🧠 Connecting Industrial PLC with DFRobot Sensors for Corrugated Box Production Automation

Hello everyone,

We’re currently working on upgrading one of our corrugated box production lines at BMC Pack (China) by integrating DFRobot sensors and industrial PLC controllers for process optimization and energy monitoring.

Our goal is to make the carton printing and packaging line more intelligent — especially at the folder-gluer and servo vacuum transfer sections. We’ve been testing DFRobot analog sensors (pressure and proximity types) together with Delta DVP and Siemens S7-1200 PLCs, connected through RS485 Modbus RTU and Ethernet.

Some of our findings so far:

Analog noise increases when multiple sensors share the same ground as servo motors – solved by isolation + external power filtering.

Response delay (~150–200ms) occurs between DFRobot sensor readout and PLC analog input under high-speed vacuum transfer.

Python-based gateway (ESP32 + Modbus RTU) can help offload some sensor read operations and send averaged values to the PLC.

Great potential for using DFRobot gravity sensors to monitor vacuum pressure in carton pickup systems.

We’d love to discuss with others who’ve tried combining DFRobot modules or microcontrollers (Arduino, ESP32, etc.) with industrial PLCs in packaging or printing machinery.

If anyone here has experience in synchronizing analog sensors with high-speed conveyors or robot arms, please share your setup!
You can see our current automation projects here:
🌐 www.bmcpack.com

— Chris L.A.
Automation Engineer | BMC Pack – Corrugated Carton Production Line Manufacturer