Talks - Jacob Lapenna: Open Source Industrial Control: Turning 2,800 Tons of Metal with Python...

Project involves controlling massive 2,800-ton rotating machines using Python and open source technologies instead of traditional PLCs

System uses Raspberry Pis, WebSockets, Flask, Celery, Redis and browser-based interfaces to control and monitor industrial equipment

Architecture consists of distributed components:

• Rotor control box (brain/server)
• Stator box (worker)
• Browser-based interface
• Air-gapped network for security

Power distribution managed through:

• 480V to 120V transformers
• Multiple power supplies controlled via PMBus/I2C
• SCRs (Silicon Controlled Rectifiers) for current switching
• Custom PCBs and relay controls

Key innovations:

• Converting large machines into DC stepper motors
• Real-time monitoring using rotary encoders
• Partial discharge mapping using NFC antennas
• Automated calibration procedures
• Portable design using Pelican cases

Benefits include:

• Reduced training needs (familiar browser interface)
• Easy version control of plain text code
• More accessible than traditional PLC programming
• Modular and scalable hardware/software
• Real-time insight for operators and managers

Current limitations:

• Not true real-time system (acceptable for this use case)
• Prototype status
• Limited organizational support/adoption

System enables precise slow-speed control for maintenance tasks like bearing alignment and testing

Used at US Bureau of Reclamation for managing 250+ rotating machines across 53 hydropower plants

Project demonstrates convergence of IT and operational technology in industrial control systems