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Enhancing Industrial Automation in Industry 4.0: Integrating Node-RED with Real PLCs for Analog and Digital Signal Simulation.  .

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Title: Enhancing Industrial Automation in Industry 4.0: Integrating Node-RED with Real PLCs for Analog and Digital Signal Simulation.  .
Authors: Hussein FA; Department of Electrical Engineering ,College of Engineering, University of Mosul, Mosul, Nineveh Governorate, 41001, Iraq., Tariq Yaseen M; Department of Electrical Engineering ,College of Engineering, University of Mosul, Mosul, Nineveh Governorate, 41001, Iraq.; Department of Communications and Intelligent Digital Systems Engineering, University of Mosul, Mosul, Nineveh Governorate, 41001, Iraq., Obaid Mustafa M; Department of Electrical Engineering ,College of Engineering, University of Mosul, Mosul, Nineveh Governorate, 41001, Iraq.
Source: F1000Research [F1000Res] 2026 Jul 17; Vol. 15, pp. 617. Date of Electronic Publication: 2026 Jul 17 (Print Publication: 2026).
Publication Type: Journal Article
Language: English
Journal Info: Publisher: F1000 Research Ltd Country of Publication: England NLM ID: 101594320 Publication Model: eCollection Cited Medium: Internet ISSN: 2046-1402 (Electronic) Linking ISSN: 20461402 NLM ISO Abbreviation: F1000Res Subsets: MEDLINE
Imprint Name(s): Original Publication: London : F1000 Research Ltd
MeSH Terms: Industry* , Automation* , Computer Simulation* , Software* , Signal Processing, Computer-Assisted*
Abstract: Background: Within the framework of Industry 4.0, industrial automation plays a pivotal role in the development of smart systems. Programmable logic controllers (PLCs) are the core components of these systems, enabling precise control of various industrial processes, while recent advancements emphasize the integration of open-source platforms to enhance system monitoring, simulation, and testing capabilities.
Methods: In this study a real PLC from Allen-Bradley has been used, specifically the MicroLogix 1400, and also used Node-RED (Node-RED is an open-source, multitasking, easy-to-use graphical programming environment based on composing flows consisting of groups of specialized nodes to perform specific tasks) as a standalone simulator for analog and digital input and output signals. The presented study demonstrates how Node-RED can be used as an advanced PLC simulator to simulate analog and digital signals, either manually or automatically, enhancing the role of industrial automation in Industry 4.0.
Results: The results demonstrated that Node-RED is a practical simulator for both analog and digital signals, with stable communication and consistent response behavior. and can be used to simulate complex industrial environments, enabling comprehensive testing and continuous improvement to achieve optimal results before implementing PLC systems in real-world settings.
Conclusions: The research confirms that connecting the Node-RED tool with a real PLC is a useful, cost-effective solution and practical technique to simulate analog and digital (input/output) signals in industrial automation systems before implementing the PLC in the real world. This strategy improves cold commissioning efficiency and system reliability; these are the aims of Industry 4.0.
(Copyright: © 2026 Hussein FA et al.)
Competing Interests: No competing interests were disclosed.
References: Sensors (Basel). 2022 Oct 20;22(20):. (PMID: 36298371)
Sensors (Basel). 2023 Mar 02;23(5):. (PMID: 36904927)
Heliyon. 2024 Sep 06;10(18):e37560. (PMID: 39309862)
Sci Rep. 2024 Nov 26;14(1):29387. (PMID: 39592689)
Contributed Indexing: Keywords: Analog and Digital Signals Simulator.; Industrial Internet of Things (IIOT); Node-RED Tool; Real PLC
Entry Date(s): Date Created: 20260912 Date Completed: 20260912 Latest Revision: 20260914
Update Code: 20260914
PubMed Central ID: PMC13560842
DOI: 10.12688/f1000research.176034.2
PMID: 42729021
Database: MEDLINE
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  Data: Enhancing Industrial Automation in Industry 4.0: Integrating Node-RED with Real PLCs for Analog and Digital Signal Simulation.  .
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  Data: <searchLink fieldCode="AU" term="%22Hussein+FA%22">Hussein FA</searchLink>; Department of Electrical Engineering ,College of Engineering, University of Mosul, Mosul, Nineveh Governorate, 41001, Iraq.<br /><searchLink fieldCode="AU" term="%22Tariq+Yaseen+M%22">Tariq Yaseen M</searchLink>; Department of Electrical Engineering ,College of Engineering, University of Mosul, Mosul, Nineveh Governorate, 41001, Iraq.; Department of Communications and Intelligent Digital Systems Engineering, University of Mosul, Mosul, Nineveh Governorate, 41001, Iraq.<br /><searchLink fieldCode="AU" term="%22Obaid+Mustafa+M%22">Obaid Mustafa M</searchLink>; Department of Electrical Engineering ,College of Engineering, University of Mosul, Mosul, Nineveh Governorate, 41001, Iraq.
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  Data: Background: Within the framework of Industry 4.0, industrial automation plays a pivotal role in the development of smart systems. Programmable logic controllers (PLCs) are the core components of these systems, enabling precise control of various industrial processes, while recent advancements emphasize the integration of open-source platforms to enhance system monitoring, simulation, and testing capabilities.<br />Methods: In this study a real PLC from Allen-Bradley has been used, specifically the MicroLogix 1400, and also used Node-RED (Node-RED is an open-source, multitasking, easy-to-use graphical programming environment based on composing flows consisting of groups of specialized nodes to perform specific tasks) as a standalone simulator for analog and digital input and output signals. The presented study demonstrates how Node-RED can be used as an advanced PLC simulator to simulate analog and digital signals, either manually or automatically, enhancing the role of industrial automation in Industry 4.0.<br />Results: The results demonstrated that Node-RED is a practical simulator for both analog and digital signals, with stable communication and consistent response behavior. and can be used to simulate complex industrial environments, enabling comprehensive testing and continuous improvement to achieve optimal results before implementing PLC systems in real-world settings.<br />Conclusions: The research confirms that connecting the Node-RED tool with a real PLC is a useful, cost-effective solution and practical technique to simulate analog and digital (input/output) signals in industrial automation systems before implementing the PLC in the real world. This strategy improves cold commissioning efficiency and system reliability; these are the aims of Industry 4.0.<br /> (Copyright: © 2026 Hussein FA et al.)
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  Data: No competing interests were disclosed.
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  Data: Sensors (Basel). 2022 Oct 20;22(20):. (PMID: <searchLink fieldCode="PM" term="%2236298371%22">36298371)</searchLink><br />Sensors (Basel). 2023 Mar 02;23(5):. (PMID: <searchLink fieldCode="PM" term="%2236904927%22">36904927)</searchLink><br />Heliyon. 2024 Sep 06;10(18):e37560. (PMID: <searchLink fieldCode="PM" term="%2239309862%22">39309862)</searchLink><br />Sci Rep. 2024 Nov 26;14(1):29387. (PMID: <searchLink fieldCode="PM" term="%2239592689%22">39592689)</searchLink>
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