Proving open source is ready for the industrial edge

For years, the industrial sector has operated under the assumption that the core of a factory, the real-time control system, must remain a locked, proprietary environment. We've often accepted these restricted systems as a requirement for the deterministic performance mission-critical machinery demands. However, the existing industrial architecture is proving difficult to maintain as we move toward a modern environment defined by interconnected systems and the need for real-time data.

Recent performance testing conducted by Red Hat and Intel provides the evidence needed to challenge the status quo. Our data shows that Red Hat Enterprise Linux (RHEL) and Red Hat Device Edge, paired with Intel hardware, meet or exceed the performance of traditional controllers. This research is a pivot point for the industry, marking a move toward a software-defined architecture that helps reduce costs and simplifies how we update and protect factory floor devices.

30 microseconds of jitter 

The primary concern regarding open source in industrial control is repeatable screw-to-screw times. This is the exact window from a physical input to a mechanical output. In a factory setting, any variation in this timing can lead to system instability. There are lots of factors that make up screw to screw time but the controller itself, running on an OS, is a major contributor. 

We put RHEL and Red Hat Device Edge to the test using a bed of Intel Atom processors and our real-time kernel to see how well a virtual PLC (programmable logic controller) would perform. We ran a high speed PLC application on top of RHEL that was also heavily loaded with large cache hungry CPU cycle consuming applications. Even under these high-CPU loading conditions, RHEL provided the deterministic behavior required for even the most challenging applications showing <30 microseconds of variability for extremely low latency controller requests.

Managing high-density workloads

The challenge in modernizing the factory floor is often workload consolidation. Running a data-heavy application, like an analytics tool, next to a control loop can create interference that slows down the control task. To test this, we introduced a workload consuming 80% of the CPU. Without Intel Cache Allocation Technology (CAT), performance variation increased. But with CAT, the worst-case jitter for the interrupt request stayed under 30 microseconds.

Surprisingly, our testing showed that running the control logic in a Podman container actually resulted in more consistent timing than a traditional bare-metal installation when Intel CAT was active. This proves that you don't have to sacrifice real-time precision to get the deployment and scaling benefits of modern container technology.

Why a platform approach matters

This shift to a software-defined architecture is about more than just speed; it’s about creating a sustainable way to manage operations. By using a consistent platform, you can use the same security policies and patch management used in the data center directly on the factory floor.

This approach helps you move at the speed of software rather than being tied to hardware procurement cycles. It also allows for processing data directly on the device, which reduces the need to move massive data sets back to the cloud or even a local factory data center. Relying on a local data center can be problematic because real-time data requires immediate response times. The most effective way to manage network delays is to eliminate them by running the logic exactly where the data is created.

Experience the results at Hannover Messe 2026

The technical barrier to using Linux for industrial control has been removed. We’re at a point where the gap between information technology and operational technology is closing.

If you're attending Hannover Messe, I encourage you to see this in action. We'll be showcasing a water tank simulation running in a containerized environment to demonstrate how an open, software-defined approach can power the next generation of industrial automation in the Schneider Electric Booth in Hall 13, stand C34. I look forward to seeing how you use these tools to build what comes next.