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OPC UA EdgeIO Controller BL191

Name: OPC UA EdgeIO Controller BL191
Brand: Beilai Tech. Co., Ltd.
SKU: BL191
Availability: InStock
Rating: 5 (1 reviews)

No.BL191

The OPC UA EdgeIO Controller BL191 is an Industry 4.0 edge controller with a built-in OPC UA server for seamless integration between industrial equipment and SCADA, MES, ERP, WMS, and cloud platforms. With Web-based logic control, secure OPC UA communication, AES-256 encryption, and IEC62443 cybersecurity support, the BL191 is ideal for smart factories, energy systems, and industrial digitalization applications.

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Description
Model Selection

⚡ Industrial OPC UA EdgeIO Controller

BL191 EdgeIO Controller

One device replaces "PLC + I/O modules + gateway". Native OPC UA server for Industry 4.0, smart manufacturing, and digital transformation – bridging OT and IT with a unified interface.

✔ Native OPC UA server (X.509, AES-256, IEC 62443) ✔ -40°C ~ +85°C wide temperature ✔ 1–3 I/O expansion slots (Y‑series)

Product Overview

From OT to IT – One Unified OPC UA Interface

The BL191 is an industrial‑grade OPC UA EdgeIO controller from BLIIOT, designed for Industry 4.0, smart manufacturing, and digital transformation. It integrates data acquisition, logic control, and remote O&M. With 1–3 Y‑series expansion slots (digital, analog, temperature, serial, pulse), it adapts to any field signal type. One BL191 replaces the cumbersome stack of "PLC + I/O modules + gateway" and connects OT to IT seamlessly via OPC UA.

Built for harsh industrial environments: electrical isolation, EMC/EMI tested, -45°C~80°C validation, hardware watchdog – a reliable edge solution for digital factories.

🏭

Model: BL191

OPC UA EdgeIO Controller

✔ Native OPC UA server

✔ 1–3 expansion slots

✔ Isolated RS485 + dual Ethernet

Why OPC UA?

OPC UA (OPC Unified Architecture) is the leading standard for secure, reliable, platform‑independent industrial data exchange. It solves the pain points of traditional protocols:

Traditional Protocol Pain Points	OPC UA Advantages
Platform dependent (often Windows‑only)	Platform independent – Linux, Windows, embedded
Weak security	Built‑in X.509 certificates, AES‑256 encryption, user role authentication – complies with IEC 62443
Single, flat data model	Supports complex structured data, methods, historical access, alarms & conditions
Complex configuration, manual address mapping	Auto‑discovery, unified namespace – no repeated address mapping

🔄 BL191 converts on‑site I/O signals, sensor data, and instrument readings into OPC UA information models – allowing SCADA, MES, ERP to consume field data directly without intermediate conversion.

Key Features

📡 Native OPC UA ServerStandard OPC UA specification, multiple concurrent clients, real‑time, secure, structured data
🔧 Flexible I/O Expansion1–3 slots, 20+ Y‑series modules (DI, DO, AI, AO, RTD, TC, pulse, etc.) – over 100,000 combinations
🔗 Dual Ethernet Daisy Chain2× 10/100M Ethernet with switch function – simplifies cabling
📟 Isolated RS485Modbus RTU master/slave – collects smart instruments (power meters, temperature controllers, etc.)

🌐 Built‑in Web ConfigurationBrowser‑based logic programming – no proprietary software
📡 Remote O&M (BLRAT)Remote firmware upgrade, parameter tuning, diagnostics – no site visit
🔒 Secure CommunicationX.509 certificates, user authentication, AES‑256 encryption – IEC 62443 ready
🎛️ Local Logic ControlArithmetic, conditional actions, interlocking – offloads main PLC

Technical Specifications – Base Controller

Power Supply

24V DC, 55mA@24VDC, reverse polarity protection

Ethernet

2× RJ45, 10/100M, isolated: ESD ±6kV/±8kV, EFT 1kV

RS485

1x isolated, baud rate 2400~230400 bps, data bits 8, parity None/Even/Odd, stop bits 1/2

Operating System

Linux, 300MHz CPU, 64MB RAM, 128MB Flash

Protocol Stack

OPC UA server (UA‑TCP), Modbus RTU master/slave, HTTP, DHCP, DNS

OPC UA Security

X.509 certificates, username/password, AES‑256 encryption, security policies

Operating Environment

-40°C ~ +85°C, 5%~95% RH

Mounting / Protection

Wall mount / DIN35 rail, IP30

Dimensions (1-slot/3-slot)

30×83×110 mm / 40×83×110 mm

Net Weight

133g (1‑slot) / 171g (3‑slot)

Use Case: Legacy Equipment Modernization – Automotive Parts Factory

Background: An automotive parts factory had 50+ legacy machines (injection molding, stamping presses, CNC machining centers) from various brands, with mixed protocols (Modbus RTU, proprietary serial, dry contact signals). An MES system was already deployed, but equipment data could not be automatically collected. Operators manually recorded uptime, production counts, and fault times – leading to inaccurate OEE and difficult quality traceability. IT required a unified interface for all equipment data; MES needed real‑time status, process parameters, and production counts.

Key pain points: No unified communication interface; high cost to retrofit PLCs; MES needed OPC UA but existing systems could not provide it; no real‑time machine monitoring.

✅ Retrofit Solution with BL191

Deploy BL191 as edge nodes, each covering 8–16 machines (depending on I/O points and distance).

Signal acquisition:
- DI: machine run/fault/idle dry contacts
- AI: spindle current, hydraulic pressure, etc.
- High‑speed counter: stamping counts, injection molding cycles
- RS485 (Modbus RTU): smart power meters, temperature controllers
Local logic: Alarm logic: AI current exceeds threshold for 5 sec → mark fault, log fault start time.
OPC UA unified interface:
- Map all acquired data to OPC UA nodes (e.g., NS=1; S=1000 → machine 1 running status)
- Support UA‑TCP protocol; MES subscribes via OPC UA clients (Kepware, Ignition)
- Enable security policies (username/password + certificate encryption) – compliant with factory cybersecurity requirements
Remote O&M: Engineers use BLRAT remote tool to modify alarm thresholds, add new device points, and upgrade firmware – no site visit, reducing downtime.

📉 Before Retrofit

▪ Data collection: manual logging
▪ OPC UA support: none
▪ Real‑time monitoring: no
▪ Maintenance: on‑site only
▪ MES integration: impossible

📈 After Retrofit

▪ Automatic data acquisition
▪ Native OPC UA server
▪ Real‑time status & alarms
▪ Remote diagnostics & tuning
▪ MES reads data directly

Key takeaway: BL191 turns dozens of “silent” legacy machines into digital nodes accessible by any OPC UA client. MES finally achieves “automated data flow” – a low‑cost digital transformation model for discrete manufacturing.

More OPC UA Applications Across Industries

🏭 Smart Manufacturing
Line sensors & actuators, local logic control – unified data model, MES/ERP reads directly, no driver conversion.

📊 Digital Shop Floor
Equipment networking, OEE calculation, fault alarms – standard interface reduces integration cost, supports historical access.

🔋 Energy Management
Energy storage cabinets, substations, PV farms – encrypted communication, secure data to energy management systems.

🏢 Building Automation
Lighting, HVAC, access control integration – OPC UA as the unified upper‑layer interface to BMS.

🌱 Environmental Monitoring
Temperature, humidity, gas sensors – structured data for direct parsing by SCADA or cloud.

🚇 Rail Transit
Station equipment status, tunnel environment control – high reliability, redundancy, and disconnect recovery.

💨 Wind Power
Turbine status, wind speed, temperature – remote encrypted access, compliant with power sector cybersecurity.

Environment & Certifications

🌡️ Wide operating temperature
-40°C ~ +85°C

🛡️ Protection rating
IP30

📜 EMC compliance
CE/FCC certified, IEC61000-4-2/4/5 Level 3 (ESD, EFT, Surge)

📳 Vibration & drop
IEC60068-2-6 (sinusoidal vibration), IEC60068-2-31 (free fall)

✅ Hardware watchdog & full electrical isolation
✅ -45°C~80°C validation

✅ Dual Ethernet switch + isolated RS485
✅ Built‑in web configuration & remote O&M (BLRAT)

Support & Customization

✔ Custom R&D and manufacturing (OEM/ODM)
✔ Long‑term after‑sales support

Available I/O Modules

💡 Click behavior: Each click adds that module to the next available slot.
🔁 Duplicate allowed: Click same module 2 or 3 times to fill multiple slots (e.g. Y31 + Y31).
⚠️ Y61 (Serial) can be selected only once per controller.

Your Selection (Slots 1–3)

Total modules: 0 / 3

Configuration summary

No modules selected. Click any Y‑series module to occupy Slot 1 → Slot 2 → Slot 3.

✅ Fully compatible with BL192Pro, BL192, BL191, BL190, BL193, BA190, BA190Pro.
📌 Each slot = physical I/O board position. Identical models allowed (click again).

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Contact: 2F, A2 Building, Fuhai Information Port, Fuyong, Baoan, Shenzhen, China; bl31@bliiot.com; 0086-755-29451836

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