Smart Controllers & PLC Solutions
We design robust, microcontroller-based smart controller boards that fit standard DIN-rail enclosures and feature opto-isolated inputs, relay outputs, and network interfaces.
Control System Bottlenecks
Industrial control applications are vulnerable to electrical noise and high deployment costs:
- Electrical Interference: Voltage spikes trigger false inputs or fry processors.
- Proprietary Vendor Lock-in: Traditional PLCs restrict programming options.
- Complex Enclosure Assembly: Clunky wiring increases mounting errors.
- No Wireless Integration: Standard PLCs lack native Wi-Fi/LTE connections.
Thinkfinity Smart Controllers
We build custom controller boards with built-in isolation and wireless options:
- Optocoupler Isolation: Protects MCU lines with 2.5kV isolated inputs.
- C/C++ Code Execution: Programmed in standard C/C++ or MicroPython for flexibility.
- DIN-rail Layouts: Custom PCBs designed to fit standard DIN-rail enclosures.
- Built-in Radio Options: Optional ESP32 or LTE modems for cloud connectivity.
Hardware Specifications
Opto-isolated 24V DC digital inputs, 0-10V/4-20mA analog inputs
Solid-state or mechanical relays, 0-10V analog outputs
DIN-rail housings, IP65 junction box sizing
RS485 Modbus, CAN Bus, Ethernet, Wi-Fi
Target Applications
- Custom Machine PLCs: Tailored controllers for packaging, labeling, and processing machines.
- Smart Relay Panels: Multi-channel relay boards for automated lighting and power control.
- Pump & Valve Controllers: Custom controllers with water-level sensors and relay drives.
- Building HVAC Control: Modbus-connected temperature and ventilation controllers.
Smart Controller FAQs
Standard PLCs are excellent but expensive and bulky. A custom smart controller is tailored to your exact IO requirements, integrates wireless communication (like Wi-Fi, Bluetooth, or cellular) natively on the board, and has a significantly lower unit cost at scale.
Our controllers are typically powered by standard 12V or 24V DC industrial power supplies. Our digital inputs are designed for 24V DC levels, and output relays can handle up to 250V AC at 10A.