Can Raspberry Pi Replace PLCs? A New Era of Industrial Control
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阅读时间 6 min
Introduction
Industrial automation has long relied on Programmable Logic Controllers (PLCs) —rugged, reliable, and purpose-built systems designed to operate in harsh environments. But in recent years, Raspberry Pi and other single-board computers (SBCs) have emerged as powerful, flexible, and affordable alternatives, raising the question: Can SBCs replace PLCs in modern industrial applications?
Let’s compare these two technologies and explore how SBCs are reshaping the landscape of industrial electronics.
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Table of Content
PLC vs PC: Which is Better for Industrial Automation
How Single Board Computers Are Shaping the Future of Industrial Automation
1. Performance and Flexibility
PLCs:
Designed for real-time, deterministic control
Limited processing power, optimized for specific I/O operations
Programmed using ladder logic, function block diagrams, or structured text
Raspberry Pi / SBCs:
Feature-rich CPUs with multicore processing
Capable of running full operating systems (Linux, Windows IoT)
Support Python, C++, Node-RED, and open-source control frameworks like OpenPLC
✅ Advantage: SBCs offer broader programming flexibility and higher processing power at a fraction of the cost.
Pros and Cons: Raspberry Pi vs PLCs
While Raspberry Pi and other SBCs offer compelling features, they also come with limitations. Here's a side-by-side comparison of the key pros and cons of each approach:
🟢 Raspberry Pi / SBCs – Pros
✅ Cost-Effective : Low entry price, scalable with inexpensive accessories.
✅ Programming Flexibility : Supports modern languages like Python, C++, and Node-RED.
✅ Connectivity : Native support for Ethernet, Wi-Fi, Bluetooth, and USB.
✅ Open Source Ecosystem : No vendor lock-in; access to a global developer community.
✅ IIoT-Ready : Seamless integration with cloud platforms and smart sensors.
🟢 PLCs – Pros
✅ Industrial-Grade Durability : Engineered for harsh, high-vibration environments.
✅ Reliable Uptime : Designed for 24/7 operation in mission-critical systems.
✅ Deterministic Control : Optimized for real-time I/O handling.
✅ Long-Term Support : Vendor-backed updates, spares, and lifecycle planning.
🔴 Raspberry Pi / SBCs – Cons
⚠️ Not Rugged by Default : Needs added protection for industrial environments.
⚠️ Power Instability : Susceptible to brownouts or power interruptions without UPS.
⚠️ Limited Real-Time Control : Lacks native deterministic timing for time-critical tasks.
⚠️ Shorter Lifecycle : Consumer-grade hardware with limited support cycles.
🔴 PLCs – Cons
⚠️ High Cost : Expensive initial investment and expansion modules.
⚠️ Limited Programming : Mostly relies on legacy languages and proprietary environments.
⚠️ Connectivity Gaps : Requires extra modules for cloud or wireless integration.
⚠️ Vendor Lock-In : Often tied to specific ecosystems and licensing structures.
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2. Connectivity and Integration
PLCs:
Offer industrial-grade protocols like Modbus, Profinet, EtherNet/IP
Require additional modules for wireless or cloud integration
SBCs:
Native support for Ethernet, Wi-Fi, Bluetooth, and USB
Easily connect to cloud platforms (AWS, Azure, MQTT brokers)
Seamless integration with IIoT sensors and devices
✅ Advantage: SBCs excel in connected environments and Industry 4.0 applications.
Further Readings
→ The Official Raspberry Pi Beginners
→ Getting Started with Arduino: The Open Source Electronics Prototyping Platform
"To improve is to change, to be perfect is to change often"
3. Cost and Scalability
PLCs:
Cost can range from hundreds to thousands of dollars per unit
Expansion modules add to the price and footprint
Locked into vendor-specific ecosystems
SBCs:
Raspberry Pi starts under $100
Easily scalable with USB-based or GPIO-based I/O boards
Use open-source software and standard programming languages
✅ Advantage: SBCs enable rapid prototyping and low-cost deployment for small to mid-size automation systems.
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4. Reliability and Industrial Readiness
PLCs:
Built for 24/7 uptime in harsh environments (temperature, vibration, dust)
Long support cycles and proven track record in mission-critical systems
SBCs:
Not designed for industrial abuse out of the box
Require protective enclosures, industrial-grade power supplies, and watchdog timers
Reliability depends on software stability and environmental safeguards
✅ Advantage: PLCs remain unmatched in extreme industrial conditions, but SBCs can be hardened with proper engineering.
5. Use Cases in Industry
PLCs Are Best For:
Assembly line control
Safety-critical systems
High-reliability applications
SBCs Excel In:
Data acquisition and monitoring
Edge computing and IIoT gateways
Low-cost control for non-critical systems
Prototyping and retrofitting legacy systems
"I have not failed. I've just found 10,000 ways that won't work."
Further Readings
→ Programmable Logic Controllers
by Frank Petruzella
"When one door closes, another opens; but we so often look so long and so regretfully upon the closed door, that we do not see the ones which open for us".
Final Verdict: Complement, Not Replace—Yet
While Raspberry Pi and other SBCs won’t fully replace PLCs in the near future, they are becoming valuable complements in industrial environments. Their affordability, flexibility, and connectivity make them ideal for bridging the gap between legacy equipment and modern smart systems.
At EcoTech Solutions, we help businesses explore hybrid automation strategies—leveraging both traditional PLCs and cutting-edge SBCs to optimize performance and lower costs. If you're looking to modernize your plant with intelligent controls and industrial IoT integration, we’re ready to help you take the next step.
📞 Let’s Talk Automation
Whether you’re exploring edge computing, retrofitting legacy systems, or developing a custom SBC-based solution—EcoTech Solutions offers consultation, sourcing, and design support tailored to your industry needs.
#EcoTechSolutions #IndustrialAutomation #RaspberryPi #SmartFactory #PLCvSBC #EdgeComputing #IIoT #Industry40 #ControlSystems #AutomationEngineering
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The Author: Joshua D Jeter
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That’s what I’ve always tried to follow throughout my 13 years as an entrepreneur, business lead, innovator, marketing expert, and an engineering pro. For me, recognizing opportunities is as critical as taking advantage of them, and I possess a natural ability to convert business opportunities into tangible profit and sustainable growth.
My approach on tackling intricate challenges sets me apart, as I leverage my technical proficiency to identify and address critical business needs. I take pride in my capacity to design and execute successful projects that align with business objectives, simultaneously developing innovative strategic solutions that pave the way for organizational success.
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Frequently Asked Questions
Can Raspberry Pi fully replace a PLC in industrial automation?
Not entirely. While Raspberry Pi and other SBCs are excellent for data collection, edge computing, and low-risk automation, PLCs are still superior in high-reliability and safety-critical applications due to their ruggedness and deterministic control.
What industries are using Raspberry Pi for automation?
Raspberry Pi is being used in manufacturing , agriculture , energy , and facility management —mainly for monitoring systems, IIoT gateways, custom HMIs, and non-critical process control.
How can I make a Raspberry Pi more reliable for industrial use?
To harden a Raspberry Pi for industrial settings:
Use industrial enclosures and DIN rail mounts
Add a UPS or regulated power supply
Enable watchdog timers
Use industrial-grade SD cards or SSDs
Implement redundant software checks and remote monitoring
What kind of software can I use to program a Raspberry Pi for automation?
You can use Python, C++, Node-RED, or open-source PLC platforms like OpenPLC. Raspberry Pi also supports full operating systems like Linux, enabling integration with cloud services and APIs.
What are the biggest risks of using SBCs in industrial automation?
Lack of ruggedness for harsh environments
Susceptibility to power loss or SD card corruption
No native real-time, deterministic control without software tweaks
Shorter lifecycle support compared to PLCs
Can I use Raspberry Pi with traditional PLC hardware?
Yes! Many integrators use Raspberry Pi as a front-end system for data logging, HMI display, or IIoT gateway functionality, while retaining PLCs for core control. It's a great hybrid strategy.
Are there industrial-grade SBCs available?
Yes. Companies like OnLogic, Siemens (IOT2040), and others offer ruggedized single-board computers or Raspberry Pi-based platforms with extended temperature ratings, DIN rail mounts, and industrial certifications.
Is it possible to scale an SBC-based system across an entire plant?
For non-critical applications, yes. SBCs can be cost-effective and scalable when used for monitoring, edge computing, or interfacing with legacy equipment. For core control systems, traditional PLCs remain more reliable at scale—at least for now.
How can EcoTech Solutions help with SBC integration?
EcoTech Solutions provides:
SBC hardware sourcing
Custom automation design support
IIoT and edge computing integration
Hybrid system consultation (SBC + PLC)
Prototyping, repair, and ongoing support