Modular embedded systems divide industrial computing and control into components that work together through defined interfaces. They can make process equipment easier to combine, adapt, or replace—but only when the modules and the receiving control system support compatible functions, communications, and engineering workflows. In process automation, NAMUR’s Module Type Package (MTP) approach describes a process module’s automation in a vendor-neutral format that can be imported into process-control engineering. That is a structured integration path, not a promise that any equipment will plug in and work.
What are modular embedded systems in industrial automation?
An embedded system is computing built into equipment to perform a dedicated task. In industrial automation, that computing may run control logic, handle communications, read inputs from sensors, or command outputs such as actuators. A modular design separates some of these responsibilities into components with defined interfaces, so a system can be assembled or changed without treating every function as part of one indivisible controller.
The word “modular” can describe different layers. A controller may use replaceable hardware modules for processing or I/O; software may package reusable control functions; or a process unit may expose its automation functions to the plant control system as a module. These layers can coexist, but they are not interchangeable concepts. A compatible I/O card does not by itself define how a process unit behaves, and a software description does not guarantee that hardware or safety functions are compatible.
How PLCs, embedded controllers, and modular I/O work together
A PLC is one common type of industrial controller: it executes control logic and exchanges signals with I/O and other devices. An embedded controller may serve a dedicated machine or package unit, while modular I/O can bring input and output connections closer to equipment or organize them as replaceable components. The exact arrangement depends on the system design and verified compatibility between the controller, I/O, communications, and engineering tools.
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Modularity is therefore best understood as an architecture choice, not as a single product category. A small machine controller, a distributed I/O arrangement, and a process skid that exports an MTP description can all be modular in different ways.
How does MTP help integrate process modules?
In process automation, a process module might be a package unit or other bounded piece of equipment with its own automation. NAMUR describes MTP as a vendor-neutral functional description of that module’s automation. The module’s engineering tool can generate an MTP for import into process-control engineering, helping the plant team integrate the module’s functions into the wider control environment. NAMUR also identifies automatic generation of a module HMI and service-based control among MTP capabilities. NAMUR’s MTP overview explains the approach.
In practical terms, MTP aims to reduce the need to recreate a module’s automation description from scratch in the plant-control engineering environment. The result still depends on what the module describes and what the receiving system implements. Teams need to confirm supported functions, states, interfaces, and engineering-tool behavior; an MTP file alone does not make arbitrary devices interoperable.
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Process modularity is not the same as factory modularity
MTP is specifically discussed in the context of modular process automation. A process plant may combine package units or process modules whose functions need to appear in a plant-level control system. Broader factory automation also uses modular controllers, machine cells, and configurable I/O, but the MTP description should not be treated as a universal integration standard for every factory device or production line.
NAMUR’s work on modules and “plug and produce” frames interface harmonization and practical modularization as engineering concerns. Flexible modules are a design goal; the amount of standardization and integration effort required varies with the application.
Which standards and architectures address which layer?
Standards and initiatives in this area solve different problems. Some concern how control logic is expressed; others define communication or information models, describe process modules, or specify a hardware architecture. Support for one layer does not prove interoperability across the entire system.
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| Standard or initiative | What it addresses | What it does not establish on its own |
|---|---|---|
| IEC 61131-3 and PLCopen | PLCopen identifies IEC 61131, especially Part 3, as the basis for its work on programmable-controller logic. It also describes reusable, hardware-independent motion-control applications using IEC 61131-3 and PLCopen function blocks. PLCopen’s standards overview. | Using IEC 61131-3 does not by itself make different controllers, I/O, or application functions interchangeable. |
| OPC UA with PLCopen | PLCopen and the OPC Foundation describe specifications connecting the IEC 61131-3 software model with OPC UA communication mechanisms and information models. PLCopen’s communication overview. | OPC UA alone does not guarantee that devices expose the same application semantics, profiles, or functions. |
| IEC 61499 and PICMG InterEdge | PICMG describes InterEdge as a modular process-control architecture for compute, switching, and I/O, and says it is compatible with IEC 61499 and IEC 61131. PICMG’s InterEdge announcement. | This specific initiative is not evidence that all vendors implement the same interfaces or that the architecture is universally adopted. |
| MTP | A process-module description and integration approach: module automation engineering can describe functionality for import into process-control engineering. NAMUR’s MTP overview. | It does not remove the need to check the module’s supported functions and the receiving system’s implementation. |
| NAMUR Open Architecture (NOA) | An approach to make production data available for monitoring and optimization through an additional communication channel while preserving the traditional automation structure. NAMUR describes use in brownfield systems and compatibility with MTP in new installations. NAMUR’s NOA overview. | It is not a replacement for the control architecture or a guarantee that every installed system can expose every desired data point. |
IEC 61131-3 versus IEC 61499
For a practical comparison, distinguish the standards by the way they enter the architecture discussion rather than assuming one automatically replaces the other. PLCopen identifies IEC 61131-3 as the foundation for its work on programmable-controller logic. PICMG’s description of InterEdge references compatibility with both IEC 61131 and IEC 61499 in a particular modular process-control initiative. These descriptions do not provide a universal product-selection rule or establish that a device supporting either standard will work with every other implementation.
Check the status of standards documents
Standards editions and status can change. The VDI page for VDI/VDE/NAMUR 2658 Part 1 displayed “Withdrawal announced” and an objection deadline of 2026-09-30. That deadline has passed; the page information cited here does not establish the final disposition. Verify the status with the publisher before treating the document as current. VDI’s Part 1 page is the relevant reference. NAMUR’s explanatory pages describe approaches and are not a substitute for the normative standards documents.
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What benefits can modularity offer—and what does it cost?
Modular systems can make it easier to configure production around process units, bring a module’s functions into plant-level control, or reuse and replace modules. Those are potential benefits and design goals, not guaranteed savings. NAMUR’s materials also emphasize the effort involved in interface harmonization and the need to consider how much modularization is practical.
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Modularity shifts some work toward defining boundaries and responsibilities. Teams must agree on module functions and states, communication behavior, engineering ownership, and expectations for security and availability. NAMUR’s work on automation architectures treats networking, IT/automation interfaces, security, and availability as design topics.
Siemens markets MTP-related reductions of “up to 50%” in time-to-market and “up to 70%” in engineering effort. These are Siemens vendor claims; the page does not state a year for them. They should not be read as independent measurements or a forecast for a particular project. Siemens’ modular production page.
Independent reader supportYour contribution helps us test, update, and keep practical guides available for everyone.What should you compare when choosing a modular automation architecture?
There is no universally preferable choice between centralized control and distributed or modular control. Compare the architecture against the process or machine requirements, and verify compatibility with the actual products and tools under consideration. The following checklist synthesizes the decision areas raised in NAMUR and PLCopen materials; it is not a published universal scorecard.
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- Control and safety: Define the control functions, safety requirements, response needs, and availability expectations. Verify that the proposed architecture and components meet them.
- I/O and physical interfaces: List required signal types and module organization. Confirm compatibility with the controller, wiring approach, and engineering tools rather than relying on a general claim of modularity.
- Communications and information models: Identify required protocols, profiles, and data semantics. Check that the specific devices and systems implement the needed functions.
- Engineering and commissioning: Estimate the work to configure, integrate, test, document, and manage changes across module and plant engineering.
- Installed-system integration: For brownfield sites, map the connection to existing controllers and control systems, along with any constraints on available interfaces and data.
- Security and availability: Define network boundaries, responsibilities for IT/automation interfaces, and the availability expectations for each part of the system.
- Lifecycle support: Check replaceability, spare-parts plans, engineering-tool support, and vendor support over the expected service life.
Can modular automation work with an existing plant control system?
It can, if the installed system and the proposed modules support an integration path that meets the project’s needs. MTP is intended to support importing process-module descriptions into process-control engineering, while NOA addresses an additional route for production data used in monitoring and optimization. NAMUR describes NOA as suitable for brownfield use and compatible with MTP in new installations. Neither approach removes the need to check the installed control system’s capabilities, supported interfaces, security constraints, and engineering requirements.
For an existing plant, start by identifying whether the objective is to integrate control functions, expose data for monitoring, or both. Then verify the relevant system implementations and define the commissioning and change-management work before selecting modules. This avoids treating a new interface or architecture description as a substitute for site-specific integration planning.
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