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Industrial
Programmable Logic Controllers
FPGAs support deterministic I/O expansion and functional-safety development in modern PLCs.
Consolidating Industrial Control
A programmable logic controller (PLC) is an industrial computer that monitors and controls automation processes in real time, often in demanding factory environments.
As Industry 4.0 connects PLCs to edge platforms, FPGAs can add deterministic parallel I/O, industrial networking, fieldbus connectivity, diagnostics, and functional-safety development support.
The Challenges, and Why FPGA
The Challenge
Closed, Domain-Specific Systems
Legacy PLCs can be difficult to adapt when control, networking, and edge workloads must converge.
Why FPGA
Workload Consolidation
FPGAs can combine PLC functions with networking and edge workloads in a programmable platform.
The Challenge
Deterministic I/O Expansion
PLCs need low-latency, predictable I/O processing for sensors, actuators, and control loops.
Why FPGA
Industrial Ethernet and Fieldbus
Programmable logic can implement parallel I/O and protocol functions with predictable timing.
The Challenge
Safety-Critical Requirements
Safety-relevant PLC designs require documented devices, tools, diagnostics, and development processes.
Why FPGA
Functional-Safety Support
Applicable Altera devices, tools, IP, and FSDP collateral can help organize safety-related development.
Why Altera
I/O Expansion and Fieldbus IP
IP and programmable logic support industrial Ethernet, TSN, and fieldbus designs.
Functional-Safety Support
Applicable devices, tools, IP, and FSDP collateral support safety-related development.
Deterministic Parallel Computing
Parallel data paths help meet predictable PLC I/O and control-loop timing requirements.
Workload Consolidation
Combine PLC, networking, and selected edge functions in a programmable device.
Get Started
More Industrial Applications
Machine Vision and AI
Build custom image-processing and selected edge-inference pipelines.
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Semiconductor manufacturing equipment
Support precision control and inspection data processing.
Smart Energy
Enable intelligent energy systems with real-time monitoring, efficient power management, and adaptable FPGA solutions for modern smart grids.
Common Questions
OpenPLC executes supported PLC program logic in a software runtime. FPGA hardware can implement interfaces, timing-sensitive I/O and acceleration around that runtime; the architecture must specify where each function executes.
Use FPGA I/O expansion when channel count, custom interfaces or coordinated timing justify integration. Compare electrical isolation, diagnostics, device resources and total board cost with external-controller options.
Define the supported runtime's variable mapping and the hardware register or driver interface explicitly. Validate data types, update boundaries and safe output states so the program's scan behavior matches the physical I/O semantics.
PLC scan time covers the software execution and update cycle, while FPGA interface latency covers a specific hardware transfer or processing path. Measure both, including synchronization between them, to establish the application's response deadline.
Record scan execution, I/O transfer timestamps, queue occupancy and fieldbus timing while varying traffic. Check driver blocking and shared-resource contention before treating the PLC program logic as the source of the timing fault.
Extend it only after defining the machine's safety functions and required assurance process. Separate ordinary PLC control from the required safety path and verify the full hardware, software and diagnostic behavior for the application.