Design and Implementation of a Prototype Industrial IIoT Monitoring and Control System Using Siemens PLC and Open-Source Software

Abstract

The Fourth Industrial Revolution has positioned digitalization and data analytics as pillars of competitiveness; however, the adoption of Supervisory Control and Data Acquisition (SCADA) systems is often limited by the high costs and rigidity of proprietary solutions. This article addresses this issue through the design and implementation of a prototype supervisory and control system based on the Industrial Internet of Things (IIoT), integrating the robustness of a Siemens S7-1200 Programmable Logic Controller (PLC) with the flexibility and zero licensing cost of an open-source software stack. The methodology focused on building a physical industrial control panel and developing a SCADA interface using Node-RED as the central orchestrator. The results demonstrated successful bidirectional communication with the PLC, enabling real-time monitoring of variables and reliable execution of remote-control commands.