Performance Evaluation of Computer Vision Algorithms in a Programmable Logic Controller: An Industrial Case Study

Abstract

This work evaluates the use of a programmable logic controller (PLC) from Phoenix Contact’s PLCnext ecosystem as an image processing platform. PLCnext controllers provide the functions of “classical” industrial controllers, but they are based on the Linux operating system, also allowing for the use of software tools usually associated with computers. Visual processing applications in the Python programming language using the OpenCV library are implemented in the PLC using this feature. This research is focused on evaluating the use of this PLC as an image processing platform, particularly for industrial machine vision applications. The methodology is based on comparing the PLC’s performance against a computer using standard image processing algorithms. In addition, a demonstration application based on a real-world scenario for quality control by visual inspection is presented. It is concluded that despite significant limitations in processing power, the simultaneous use of the PLC as an industrial controller and image processing platform is feasible for applications of low complexity and undemanding cycle times, providing valuable insights and benchmarks for the scientific community interested in the convergence of industrial automation and computer vision technologies.