Design and Performance Analysis of LoRa-Enable IoT Architecture for PLC-Base Industrial Automation

Abstract

Industrial automation systems traditionally rely on wired communication networks for reliability, deterministic control, and high-speed data exchange. However, the increasing demand for scalable, cost-effective, and remotely accessible industrial monitoring has accelerated the adoption of Internet of Things (IoT) technologies. This paper presents the design and performance analysis of a LoRa-enabled IoT architecture integrated with PLC-based industrial automation systems. The proposed architecture combines conventional Programmable Logic Controllers (PLCs) with Long Range (LoRa) wireless communication technology to enable low-power, long-distance, and secure data transmission for industrial monitoring and supervisory control applications. The system architecture includes PLCs for real-time control, LoRa end nodes for wireless data acquisition, and a centralized IoT cloud platform for remote visualization and analytics. Performance parameters such as communication range, latency, packet delivery ratio, power consumption, and network scalability are evaluated under industrial environmental conditions. Experimental results demonstrate that LoRa communication provides reliable long-range connectivity with minimal infrastructure cost while maintaining acceptable latency for non-time-critical industrial applications. The proposed architecture enhances flexibility, reduces wiring complexity, and supports predictive maintenance strategies, making it suitable for smart manufacturing and Industry 4.0 environments.

Introduction

This project presents a hybrid PLC–IoT industrial automation system that integrates Delta DVP-SS2 Programmable Logic Controllers (PLCs) with LoRa (Long Range) wireless communication to support Industry 4.0 applications. Traditional PLC-based automation systems provide reliable, deterministic, and real-time control but rely on wired communication protocols such as RS-485 and Modbus RTU, which increase installation costs and limit scalability. By incorporating LoRa technology, the proposed system enables long-range, low-power wireless monitoring while maintaining the reliability of local PLC control.

The system consists of four functional layers: a power layer using a 24V SMPS, a control layer based on the Delta DVP-SS2 PLC, an actuation layer using a 4-channel relay module, and a communication and monitoring layer comprising a LoRa module and a Delta DOP-B07S411 Human Machine Interface (HMI). The PLC performs logical decision-making, relay control, and serial communication, while the HMI provides real-time visualization, status monitoring, and manual control. The LoRa module communicates with the PLC through RS-485 and wirelessly transmits system data to a remote gateway or monitoring station.

The literature review highlights the increasing adoption of Industrial Internet of Things (IIoT) technologies for decentralized automation. Previous automation systems commonly relied on Wi-Fi or GSM communication, which suffer from limited range and high power consumption. LoRa offers significant advantages for industrial environments, including communication over distances of up to several kilometers, low energy consumption, and improved interference resistance, making it suitable for remote monitoring, agricultural automation, warehouse management, and distributed industrial control.

The implementation methodology includes hardware integration, PLC programming, communication configuration, and performance evaluation. The PLC is programmed using ladder logic in WPLSoft, while the HMI interface is designed in DOPSoft using the Modbus RTU protocol. The relay module controls industrial devices such as motors, lamps, alarms, and other electrical loads. All components are housed within a properly grounded industrial enclosure featuring DIN rail mounting, cable management, ventilation, and external antenna support to ensure safety, reliability, and ease of maintenance.

During operation, sensors and input devices provide data to the PLC, which executes control logic and activates relay outputs based on programmed conditions. System parameters are stored in PLC registers and transmitted via RS-485 to the LoRa module, which wirelessly forwards the data to a remote monitoring station. The HMI simultaneously displays system status and allows local supervisory control.

Experimental evaluation demonstrated strong system performance. The LoRa communication achieved a stable transmission range of 3 km, an average latency of 1.8 seconds, power consumption of 65 mA during active transmission, and 98.4% relay switching accuracy over 500 test cycles, with only 0.8% data loss. These results confirm that LoRa is suitable for non-time-critical industrial monitoring applications while the PLC continues to handle deterministic real-time control.

Conclusion

This project presented the design and performance analysis of a LoRa-enabled IoT architecture integrated with a PLC-based industrial automation system. The proposed system successfully combines deterministic local control using the Delta DVP-SS2 PLC with long-range wireless communication through the USR-LG206-H-P LoRa module. The Delta DOP-B07S411 Series HMI provides real-time local monitoring and manual supervisory control, while the 4-channel relay module enables safe switching of industrial loads.

References

[1] Performance assessment of a Low-Power Wide-Area wireless network based on LoRa technology using IoT devices in different Bolivia areas Eynar Calle Viles;Edgar Roberto Ramos Silvestre;Elias Brayan Choque Maydana;Wilder Orellana Lopez;Cristian Capriles Olivera 2024 IEEE Eighth Ecuador Technical Chapters Meeting (ETCM) [2] Premalatha Gurumurthy et al., IoT-based Automation System for Household Appliances, IEEE ICAECA, 2025. [3] Deployment of a LoRa-based Network and Web Monitoring Application for a Smart Farm Mohamed Saban;Otman Aghzout;Alfredo Rosado-Muñoz 2022 IEEE.

Copyright

Copyright © 2026 Shashikant V. Golande, Mukesh K. Meshram, Tushar D. Sontakke, Buddhabushan R. Sable, Abhijit V. Jagtap. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.