Deep Dive into OpenPLC: Understanding the Underlying Scripts and Performance Optimization

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Francesco Manghi’s exploration into the OpenPLC project reveals critical insights into its internal workings, focusing on script analysis and performance optimization—particularly on Raspberry Pi with a PREEMPT Linux Kernel. His upcoming Udemy course promises an in-depth look at OpenPLC’s architecture, customization, and real-time capabilities.

Key Findings:

  • PREEMPT Kernel Performance: Tests on Raspberry Pi 3 Model B with Linux Kernel 6.12.25 show improved real-time task handling.
  • OpenPLC Customization: The course will cover modifying OpenPLC scripts to adapt the system for specific industrial needs.

You Should Know: Practical OpenPLC & Linux Commands

1. Install OpenPLC on Linux

git clone https://github.com/thiagoralves/OpenPLC_v3.git 
cd OpenPLC_v3 
./install.sh linux

2. Enable PREEMPT Kernel on Raspberry Pi

sudo apt update 
sudo apt install raspberrypi-kernel-headers 
sudo rpi-update

Edit `/boot/cmdline.txt` to add:

preempt=full

3. CPU Pinning & Isolation for Real-Time Performance

 Isolate CPU Core 3 for OpenPLC 
sudo nano /etc/default/grub

Add:

GRUB_CMDLINE_LINUX_DEFAULT="isolcpus=3"

Update GRUB:

sudo update-grub

4. Lock OpenPLC Memory to RAM (Prevent Swap)

Apply Davide Nardella’s patch:

sudo sysctl -w vm.swappiness=0 
sudo systemctl disable swap.target

5. Monitor Latency

Use `cyclictest` to measure real-time performance:

sudo apt install rt-tests 
cyclictest -t1 -p80 -n -i 10000 -l 10000

What Undercode Say

OpenPLC’s flexibility makes it a powerful tool for industrial automation, but optimizing it requires Linux kernel tweaks and hardware-level adjustments. The PREEMRT patch, CPU isolation, and memory locking significantly enhance real-time performance. Future developments may integrate AI-driven predictive maintenance and containerized PLC deployments (e.g., Docker/Kubernetes).

Expected Output:

  • Lower latency (sub-millisecond) for SoftPLC operations.
  • Stable performance under high-load industrial environments.
  • Customizable PLC logic via OpenPLC’s Python/C++ scripting.

Prediction

As edge computing grows, OpenPLC could merge with AI-based anomaly detection (e.g., TensorFlow Lite on Raspberry Pi) for smarter industrial automation.

Relevant URLs:

References:

Reported By: Francesco Manghi – Hackers Feeds
Extra Hub: Undercode MoN
Basic Verification: Pass ✅

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