An Applied Approach for Integrating Legacy PLC-Based Systems into Industry 4.0 Environments using Low-Code Platforms

An Applied Approach for Integrating Legacy PLC-Based Systems into Industry 4.0 Environments using Low-Code Platforms | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article An Applied Approach for Integrating Legacy PLC-Based Systems into Industry 4.0 Environments using Low-Code Platforms Eduardo Vieira Nascimento, Vinicius dos Santos, Rafael Vidal Aroca This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-8503985/v1 This work is licensed under a CC BY 4.0 License Status: Published Journal Publication published 14 Apr, 2026 Read the published version in The International Journal of Advanced Manufacturing Technology → Version 1 posted 5 You are reading this latest preprint version Abstract Context Industry 4.0 initiatives have promoted the adoption of new digital technologies in industrial environments. However, a large portion of industrial plants still rely on legacy Programmable Logic Controllers (PLCs) and software systems developed over several decades. In developing countries, economic constraints often make full system replacement impractical, resulting in limited interoperability between legacy and modern industrial technologies. Objective This paper proposes an applied approach for the digital modernization of industrial systems through the integration of legacy PLCs with low-code-based platforms, aiming to support incremental Industry 4.0 adoption without requiring hardware replacement. Method A Design Science Research (DSR) methodology was adopted to design and refine a workflow for legacy system integration. The problem context was characterized through a practitioner survey and a Systematic Literature Review. Based on the identified challenges, a set of requirements was defined and iteratively refined through three industrial case studies, allowing the evaluation of the proposed workflow under different legacy system conditions. Results The results demonstrate the technical feasibility of integrating legacy PLC-based systems with contemporary digital platforms. Tools such as Node-RED and BIPES enabled data acquisition, processing, and interoperability between legacy and modern components, provided that constraints related to legacy code, communication protocols, and physical interfaces are properly addressed. Conclusion The proposed workflow offers a practical contribution to industrial digitalization by supporting the gradual integration of legacy systems into Industry 4.0 environments. The approach can reduce technological and economic barriers for industrial modernization, particularly in scenarios where full system replacement is not viable. Digital Retrofit PLCs Programmable Logic Controllers Low-Code Node-RED BIPES Legacy Systems Interoperability Full Text Cite Share Download PDF Status: Published Journal Publication published 14 Apr, 2026 Read the published version in The International Journal of Advanced Manufacturing Technology → Version 1 posted Editorial decision: Minor Revisions Needed 08 Mar, 2026 Reviewers agreed at journal 01 Feb, 2026 Reviewers invited by journal 07 Jan, 2026 Editor assigned by journal 07 Jan, 2026 First submitted to journal 05 Jan, 2026 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. 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Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-8503985","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":570905357,"identity":"3db730c7-def7-437b-bbfc-d013b48afdd2","order_by":0,"name":"Eduardo Vieira 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