All subsystems

Networks carry information. Never protection.

Five layers, each with one job. When a network fails, the line either keeps running or stops safely.

MQTT, Modbus TCP, OPC UA

The heartbeat is a wire.

The Jetson's 1 Hz square wave reaches PLC input X0.5 through an opto-isolator. It does not travel over MQTT, Modbus or any other network, so a network fault cannot fake a healthy AI.

The gateway translates.

The Raspberry Pi 5 takes MQTT from the Jetson, writes Modbus TCP registers to the PLC and exposes the same data as OPC UA tag names. Changing the PLC vendor changes the gateway, not the AI node or the dashboard.

If the gateway's counter stops for 5 s, the PLC raises an alarm and discards stale requests. The line keeps running.

Remote is the weakest link, by design.

The dashboard views and requests. Remote start works only with the key switch at REMOTE. Losing the dashboard or the internet loses the view, nothing else.

Failure response, layer by layer

Hardwired safety path
Cuts motor power. Restart inhibited.
PLC
Outputs de-energise. Hardwired path unaffected.
Edge AI
Heartbeat timeout at the PLC, line stops, manual reset.
Gateway
Detected by the PLC, alarm only. Line keeps running.
Dashboard
Remote view lost. Control unaffected.
Registers
D100 gateway counter, D102 risk, D103 to D105 requests, D120 status, D122 stop code