Design of an Open-Source SCADA System for a Three-Machine Production Line Using OpenPLC and FUXA

Abstract

The implementation of Supervisory Control and Data Acquisition (SCADA) systems in industrial environments is often constrained by the high cost of proprietary software licenses. This study proposes the design and implementation of an open-source SCADA system utilizing OpenPLC as the programmable logic controller and FUXA as a web-based Human–Machine Interface (HMI) platform. The proposed system is applied to a simulated production line consisting of one conveyor unit and three robotic units. To reduce electrical load surges during system startup, a sequential activation mechanism with a 5-second interval between machines is implemented using timer-based ladder logic. Data communication between the control layer and the monitoring interface is established through the Modbus TCP protocol with precise register address mapping between OpenPLC and FUXA. Experimental results demonstrate that the system successfully performs real-time monitoring of total power consumption, reaching 980 W under full-load conditions, while maintaining stable network communication. Additionally, the system provides remote operational control features, including Emergency Stop (E-Stop) and Restart functions, ensuring operational safety and system reliability. The findings indicate that the proposed open-source SCADA solution provides a cost-effective and flexible alternative suitable for educational environments, laboratory-scale automation systems, and small-scale industrial applications.