fibers’ growing popularity, and fierce price competition from foreign exporters. Enter Tecnoseta, a small startup founded in 2019 with a bold mission: to rebuild and innovate the silk production chain, making it 100% Made in Italy.
By combining traditional silk production expertise with modern Industry 4.0 technology, Tecnoseta’s founders have envisioned a sustainable, modular system to produce high-quality Italian silk. Their goals include not only manufacturing efficient, high-tech machinery but also revitalizing rural communities and offering hope to younger generations by creating local job opportunities.
“We’ve grown alongside Arduino. As the platform evolved, we were ready to seize the new possibilities.” – Maddalena Mariani, co-founder and CEO of Tecnoseta
Tecnoseta turned to Arduino’s accessible and reliable technology to bring their vision to life. Thanks to our open-source platform, their in-house team has developed a modular line of high-performance machinery tailored for each step of silk production, including reeling, re-reeling, twisting, and spooling.
Using the Arduino Nano Every and Nano 33 IoT, they implemented automated processes and sensor-based monitoring across their specialized equipment. This allows for real-time fault detection, such as alerting operators when a silk thread breaks. This innovation drastically reduces downtime and improves efficiency, even for small-scale production.
The modularity of Tecnoseta’s system means clients can scale operations according to their needs, from artisanal to industrial. The machines are also designed to integrate with renewable energy sources like solar panels, reflecting a strong commitment to sustainability.
Now the company is looking to the future, exploring ways to enhance their machinery with advanced sensors for predictive maintenance.
Leveraging tools like Arduino Cloud and the Opta micro PLC, Tecnoseta plans to collect data from the machines to monitor their performance and quickly intervene remotely in case of any issues, ensuring even greater reliability and precision. As their technology evolves, the company’s mission remains rooted in their heritage: combining cutting-edge innovation with traditional craftsmanship to create a sustainable future for the Italian silk industry.
Tecnoseta is now working within an agritech framework, to develop high-tech architectures and AI models for the automated management of silkworm breeding. “By supporting the transition of Italy’s sericulture to truly modern standards, we aim to have a positive impact on the local territory by attracting highly specialized professionals. What’s more, it will add to Italy’s competitive edge while making the supply chain more efficient and sustainable,” says Maddalena Mariani, co-founder and CEO.
A mainstay in most machine shops, the belt grinder assists in greatly increasing the speed at which parts can be ground down in a safer, more controlled manner compared to an angle grinder. As an effort to build a tool like this one for the first time, Julien Alexandre chose to use Arduino Opta as its controller while designing it from the ground up.
Belt grinders, as the name implies, use a rapidly moving, abrasive belt that has been wound around a set of pulleys and gets driven by a large motor. The main drive pulley was mounted at the rear of the machine and securely connected to a three-phase AC motor. Above it is a height-adjustable point for controlling the belt’s tension, which also aids in swapping belts when needed. The last two pulleys are situated across from the motor and can be tilted vertically to alter the grinding angle. Lastly, the entire assembly can pivot to lay flat on the table or raised at an angle to it.
Facilitating the belt grinder’s operation is an Arduino Opta micro PLC. It receives a signal from two digital inputs that, when either is active, cause the Opta to blink a blue LED indicating to the operator that an error occurred in the security relay that manages the safety chain.. The motor controller (a variable-frequency drive) receives its values from a switch and a potentiometer located on the control panel, with the former dictating if the system is active and the latter being used for adjusting the speed. To see more about Alexandre’s ongoing projects, you can visit his Instagram page here.
Makers have long asked the question “why bother with an expensive PLC when I can just use an Arduino?” The answer comes down to the priorities and needs of industrial clients. In a factory automation setting, the client will prioritize durability, reliability, and serviceability over the one-time purchase price of the device itself. But to prove that Arduino’s professional turnkey solutions are just as easy to use as their developer-focused educational counterparts, Jeremy Cook leveraged an Arduino Opta micro PLC to build a drum machine.
This isn’t any old drum machine that plays sound samples or synthesized notes, but rather a robotic drum machine that makes noise by banging on stuff like a true percussion instrument. Cook could have built this with any Arduino board and a few relays, but instead chose to implement the Opta and new Opta Digital Expansion. That is robust enough for serious commercial and industrial applications, but is still simple to program with the familiar Arduino IDE. Programmers can also use conventional PLC languages if they prefer.
In this case, Cook made noise with relays and solenoids. The Opta has four built-in relays and Cook’s sketch flips one of them to make a sound analogous to a hi-hat. Cook added an Arduino Pro Opta Ext D1608S module with its solid-state relays for the other two “drums.” One of those fires a solenoid that taps a small hand drum (the kick drum sound), while the other controls a solenoid that hits a power supply enclosure (the snare sound).
Together, those three sounds can cover the basics of a drum track. Cook’s sketch is a drum sequencer program that stores each sound sequence as array, looping through them until turned off.
An Opta may be overkill for a project like this one, but this does a great job of demonstrating the ease at which an Arduino user can transition to professional PLC work.
Blues Wireless and Arduino have joined forces to create the game-changing Blues Wireless for Arduino Opta, unveiled this week at the Automate Show in Chicago. The expansion module is an affordable solution to enhance connectivity options for Arduino Opta micro PLCs, and marks a significant milestone in PLC technology and in making technology more easily accessible to all.
“The IIoT is on the cusp of a revolution in democratized connectivity and computing not unlike the PC era of a generation ago,” said Brandon Satrom, Senior Vice President of Product & Experience at Blues. “Products like Lotus Notes, Microsoft Access, and FrontPage sparked a revolution, offering teams and organizations a red tape-free path to connect with one another. With the Opta and Blues’ Wireless Expansion, Blues and Arduino are fueling a similar revolution, empowering OT teams with a direct path to cloud-connected PLC systems.”
The expansion module adds cellular or LoRa® connectivity to any Arduino Opta micro PLC, in addition to existing Ethernet, RS485, or Wi-Fi®/Bluetooth® capabilities (depending on the specific variant). It is easy to connect via the Opta’s standard AUX expansion port in a daisy-chain setup with other modules, and allows users to quickly and securely communicate with the Cloud.
“The market is seeking effective, manageable embedded solutions for routine industrial challenges, as exemplified by the Arduino Opta micro PLC,” said Marcello Majonchi, Chief Product Officer at Arduino. “With Opta, Arduino empowers engineers to swiftly create professional-grade solutions that integrate seamlessly with existing systems and connect to their chosen cloud platforms. The partnership with Blues Wireless expands these connectivity possibilities into the cellular realm, enabling comprehensive remote monitoring and control with just a few clicks. If you think about a remote plant, a solar farm, a water well pump, an industrial vehicle or a large machine, like an air compressor, that you want to monitor and control, these are the scenarios we are targeting.”
Last year, we launched the Arduino Pro Opta: it was an instant success with our community, and allowed us to reach PLC engineers with a new solution specifically designed for their needs.
To further expand Opta’s capabilities, today the Arduino ecosystem welcomes various expansions that allow you to add new I/Os in the simplest and fastest way possible.
Meet the Opta Digital Expansions
The digital expansions, Arduino Pro Opta Ext D1608E and Arduino Pro Opta Ext D1608S, are ideal to multiply the number of real-time control points in the manufacturing sector and in any building automation project. The new, ready-to-use I/Os are seamlessly adopted by the Opta controller, giving you a native-like management experience. Each expansion offers 16 programmable inputs and eight relay outputs (electromechanical or solid state), and up to five expansions can be mixed to obtain the best fit for each project.
Stay tuned for the Opta Analog Expansion!
We are also finalizing an analog option: the Arduino Pro Opta Ext A0602 (coming soon) will allow you to diversify your data acquisition capabilities, and expand your devices’ actuation possibilities with great flexibility and process efficiency. Configuring new inputs/outputs to acquire 0-10 V and 0/4-20 mA signals and temperature values through PT100 will help you take Opta’s monitoring and control capabilities to a new level.
The Opta is our industrial-grade micro PLC, developed in partnership with Finder to provide engineers with a durable, reliable, secure and high-performance hardware, while still maintaining our signature flexibility and ease of deployment in production.
All three variants of Opta are based on a powerful STM32H747XI Dual ArmARM® Cortex® microcontroller and can be programmed using C++ in Arduino sketches, but also offer the flexibility of incorporating any or all of the 5 traditional IEC 61131-3 PLC automation control languages.
To find out more, check out the three variants in our Store:
• Opta Lite: with Ethernet onboard and USB-C® programming ports (SKU: AFX00003)
• Opta RS485: which also adds RS485 half duplex connectivity interface (SKU: AFX00001)
• Opta WiFi: the most versatile option, featuring also Wi-Fi®/Bluetooth® Low Energy connectivity (SKU: AFX00002)
We’re ready to bring our unconventional take on automation to one of North America’s leading industry events: come meet us at Automate Show in Chicago, taking place May 6th-9th, to find out more about open-source hardware and software solutions unlocking new opportunities to empower engineers and educators alike.
1. Get a closer look at the Arduino Opta: with its small form factor, low power consumption, and built-in connectivity options, our groundbreaking micro PLC is “the Swiss Army knife” of industrial automation. Zero vendor lock-in, tons of programming flexibility: choose among the key IEC 61131-3 languages or the Arduino environment, or even combine the two approaches to further boost capabilities.
2. Discover the brand newArduino PLC Starter Kit, based on the Opta WiFi and Arduino PLC IDE: a training solution that plugs right into the future of industrial automation, designed to introduce students in vocational institutes and tech-oriented academies to IEC 61131-3 standard programming languages and Modbus communication.
3. Be the first to know about the Opta’s I/O Expansion Modules: Arduino ProOpta Ext D1608E and Arduino Pro Opta Ext D1608S multiply real-time control points with 16 programmable inputs and 8 digital (electromechanical or solid-state) relay outputs; Arduino Pro Opta Ext A0602 instead allows users to configure new analog I/O to interact with 0-10 V and 0/4-20 mA signals, and get temperature values through PT100, diversifying data acquisition capabilities and expanding actuation possibilities.
4. Learn more about ACE-100: a comprehensive training program designed to equip participants with the skills and knowledge needed for industrial and building automation using the Arduino Opta. Gain hands-on experience and practical insights into PLC programming, and earn your Arduino Certified Engineer credential!
5. Live demos featuring products from our ecosystem, from a manufacturing command and control platform developed with AWS Monitron and the Opta WiFi to a vibration-based anomaly detection solution powered by the Nicla Sense ME to… you’ll have to visit to discover how many different challenges can be solved with open-source!
Keep an eye out for Arduino even beyond the booth! Weintek USA (#5463) will showcase a joint Opta demo, part of a strategic partnership aimed at enhancing STEM HMI+PLC training programs across the United States.
So, whether you work in automation or are simply curious about the technology trends shaping your industry today, Automate Show is the fair for you!
Register to attend here, and visit the Arduino team at booth #2853 at McCormick Place in Chicago, from May 6th to 9th. Want to schedule some one-on-one time with our experts? Click here to schedule.
In the rapidly evolving landscape of industrial technology, three interesting trends are intertwining to streamline processes, improve efficiency, and reduce downtime. They are retrofitting, remote control/monitoring, and power metering – and together, they make for a great strategy to upgrade and improve existing machinery, reaping all the benefits of connected things and data analysis without the huge investment of completely new equipment.
Retrofitting industrial machinery Retrofitting industrial machinery involves updating existing equipment with modern technology to enhance functionality and performance. It allows businesses to extend the lifespan of their machinery while adapting to evolving industry standards and requirements.
Remote monitoring and control Remote monitoring and control enable businesses to oversee their operations from anywhere in the world. This capability not only improves operational efficiency but also facilitates proactive decision-making and troubleshooting, ultimately reducing costs and downtime.
Power metering Power metering entails tracking and analyzing energy consumption. By monitoring power usage, businesses can identify areas for optimization, reduce waste, and lower energy costs, contributing to sustainability efforts and improving their own bottom line at the same time.
Our latest demo showcases the seamless integration of these three crucial aspects into a single solution, using Arduino technology.
The demo in detail
We focused on retrofitting an injection molding machine – a common piece of industrial equipment – with advanced automation capabilities. By replacing the original controller with the Arduino Opta WiFi micro PLC, we transformed the machine into a connected device.
Now, integrating with the Arduino Cloud, users can monitor and control the injection molding machine remotely via intuitive dashboards. This connectivity allows for real-time oversight of production cycles, performance metrics, and equipment status from anywhere with an Internet connection.
Additionally, the Arduino Opta WiFi is equipped with RS485 communication capabilities, enabling seamless integration with an external power meter – in our case, a Finder model. This provides valuable insights into energy consumption, production output, material usage, and equipment health.
The collected data is then analyzed through dedicated dashboards, offering information about operational efficiency and potential issues. By leveraging this data, businesses can proactively schedule maintenance and repairs, minimizing downtime and optimizing production processes.
Retrofitting for a connected future
Many businesses today can retrofit existing machinery to embrace the benefits of connectivity and automation. Our demo provides a practical example of how common industrial equipment can become smarter, more efficient, and easier to manage. From remote monitoring and control to power metering and predictive maintenance, retrofitting offers a sustainable way to modernize industrial infrastructure.
Unlocking potential across industries
Moreover, the versatility of Arduino’s open-source ecosystem ensures that this solution can be adapted and applied to a wide range of existing machines and equipment, enhancing their operation effectively – whether in manufacturing, logistics, or any other industry relying on machinery.
To learn more about how you can leverage Arduino technology to upgrade your infrastructure and achieve tangible results, contact us today. Let us help you unlock the full potential of your industrial assets with practical, cost-effective solutions.
In a world where industrial automation is rapidly advancing, education often struggles to keep pace.
This disconnect leaves a big gap in practical, industry-relevant skills among graduates.
Addressing this critical need, we’re excited to introduce the Arduino PLC Starter Kit. Powered by the robust Arduino Opta mini PLC and backed by the intuitive Arduino PLC IDE, this kit is set to revolutionize programmable logic control education.
Continue reading to find out more about the PLC Starter Kit.
What is the Arduino PLC Starter Kit?
Before we delve into the details of this exciting new offering, let’s explain exactly what a PLC is. A Programmable Logic Controller (PLC) is a type of industrial computer that’s used to automate, control and coordinate a wide range of manufacturing processes and machinery.
The Arduino PLC Starter Kit isn’t just another educational tool; it’s a comprehensive solution designed to bridge the gap between theoretical knowledge and practical application in industrial automation — a powerful simulation tool specifically created for vocational and university students considering a career in manufacturing.
Here’s what this groundbreaking kit offers:
20 hours of in-depth lessons — Explore the world of programmable logic control with the ‘Explore PLC’ course. The course has been created by educators and covers all the essential contents including the history of programmable logic controllers, Modbus RS-485 communications, and how PLCs integrate with industrial simulated systems.
Arduino Opta WiFi — Built with industrial IoT capabilities, our versatile and easy-to-use micro PLC offers real-time control, monitoring, and predictive maintenance for a variety of applications. Based on the existing Arduino Opta WiFi, it includes the STM32H747XI dual-core Arm® Cortex®-M7 +M4 MCU, making it exceptionally reliable and robust for your classroom.
Digital input and output simulators – The kit’s custom-designed hardware helps bring learning to life by allowing users to replicate real-world situations. The input simulator (DIN Simul8) includes 8 switches and power control, while the output simulator (DIN Celsius) features a resistor array and a temperature sensor.
Arduino PLC IDE — Our popular programming tool, Arduino PLC IDE, makes programming simple. Choose from any of the five programming languages defined by the IEC 61131-3 standard (Ladder, Functional Block Diagram, Structured Text, Sequential Function Chart, or Instruction List) to quickly code a range of PLC applications
Arduino IDE 2 — Another benefit of the kit is that it can be programmed using our powerful IDE 2. A step up from the classic Arduino IDE, the Arduino IDE 2 offers increased performance, an improved user interface and other new features, such as autocompletion and a built-in debugger.
And let’s not forget that all the kit’s hardware is fully compatible with the Arduino Cloud.
Get industry-ready with real-life simulations
Thanks to their exceptional flexibility, programmable logic controllers are being used more and more frequently in a wide range of industries. From production plants, assembly lines and packaging machines to heating control systems, traffic lights and elevators, PLC applications are vast and varied.
To help students prepare for the demands of these competitive industries and the challenges they face, we believe they need access to high-quality PLC simulation tools. After all, there’s a big difference between reading about programming in a textbook and actually doing it. As Benjamin Franklin once famously said, “Tell me and I forget, teach me and I may remember, involve me and I learn”. And that’s where the PLC Starter Kit comes into play.
Boasting industrial IoT capabilities, the kit’s Opta WiFi mini PLC — together with the input and output simulators – allows students to design and implement programs that simulate real-life industrial automation projects.
Take a manufacturing production line, for instance. To prevent overheating and a potential fire, the equipment’s PLC might be programmed to shut down when the input sensor detects a high temperature. With the PLC Starter Kit, students can simulate a similar scenario and gain practical knowledge about how inputs and outputs interface with a PLC.
It’s a great way to promote a deeper understanding of industrial automation and system behavior, while giving students the hands-on experience and critical thinking skills they’ll need to tackle real-world challenges in their professional careers.
Try the Arduino PLC Starter Kit today
With its powerful industrial IoT capabilities, easy programming software and wealth of online content, the PLC Starter Kit is the perfect introduction to automated programming for students and educators.
Interested in using the PLC Starter Kit in your education setting? Order the PLC Starter Kit here or get in touch through your local distributor and discover how it can transform your learning environment.
Connecting machines and equipment to the internet became easier than ever when we launched the Arduino Opta micro PLC, enabling real-time control, monitoring, predictive maintenance and more – in industries ranging from smart agriculture to large-scale manufacturing to building automation.
Supporting our well-known Arduino sketch programming experience and any of the five IEC 61131-3 PLC standard languages, the Opta was designed to be powerful yet easy to use from the start – as well as highly secure. Indeed, the Opta supports OTA firmware updates and ensures data security from the hardware to the Cloud thanks to the physical onboard secure element and X.509 Standard compliance.
In addition, as part of the go-to-market for this innovative hardware solution, we actively committed to verifying its security against the threats posed by cyberattacks.
To this end, in late 2023 we started a collaboration with global cybersecurity provider HWG Sababa: their Offensive Team engaged in a penetration test that lasted weeks, assessing Opta’s security posture and pinpointing any weaknesses. Their meticulous report allowed us to remedy any vulnerabilities before they became actual issues, and now we are proud to say the Opta is more secure than ever.
The software patches and configuration updates we carried out are part of our ongoing commitment to providing you the most robust solutions on the market in every respect – including against ever-evolving cyber threats. The rigorous testing process and following activities our team completed only confirms Opta as an ideal candidate for any industrial automation project you have in mind.
We all know that one neighbor who always goes the extra mile when decorating for the holidays, and after taking inspiration from these large displays of light and sound, Marcelo Arredondo, Andres Sabas, and Andrea ZGuz of the Electronic Cats crew decided to build a smaller version for their Christmas tree using the Arduino Opta micro PLC.
The team chose to create their music-synchronized light show with the Opta because of its reliability and bank of four built-in relays that could be utilized to switch specific light strings on or off. Lining up and triggering certain lighting effects for the music was all handled through the open-source Vixen Lights software. In here, the Opta was configured as a quad-channel controller that receives its commands over a GPIO connection sent by an Arduino UNO mediator. The PLC is programmed visually to read a programmable input pin for each relay and then leverage a comparator to toggle the relay when the signal is high.
Back in the Vixen Light software, the team imported their favorite Christmas song and began the process of charting it. First, they generated markers over the audio waveform to signify the beats and overall tempo. Next, various effects were added to the timeline which trigger the lighting channels in a particular sequence. Lastly, the UNO was flashed with a sketch that allowed it to read the incoming Serial data from Vixen over USB and then toggle its digital outputs for the Opta to register.
Hospitality professionals are constantly looking for ways to offer guests an enhanced experience while improving operational efficiency and optimizing energy management. To achieve this, they require cost-effective solutions that are easy to install and maintain while also providing the scalability of future-ready systems – such as automating hotel rooms or B&B rentals to increase safety, comfort, and energy savings.
Indeed, automation can be integrated seamlessly in various aspects including climate control, lighting, security, and entertainment. Upgrading these functions allows guests to enjoy customization and convenience throughout their stay, and staff to efficiently manage room settings remotely. Moreover, hoteliers can achieve substantial energy savings through optimized control and scheduling, contributing to sustainability goals.
Long-term scalability and future-proofing of automation systems, however, can be an issue. As hotels and rental properties undergo renovations or expansions, the ideal solution should accommodate changes without requiring substantial modifications or replacements. Adopting open and standardized protocols, as well as selecting flexible and modular automation projects, can help mitigate these challenges and provide a foundation for future enhancements.
Our solution
A comprehensive IoT automation solution can address these challenges effectively by aggregating sensor and user data and then intelligently managing lighting, cooling/heating and more – for a smart, connected experience. The elements required to achieve this kind of outcome are environmental sensors, a programmable logic controller (PLC), a human-machine interface (HMI), and cloud connectivity.
Programmable logic controller (PLC)
PLC-based automation systems are widely used due to their reliability, flexibility, and ability to handle complex tasks. Arduino Pro’s Opta microPLC can serve as the central control unit for hotel room automation by connecting and monitoring various devices and subsystems such as HVAC (heating, ventilation, and air conditioning), lighting, and door locks. The microPLC receives data from sensors and users and processes them to trigger appropriate actions or adjustments in the room.
Human-machine interface (HMI)
A touchscreen panel through which guests and staff can control various room parameters – such as lighting status, fan status, and door lock status – provides a user-friendly and intuitive interface to interact with the automation system. This HMI also communicates data to the microPLC for execution.
The Modbus communication protocol
The HMI and Opta PLC communicate via Modbus RTU over RS-485. Modbus RTU communication protocol is widely adopted in industrial applications due to its reliability, provided by the physical layer strength and by the cyclic redundancy check included in the data packets. It allows for multiple devices to be connected to the same bus, forming a multidrop network where each device has a unique address, used to identify the recipient of the transmitted data. The Arduino Opta can communicate with other Modbus devices, such as sensors, actuators, or traditional PLCs, by addressing them individually.
IoT Cloud solution
Cloud connectivity enables seamless communication between the hotel room or rental property’s automation system and the central management system. The Opta and HMI connect to the cloud infrastructure, allowing remote access, monitoring, and control of multiple locations. The solution also enables data logging and analytics for better energy management, predictive maintenance, and guest experience personalization.
Solving it with Arduino Pro
Let’s get into the details of how this solution can be put into action, and identify the hardware and software resources needed for deployment. Arduino Opta is a great option for deploying building automation solutions, as it offers simple integration with current systems, real-time control capabilities, support for Over-The-Air (OTA) firmware updates, and hardware-to-cloud data security. The Arduino Pro ecosystem allows users to benefit from easy integration, along with a range of scalable, secure, and professionally supported services.
The Arduino IDE 2.0 can be used to program Opta using C/C++. Opta acts as the main controller, communicating with the HMI via the Modbus RTU protocol. The HMI gathers data from various sensors – including light, temperature and humidity, and PIR (movement sensor) – as well as user inputs from its interface buttons related to room climate, lights, and door lock status. It then forwards this data to Opta, which controls the relay outputs that will activate the lights, thermostat or door lock.
Opta also sends this data via Wi-Fi® to the Arduino IoT Cloud. After connecting it to the Arduino Cloud using the Arduino Create Agent, cloud variables corresponding to the sensor data being monitored can be defined.
Arduino Pro’s Opta microPLC offers an ideal solution for the automation of hotel rooms and B&Bs or rental properties. By leveraging standard communication protocols, easy integration, real-time control capabilities, secure hardware-to-cloud data exchange, and remote access to multiple rooms from a centralized location, Opta provides the cornerstone of a comprehensive platform for smart hospitality.
On June 26th-28th, the Arduino Pro team will be in Amsterdam for the tinyML EMEA Innovation Forum – one of the year’s major events for the world where AI models meet agile, low-power devices.
This is an exciting time for companies like Arduino and anyone interested in accelerating the adoption of tiny machine learning: technologies, products, and ideas are converging into a worldwide phenomenon with incredible potential – and countless applications already.
At the summit, our team will indeed present a selection of demos that leverage tinyML to create useful solutions in a variety of industries and contexts. For example, we will present:
A fan anomaly detection system based on the Nicla Sense ME. In this solution developed with SensiML, the Nicla module leverages its integrated accelerometer to constantly measure the vibrations generated by a computer fan. Thanks to a trained model, condition monitoring turns into anomaly detection – the system is able to determine whether the fan is on or off, notify users of any shocks, and even alert them if its super precise and efficient sensor detects sub-optimal airflow.
A vineyard pest monitoring system with the Nicla Vision and MKR WAN 1310. Machine vision works at the service of smart agriculture in this solution: even in the most remote field, a pheromone is used to attract insects inside a case lined with glue traps. The goal is not to capture all the insects, but to use a Nicla Vision module to take a snapshot of the captured bugs, recognize the ones that pose a real threat, and send updated data on how many specimens were found. New-generation farmers can thus schedule interventions against pests as soon as needed, before the insects get out of control and cause damage to the crops. Leveraging LoRa® connectivity, this application is both low-power and high-efficiency.
An energy monitoring-based anomaly detection solution for DC motors, with the Opta. This application developed with Edge Impulse leverages an Opta WiFi microPLC to easily implement industrial-level, real-time monitoring and fault detection – great to enable predictive maintenance, reducing downtime and overall costs. A Hall effect current sensor is attached in series with the supply line of the DC motor to acquire real-time data, which is then analyzed using ML algorithms to identify patterns and trends that might indicate faulty operation. The DC motor is expected to be in one of two statuses – ON or OFF – but different conditions can be simulated with the potentiometer. When unexpected electric consumption is shown, the Opta WiFi detects the anomaly and turns on a warning LED.
The Arduino Pro team is looking forward to meeting customers and partners in Amsterdam – championing open source, accessibility, and flexibility in industrial-grade solutions at the tinyML EMEA Innovation Forum!
Optimizing manufacturing processes is a requirement in any industry today, with electricity consumption in particular representing a major concern due to increased costs and instability. Analyzing energy use has therefore become a widespread need – and one that can also lead to early identification of anomalies and predictive maintenance: two important activities to put in place in order to minimize unexpected downtime and repair costs.
In particular, this approach can be applied to DC motors: used in a wide range of applications, from small household appliances to heavy industrial equipment; these motors are critical components that require regular maintenance to ensure optimal performance and longevity. Unfortunately, traditional maintenance practices based on fixed schedules or reactive repairs can be time-consuming, expensive, and unreliable. This is where energy monitoring-based anomaly detection comes in: it can provide a crucial solution for the early detection of potential issues and malfunctions before they can cause significant damage to the motor.
This more proactive approach to maintenance continuously monitors the energy consumption of the motor and analyzes the data to identify any deviations from normal operating conditions. By tracking energy usage patterns over time, the system can detect early warning signs of potential problems, such as excessive wear and tear, imbalances or misalignments, and alert maintenance personnel to take corrective actions before the issue escalates.
Our solution
This Arduino-powered solution implements an energy monitoring-based anomaly detection system using a current sensor and machine learning models running on edge devices. By capturing the electricity flowing in and out of a machine, it can collect large amounts of data on energy usage patterns over time. This data is then used to train a machine learning model capable of identifying anomalies in energy consumption behaviors and alerting operators to potential issues. The solution offers a cost-effective and scalable method for maintaining equipment health and maximizing energy efficiency, while also reducing downtime and maintenance costs.
Motor Current Signature Analysis (MCSA)
In this application, a technique called Motor Current Signature Analysis is used. MCSA involves monitoring the electrical signature of the motor’s current overtime to detect any anomalies that may indicate potential issues or faults. To acquire real-time data, a Hall effect current sensor is attached in series with the supply line of the DC motor. The data are then analyzed using machine learning algorithms to identify patterns and trends that might indicate a faulty motor operation. MCSA can be used to detect a number of issues like bearings wear, rotor bar bendings or even inter-turn short circuits.
Depending on the dimensions of the motor, using a non-invasive clamp-style current sensor – also known as a Split-Core Current Transformer – is recommended if a larger current draw is expected.
Edge ML
To monitor the current fluctuation and run the anomaly-detecting ML model, the solution uses anArduino Opta WiFi: a micro PLC suitable for Industrial IoT, which is excellent for this project because of its real-time data classification capabilities, based on a powerful STM32H747XI dual-core Cortex®-M7 +M4 MCU. The Arduino Opta WiFi works with both analog and digital inputs and outputs, allowing it to interact with a multitude of sensors and actuators. The Arduino Opta WiFi also features an Ethernet port, an RS485 half duplex connectivity interface and WiFi/Bluetooth® Low Energy connectivity, which makes it ideal for industrial retrofitting applications. You can find the full datasheet here.
To train the anomaly detection model, the project leverages the Edge Impulse platform: being integrated within the Arduino ecosystem, it makes it easy to develop, train, and deploy machine learning models on Arduino devices.
Connectivity
Once the machine learning model was successfully deployed on the Arduino Opta, the anomaly detection results were forwarded via WiFi to the Arduino IoT Cloud. This enables easy monitoring and analysis of the data from multiple sensor nodes in real time.
Solving it with Arduino Pro
Let’s take a look at how we can put all of this together and what hardware and software solutions we would need for deployment. The Arduino Pro ecosystem is the most recent version of Arduino solutions, offering users the benefits of easy integration along with a range of scalable, secure, and professionally supported services.
The Arduino IDE 2.0 was used to program the Arduino Opta WiFi using C/C++. To train the Edge Impulse model, data was gathered from the current sensor for two classes: Normal Operation and Machine Off. The Motor Current Signature Analysis (MCSA) technique was implemented by extracting the frequency and power characteristics of the signal through a Spectral Analysis block. Additionally, an anomaly detection block was incorporated to identify any abnormal patterns in the data.
Here is a screenshot from a dashboard created directly in the Arduino Cloud, showcasing data received from the sensor nodes:
Here is an overview of the software stack and how a minimum deployment with one of each hardware module communicates to fulfil the proposed solution:
Conclusion
Through the implementation of a predictive maintenance system on an Arduino Opta WiFi PLC, using Edge Impulse ML models and the Arduino Cloud, this solution demonstrates the powerful potential of IoT technologies in industrial applications. With the use of current sensors and AI-driven anomaly detection models, the system enables real-time monitoring and fault detection of DC motors, providing valuable insights for predictive maintenance. The flexibility and scalability of the Arduino Opta WiFi platform make it a robust and cost-effective solution for implementing predictive maintenance systems in various industrial processes. Overall, the project highlights the significant advantages that MCSA and machine learning can offer in promoting efficiency, productivity, and cost savings for industrial processes.
Mark your calendars: May 23rd-25th we’ll be at SPS Italia, one of the country’s leading fairs for smart, digital, sustainable industry and a great place to find out what’s new in automation worldwide. We expect a lot of buzz around AI for IoT applications – and, of course, we’ll come prepared to give our own, open-source perspective on the AIoT trend.
At Arduino Pro’s booth C012, pavilion 7, our experts will be presenting some of the latest additions to our ever-growing ecosystem, which includes everything companies need to fully embrace digital transformation with professional performance paired with Arduino’s ease of use and open-source philosophy. You can explore our complete digital brochure here, but let us point out some recent highlights.
Meet the Arduino Pro ecosystem at SPS Italia 2023
Over the years, Arduino Pro has built quite the presence on the market with SOMs like the Portenta H7 and X8, recently joined by the Portenta C33: a cost-effective, high-performance option that makes automation accessible to more users than ever, based on the RA6M5, an Arm® Cortex®-M33 microcontroller from Renesas.
Our Nicla family of ultra-compact boards also expanded: after Nicla Sense ME and Nicla Vision, Nicla Voice packs all the sensors, intelligence and connectivity you need for speech recognition on the edge, leveraging AI and ML.
What’s more, the Arduino ecosystem also includes turnkey solutions like the Portenta Machine Control and the new Opta, our very first microPLC, designed in partnership with Finder to support the Arduino programming experience with the main PLC standard languages – and available in 3 variants with different connectivity features: Opta Lite, Opta RS485, and Opta WiFi. Both the Portenta Machine Control and Opta can be programmed via the new PLC IDE, designed to help you boost production and build automation with your own Industry 4.0 control system.
Finally, since SPS Italy’s last edition we have launched Arduino Cloud for Business: a dedicated Cloud plan for professional users requiring advanced features for secure device management including OTA updates, user-friendly fleet management, and RBAC to safely share dashboards among multiple users and organizations. Specific optional add-ons allow you to further customize your solution with Portenta X8 Manager, LoRaWAN Device Manager or Enterprise Machine Learning Tool – accelerating your IoT success, whatever the scale of your enterprise may be.
Images from SPS Italy 2022
Team Arduino Pro at SPS Italy 2022
If you are attending SPS Italia, don’t miss the conference by our own Head of Arduino Pro Customer Success Andrea Richetta, joined by Product Managers Marta Barbero and Francesca Gentile (in Italian): on May 24th at 2:30pm they will dive deep on the tools Arduino Pro makes available for all companies ready to take part in the IoT revolution, with a unique combination of performance and ease of use. This is your chance to discover how you too can integrate safe and professional Industry 4.0 solutions in new or existing applications, quickly growing from prototype to large-scale production with sensors, machine vision, embedded machine learning, edge computing, and more.
Curious? Register to access the fair if you are an industry professional, and reach out to book a meeting with a member of our team.
We can finally tell you all about the new product we had announced for SPS! Today, we are excited to expand the Arduino Pro range with Opta, our first micro PLC with Industrial IoT capabilities.
We designed it specifically with PLC engineers in mind: supporting standard languages including LD (Ladder Logic Diagram) and FBD (Function Block Diagram), it allows professional users to scale up industrial and building automation projects leveraging our signature open-source, easy-to-use, anti-vendor-lock-in approach.
We partnered with none other than Finder — a leader in the field of mission-critical electromechanical and electronic components with 65+ years of excellence and expertise to its name — to create the most durable, reliable, secure and high-performance component possible, while still maintaining our signature flexibility and ease of deployment in production.
Through its onboard connectivity and machine learning capabilities, Opta opens up new opportunities for industrial automation within everyone’s reach: design, iterate and implement increasingly ambitious ideas for higher-quality manufacturing, increased efficiency, better productivity and profitability. If you agree with us that innovation is here to help us face every possible challenge, we look forward to seeing the solutions you create to work better with Opta!
Here is a taste of its tech specs:
High-performance computing. Its powerful STM32H747XI dual-core Cortex®-M7 +M4 MCU enables users to perform real-time operations and implement predictive maintenance capabilities.
Secure and durable by design. Opta supports OTA firmware updates and ensures data security from the hardware to the Cloud through M2M communication, thanks to the onboard secure element and X.509 Standard compliance.
Faster turnaround. Get to work quickly with Arduino’s ease of use, flexibility and extensive sketches, tutorials and software libraries.
Three configurations to suit any user’s needs. Opta is available in three variants with incremental features: Opta Lite with onboard Ethernet and USB-C programming ports, Opta RS485 which also adds RS485 half duplex connectivity interface, and Opta WiFi, the most versatile option, featuring also Wi-Fi/Bluetooth® Low Energy connectivity.
Ready to opt in to industrial automation? Whether you are interested in real-time control, monitoring or predictive maintenance applications, find out more about Opta on our website’s dedicated page.
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