Exploring CODESYS Runtime Toolkit for IoT-enabled Industrial Automation

Exploring CODESYS Runtime Toolkit for IoT-enabled Industrial Automation

The CODESYS Runtime Toolkit is a powerful software solution designed for industrial automation systems. It serves as a runtime environment that enables the execution and management of control applications developed using the CODESYS development system. With CODESYS Runtime Toolkit, industrial automation professionals can deploy and run applications on various hardware platforms and operating systems.

Its significance lies in its ability to provide a robust and flexible framework for controlling and monitoring industrial processes. It allows seamless integration of different devices and systems, enabling efficient communication and interoperability. Moreover, the link between IoT and industrial automation is becoming increasingly important. By incorporating IoT devices and sensors into industrial environments, CODESYS Runtime Toolkit facilitates the collection and analysis of real-time data. This integration enables advanced capabilities such as predictive maintenance, optimised energy management, and enhanced overall efficiency in industrial automation systems.

Table of Content:

  1. IoT-enabled Industrial Automation
  2. Overview of CODESYS Runtime Toolkit
  3. CODESYS Runtime Toolkit Applications
  4. Best Practices for Successful Integration in IoT-enabled Industrial Automation
  5. Conclusion

IoT-enabled Industrial Automation

IoT-enabled industrial automation refers to the integration of Internet of Things (IoT) devices and sensors into industrial environments to enhance automation processes and improve operational efficiency. By connecting various physical devices and assets, such as machinery, sensors, actuators, and controllers, to the internet, IoT enables seamless communication, data exchange, and intelligent decision-making in industrial settings.

The benefits of IoT-enabled industrial automation are numerous. Firstly, it enables enhanced monitoring and control capabilities, providing real-time visibility into industrial processes. This visibility allows for proactive maintenance, reduced downtime, and optimised resource utilisation.

Secondly, IoT integration enables remote monitoring and management of industrial systems, providing flexibility and convenience for operators and maintenance personnel. Lastly, it facilitates the implementation of predictive maintenance strategies, where IoT devices collect data and trigger alerts or maintenance actions based on predefined thresholds or patterns, thus reducing equipment failures and unplanned downtime.

The integration of IoT devices and sensors in industrial environments is a key aspect of IoT-enabled industrial automation. These devices and sensors are strategically placed throughout the industrial infrastructure to capture data related to process variables, environmental conditions, equipment performance, energy consumption, and more. They collect and transmit this data to a centralised system, such as the CODESYS Runtime Toolkit, for real-time processing and analysis.

Real-time data processing and analytics play a crucial role in IoT-enabled industrial automation. The collected data is processed and analysed in real-time to derive meaningful insights and actionable intelligence. This allows for immediate response to changing conditions, faster decision-making, and the ability to optimise industrial processes on-the-fly.

Real-time data analytics can uncover patterns, anomalies, and trends, enabling predictive and prescriptive analytics for improved operational efficiency, quality control, and cost savings. Ultimately, the integration of IoT devices and the role of real-time data processing empower industrial automation systems to operate more intelligently, adaptively, and efficiently in dynamic environments.

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Overview of CODESYS Runtime Toolkit

CODESYS Runtime Toolkit offers a range of features and capabilities that make it a versatile and powerful tool for industrial automation:

1. Execution Environment: The toolkit provides a robust runtime environment where control applications developed using the CODESYS development system can be executed. It ensures reliable and efficient execution of automation logic and facilitates real-time control of industrial processes.

2. Device Integration: CODESYS Runtime Toolkit enables seamless integration with a wide range of hardware platforms, including programmable logic controllers (PLCs), industrial PCs, embedded systems, and more. This compatibility allows users to select the most suitable hardware for their specific industrial automation requirements.

3. Operating System Compatibility: The toolkit is designed to be compatible with various operating systems, including Windows, Linux, and real-time operating systems (RTOS) like VxWorks. This flexibility allows users to deploy their control applications on the operating system that best fits their needs.

4. Support for Multiple Programming Languages: CODESYS Runtime Toolkit supports multiple programming languages, including IEC 61131-3 standard languages such as ladder diagram (LD), function block diagram (FBD), structured text (ST), and sequential function chart (SFC). This broad language support enables developers to choose their preferred programming language for application development and maintenance.

5. Communication and Connectivity: The toolkit provides extensive communication capabilities, allowing seamless integration with various industrial communication protocols such as OPC UA, Modbus, Ethernet/IP, and more. This enables communication with a wide range of devices, subsystems, and control networks, promoting interoperability and data exchange in industrial automation systems.

6. Visualisation and HMI Capabilities: CODESYS Runtime Toolkit offers built-in tools and libraries for creating human-machine interfaces (HMIs) and visualising process data. It provides features like graphical displays, trend charts, alarm handling, and user-friendly interfaces for operators and maintenance personnel.

7. Scalability and Flexibility: The toolkit is scalable, accommodating projects of varying sizes and complexities. Whether it’s a small standalone application or a large distributed control system, CODESYS Runtime Toolkit can be tailored to meet specific requirements. It allows users to expand and adapt their automation systems as needed.

8. Security Measures: CODESYS Runtime Toolkit emphasises security in industrial automation. It incorporates features like user authentication, access control, secure communication protocols, and data encryption to protect sensitive data and ensure the integrity and confidentiality of industrial processes.

CODESYS Runtime Toolkit provides a comprehensive set of features and capabilities that enable developers to build robust and efficient industrial automation systems. Its compatibility with different hardware platforms and operating systems, along with support for multiple programming languages, makes it a flexible and widely applicable solution in the field of industrial automation.

CODESYS Runtime Toolkit Applications

CODESYS Runtime Toolkit has been successfully implemented in various real-world applications, enabling IoT-enabled industrial automation across different industries including but not limited to smart factories, predictive maintenance, energy management, condition monitoring, and industrial control system.

CODESYS Runtime Toolkit plays a crucial role in building smart factories, where IoT devices and sensors are integrated with industrial automation systems. It enables real-time data acquisition, analysis, and control, allowing factory managers to monitor production processes, optimise resource utilisation, and enable predictive maintenance. By leveraging CODESYS Runtime Toolkit, smart factories can achieve improved efficiency, reduced downtime, and enhanced overall productivity.

Data is usually analysed to identify patterns and anomalies to enhance predictive maintenance systems through trigger alerts, generating work orders, and scheduling maintenance activities proactively. In addition, smart meters and sensors can be integrated to collect energy consumption data, real-time. The outcomes include minimised equipment downtime, optimised maintenance schedules, and improved cost-efficiency through energy optimisation strategies, load balancing, and peak demand management.

Sustainability and compliance are one of CODESYS’ main focuses. CODESYS Runtime Toolkit is widely used as a foundation for IoT-enabled industrial control systems. By integrating IoT devices and sensors, CODESYS Runtime Toolkit enables precise control and monitoring of industrial processes. This includes regulating temperature, pressure, flow rates, and other variables. The advantages include improved process accuracy, enhanced productivity, and the ability to adapt to changing conditions swiftly.

By leveraging these capabilities, organisations can achieve increased efficiency, optimised resource utilisation, reduced downtime, predictive maintenance, and improved overall operational performance in their IoT-enabled industrial automation systems.

Best Practices for Successful Integration in IoT-enabled Industrial Automation

For a successful integration of CODESYS Runtime Toolkit in IoT-enabled industrial automation projects, consider the following recommendations:

  1. Plan and Design: Start by thoroughly planning and designing the system architecture and functionalities. Define the scope of the project, identify the specific requirements, and create a roadmap for implementation. This will help ensure that CODESYS Runtime Toolkit is effectively utilised to meet the project objectives.
  • Hardware and Software Compatibility: Select compatible hardware and software components that work seamlessly with CODESYS Runtime Toolkit. Consider factors such as communication protocols, interface compatibility, and scalability. Choose hardware devices, sensors, and controllers that are supported by CODESYS and have a proven track record in industrial automation applications.
  • Robust Network Infrastructure: Build a reliable and secure network infrastructure to support the IoT-enabled industrial automation system. Ensure proper network segmentation, implement firewalls, and employ secure communication protocols to protect data transmission. Design the network architecture to handle the data traffic generated by IoT devices and provide sufficient bandwidth for real-time communication.
  • Security Measures: Implement robust security measures to protect IoT devices and industrial systems. Utilise strong authentication mechanisms, access control policies, and encryption techniques to safeguard the integrity and confidentiality of data. Regularly update and patch software components to address any security vulnerabilities. Conduct security audits and risk assessments to identify and mitigate potential threats.
  • Data Management and Analytics: Establish a data management strategy to handle the vast amount of data generated by IoT devices. Implement data storage solutions, such as databases or cloud platforms, that can efficiently store and process the data. Leverage CODESYS Runtime Toolkit’s data processing and analytics capabilities to extract valuable insights and support decision-making processes.
  • Regular Updates and Maintenance: Regularly update CODESYS Runtime Toolkit, hardware firmware, and software components to ensure compatibility, performance improvements, and security patches. Implement a proactive maintenance plan to monitor and troubleshoot issues promptly. Conduct periodic system audits, performance evaluations, and preventive maintenance to maximise system uptime and minimise disruptions.
  • Training and Expertise: Invest in training for your team members to ensure they have the necessary skills and knowledge to effectively utilise CODESYS Runtime Toolkit. Stay updated with the latest developments and advancements in industrial automation and IoT technologies to leverage new features and functionalities.

Millions of CODESYS-compatible single devices and over 1,000 different device types from more than 500 manufacturers offer you a large range of hardware for your automation projects. CODESYS Inside offers a selection of manufacturers that offer CODESYS-compatible devices.


In conclusion, CODESYS Runtime Toolkit plays a crucial role in enabling IoT-enabled industrial automation by providing a powerful runtime environment for control applications. It allows seamless integration of IoT devices, enables real-time data processing and analytics, and empowers organisations to achieve improved efficiency, optimised resource utilisation, and enhanced overall operational performance.

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