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Embedded Automation Solutions

 

BCS Digital - We design and deliver custom embedded automation systems for non-safety-critical applications, focused on reliable control, predictable response, and long-term stability.
Our solutions are suited for environments where clear logic execution, fast reaction to inputs, and consistent operation are required — without the overhead of large industrial PLC platforms.

 

 

Automation Capabilities & Application Areas

 

Smart Garden & Irrigation Automation

 

Embedded automation systems are well suited for outdoor and environmental control tasks where timing, sequencing, and sensor-based decisions are essential.

Typical capabilities include:

  • Automated watering and irrigation control

  • Soil moisture, rainfall, and temperature-based logic

  • Pump and valve sequencing with configurable timing

  • Greenhouse and outdoor automation workflows

Suitable for residential gardens, allotments, greenhouses, and small outdoor installations.

 

 

Workshop & Small-Scale Industrial Automation

 

For workshops and light industrial environments, embedded controllers provide precise control behaviour and fast reaction to process events.

Supported automation tasks include:

  • Machine sequencing and process control

  • Conveyor and actuator coordination

  • Sensor-driven automation logic

  • Equipment monitoring and status indication

Ideal for workshops, small production lines, and R&D environments.

 

 

Lighting & Signalling Systems

 

Automation systems can be configured for accurate and repeatable control of lighting and visual signalling equipment.

Common use cases:

  • Custom LED and indicator control

  • Status lights and visual alerts

  • Timed and event-driven lighting logic

  • Warning and process indication systems

Used in workshops, commercial spaces, and technical environments.

 

 

Monitoring & Local Interfaces

 

Embedded control systems can provide local monitoring and configuration interfaces suitable for on-site operation.

Typical functions include:

  • Real-time system status and sensor monitoring

  • Parameter configuration and operating mode selection

  • Local network access for diagnostics and updates

  • No mandatory cloud dependency

 

 

Control Platform Characteristics

 

The automation systems are built around STM32-based controllers (belongs to the STM32 Dynamic Efficiency product line), selected for their industrial-oriented performance and predictable real-time behaviour.

Key characteristics include:

  • Deterministic real-time execution
    Predictable timing suitable for control loops, sequencing, and automation logic.

  • Low-latency response
    Fast interrupt handling and high-resolution timers enable accurate reaction to input events.

  • Hardware watchdog supervision
    Built-in monitoring mechanisms support reliable recovery from unexpected software states.

  • Industrial temperature capability
    Support for extended operating temperature ranges (device-dependent, up to –40 °C to +85 °C).

  • Floating-point processing
    Efficient handling of control calculations, thresholds, and sensor data.

  • Comprehensive peripheral support
    Timers, ADC, DMA, UART, SPI, I²C and other interfaces commonly required in automation systems.

These properties allow the controller to operate consistently under load and environmental variation.

 

 

Reliability and Scope

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All systems are designed with reliability and predictable behaviour as primary goals.

They are intended for non-safety-critical automation and do not replace certified PLC or safety-rated control systems.
For applications requiring SIL / PL compliance or emergency-stop integration, certified industrial PLC solutions should be used.

 

 

Delivery Approach

 

  • Clear definition of requirements and scope

  • Pre-configured and tested embedded controller

  • Project-specific firmware and control logic

  • Basic documentation and integration guidance

Each system is prepared and verified prior to delivery.

 

 

Get in Touch

 

If you require a reliable embedded automation solution for workshop, outdoor, or bespoke control applications, feel free to get in touch to discuss your project requirements.

BCS Digital - we are department of Body Cast Studio.

Generator Automations

Generator Automations

Off-grid power management for remote CCTV systems.
The premises operate fully off-grid, powered exclusively by renewable energy sources — a hybrid solar and wind setup.
During periods of low sunlight or wind, a backup generator is used to ensure uninterrupted operation.
We designed and deployed a remote power management and monitoring system that provides full control over the energy storage (power bank) and charging process — even in locations with no grid electricity access.

The system enables:
Real-time monitoring of battery status and power flow
Remote control of charging and generator usage (start/stop)
Continuous availability of CCTV infrastructure
Centralised access and control from anywhere

This solution significantly improves reliability, safety, and operational efficiency, while reducing maintenance visits, downtime, and overall costs.

Chinese Diesel Heater

Chinese Diesel Heater

Smart heating automation for premises.

Another automation solution delivered by us — intelligent premises heating control, designed to operate only when heating is actually needed. Heating can be scheduled to switch on, for example, 20 minutes before arrival, ensuring the space is already warm and comfortable when you come in — without wasting energy during idle hours.

 

The system provides:

Real-time monitoring of heating status

Remote on/off control from anywhere

Flexible scheduling based on real usageImmediate response to weather or plan changes

 

Forgot to switch heating off when leaving the office?No need to return and waste time or fuel — it’s managed remotely.

 

Sudden change in weather while you’re far away? No need for on-site adjustments — heating can be optimised instantly from anywhere. 

This approach delivers energy savings, comfort, and operational efficiency, reducing unnecessary consumption while maintaining full control at all times.

Chinese Diesel Heater Updated "Thermostat" version

Chinese Diesel Heater Updated "Thermostat" version

Updated version of heating, with Thermostat.

FAQ — Control System vs Full Engineering Solution

 

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Do I need just a controller (PLC), or a full engineering solution?

 

This depends on your level of technical readiness and project complexity.

In both cases you'll need for electrician/engineer on your side.

We offer two distinct service levels:

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Option 1 — Control System Only (Controller / PLC Part)

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This option is suitable if:

  • You already know what needs to be controlled

  • You know how many inputs and outputs you need

  • Load types and power levels are already defined

  • Electrical installation will be completed by a qualified electrician

  • You only need reliable control logic and interface

 

What we provide:

  • PLC-style controller (ESP32 / STM32 based)

  • Local control logic (no cloud dependency)

  • Web / SCADA-style interface for monitoring and control

  • Clearly defined control terminals (digital outputs / inputs)

  • Documentation for connection

 

What is NOT included:

  • Load sizing (motors, heaters, contactors)

  • Electrical design for mains wiring

  • Selection of relays, contactors or protection devices

  • Responsibility for final electrical connection

 

👉 This option is ideal for technically competent clients, system integrators, or projects where electrical design is already completed.

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Option 2 — Full Engineering Solution 

 

This option is recommended if:

  • You are not sure how many outputs or inputs you need

  • Loads include motors, pumps, heaters, valves

  • You need help deciding relay vs contactor vs SSR

  • Safety, reliability and compliance are important

  • You want a complete, ready-to-install solution

 

What we provide:

  • Full control system design

  • Load analysis (current, startup/inrush, duty cycle)

  • Selection of appropriate output stages (relays, contactors, SSR)

  • I/O count and signal type definition

  • Power supply sizing (12V / 24V DC, separation of logic and loads)

  • Control logic + interface

  • Wiring diagrams and system documentation

 

Result:
A properly engineered system where:

  • Control logic runs locally and safely

  • Output stages are matched to real loads

  • Expansion and maintenance are straightforward

 

👉 This option is strongly recommended for industrial, agricultural and commercial applications.

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Why is load and I/O definition important?

 

Incorrect assumptions about loads often lead to:

  • relay failure

  • controller damage

  • overheating

  • unreliable operation

  • safety risks

 

Motors, solenoids and heaters behave very differently from simple loads.
Proper engineering ensures long-term reliability and safety.

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Can I upgrade from “controller only” to a full solution later?

 

Yes.
However, upgrading later may require:

  • additional hardware

  • rewiring

  • logic changes

For new installations, a full engineering approach is usually more cost-effective in the long term.

 

 

 

Who is responsible for mains (230V AC) wiring?

 

Final mains wiring must be carried out by a qualified electrician.

We provide control logic, interface and technical documentation.
Electrical installation and compliance remain the responsibility of the installer.

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Is the system cloud-dependent?

 

No.
All control logic runs locally on the controller.

Network access is used only for:

  • monitoring

  • configuration

  • supervisory control (SCADA-style)

If the network or interface is unavailable, the system continues operating safely.

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What information do you need to start?

 

For controller-only projects:

  • Number of required outputs and inputs

  • Supply voltage for outputs (12/24V DC or 230V AC)

  • Load types (on/off only)

 

For full engineering projects:

  • Type of loads (motors, heaters, valves, etc.)

  • Voltage and rated current

  • Switching frequency

  • Startup/inrush characteristics (if motors)

  • Site power availability

  • Expansion expectations

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Which option should I choose?

 

If you are unsure — start with a full engineering consultation.
It avoids incorrect assumptions and ensures a robust, scalable solution.

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Short version you can put in a highlighted box

 

If you know exactly what you need — we can supply the control system only.
If you want a reliable, safe and future-proof installation — we provide full engineering and system design.

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