BL190 Practical Project: Smart Factory Production Line Equipment Monitoring & Control

Project Core Configuration

• Core Device: BL190 Modbus TCP edge I/O module (built-in 2 Ethernet ports, 1 RS485 interface, 2 I/O expansion slots, Linux system with 300MHz CPU)
• Expansion Modules:
  • Y31 (4-channel AI module): Collects 4~20mA analog signals from temperature/pressure sensors on the production line
  • Y13 (8-channel dry contact DI module): Captures equipment running status (e.g., conveyor start/stop, fault alarms)
  • Y24 (4-channel relay DO module): Controls high-power equipment (e.g., conveyor motors, cooling fans)
• Terminal Devices: 4 temperature sensors (4~20mA), 6 equipment fault dry contact switches, 3 conveyor motor relays, 2 cooling fan relays
• Upper-Layer System: Factory central PLC (supports Modbus TCP client protocol)
• Auxiliary Equipment: DIN35 rail mounts, 24VDC power supply, STP Cat 5 Ethernet cables, RS485 terminal blocks

Clear Project Process

1. Hardware Connection

• Power Supply Deployment: Connect the 24VDC power supply to BL190’s power terminal, ensuring correct polarity (BL190 supports reverse connection protection to avoid wiring errors). Install the power supply in the production line control cabinet, separating power lines from signal lines to reduce interference.
• AI Module (Y31) Connection: Mount 4 temperature sensors on key equipment (stamping machines, conveyors). Connect the sensor’s 4~20mA output terminals to Y31’s AI1~AI4 channels: sensor positive (+) to AI+ terminal, negative (-) to AI- terminal. Use shielded cables (AWG18) with a maximum length of 20m to resist electromagnetic interference from production line motors.
• DI Module (Y13) Connection: Link 6 equipment fault dry contact switches to Y13’s DI1~DI6 channels: each switch’s normally open contact to the DI channel terminal, and the COM terminal to the switch’s common ground. When equipment malfunctions, the switch closes to send an alarm signal.
• Relay DO Module (Y24) Connection: Insert Y24 into BL190’s second expansion slot. Wire Y24’s AO1~AO3 relay output terminals to the conveyor motor relays, and AO4 to the cooling fan relay: AO+ to the relay coil positive, AO- to the 220VAC neutral line (matching the motor’s voltage requirements).
• BL190 Core Connections: Insert Y31 and Y13 into BL190’s two expansion slots, fasten with screws to ensure reliable pin contact. Connect BL190’s Ethernet Port 1 to the factory industrial switch via STP Cat 5 cable, and the switch is connected to the central PLC (network segment: 192.168.1.0/24, BL190 static IP: 192.168.1.120). Reserve BL190’s built-in RS485 interface for future connection of intelligent energy meters.

2. Parameter Configuration 

• I/O Channel Configuration: In the Web interface, set Y31’s AI channels to 4~20mA input type, enable 16-bit resolution. Configure Y13’s DI channels to dry contact input (closed = alarm triggered). Set Y24’s relay output mode to "normally open" to match the motor control logic.
• Logic Control Setup: Use BL190’s built-in logic control function (via Web server’s "Calculation and Control" page) to set simple interlocks: when the temperature sensor (Y31 AI1) detects a value exceeding 60℃, automatically trigger Y24 AO4 to turn on the cooling fan; when the fault switch (Y13 DI1) is closed, trigger the PLC alarm and stop the corresponding conveyor via Y24 AO1.

3. Data Flow & Control Logic

• Data Collection: Y31 converts the 4~20mA analog signals from temperature sensors into digital data with ±0.1% FSR accuracy. Y13 captures the dry contact status of fault switches and transmits it to BL190 via the internal bus.
• Data Upload: BL190 unifies the heterogeneous data (analog signals, digital status) into Modbus TCP standard data, then transmits it to the central PLC via Ethernet Port 1. The PLC displays real-time equipment status on the monitoring dashboard, with abnormal thresholds set for timely alerts.
• Control Execution: When the PLC detects abnormal temperature or a fault signal, it sends a Modbus TCP control command to BL190. BL191 activates the corresponding Y24 relay output to control the motor or cooling fan, realizing automatic adjustment and fault handling without manual intervention.

4. Remote Maintenance 

• BLRAT Remote Access: The factory’s technical team installs the BLRAT tool on an off-site PC, enters BL190’s unique token (generated via the Web server), and establishes a remote connection through the BLIoT cloud server—no need for on-site visits during off-hours.
• Status Monitoring & Troubleshooting: Remotely view real-time data of Y31/Y13/Y24 channels via the Web server, check system logs to locate abnormal sensors or communication failures. If a temperature sensor’s data is unstable, remotely calibrate Y31’s AI channel or adjust the sampling interval.
• Firmware & Configuration Management: Periodically back up BL190’s configuration parameters and logic programs via the Web server. When a new firmware version is released, upload the .bin file via BLRAT for remote upgrade (supports breakpoint resumption to avoid upgrade failures).

Project Outcomes

• Simplified System Architecture: BL190’s native Modbus TCP protocol directly connects terminal devices to the central PLC, eliminating intermediate protocol converters and reducing the production line’s control system complexity by 35%.
• Efficient Operation & Maintenance: Remote monitoring and maintenance reduce on-site workload by 60%—the technical team no longer needs to patrol the production line to check equipment status, cutting labor costs significantly.
• Stable & Reliable Operation: BL190’s industrial-grade design (-40~85℃ wide temperature, IP30 protection, EMC Level 3 certification) ensures 7×24 stable operation in the dusty, vibrating factory environment, with zero downtime over 8 months.
• Flexible Scalability: The reserved expansion slot and RS485 interface allow the factory to later add energy meters and pressure sensors, extending the system to energy consumption monitoring without replacing the core module.