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  • https://doi.org/10.1109/access.2026.3674238Copy DOI Icon

An Open-Source, Low-Cost PLC Framework with FBD-Based Graphical Programming

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Abstract

Traditional programmable logic controllers (PLCs) remain central to industrial automation but are often expensive due to stringent compliance requirements. To address this challenge, this work proposes a low-cost and customizable framework for automation systems built upon open-source hardware and software components. The proposed solution integrates Linux-capable boards with an intermediate hardware module for input/output (I/O) management. A graphical user interface (GUI) based on the function block diagram (FBD) paradigm enables intuitive, visual logic programming, making the system accessible to users with different levels of expertise. Control logic is executed dynamically using a directed acyclic graph approach, which facilitates flexible processing and supports real-time updates without interrupting operation. The open-source design promotes flexibility and customization, positioning the framework as a versatile alternative to traditional PLCs. It is particularly suited for research laboratories, educational environments, small-scale industrial automation, and other cost-sensitive applications. Two case studies demonstrate its effectiveness in real-time control tasks, highlighting its practicality and ease of use. Given its open and modular nature, the framework is intended for educational use, research laboratories, and non-critical automation scenarios.

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