Configure. Don’t Program.
ForgeLogic is the iPad of industrial controllers — a touchscreen PLC replacement where you configure inputs, outputs, and logic through settings screens instead of code. No proprietary software. No programming language. No outside contractor.
PLCs in the Field Are Dinosaurs.
They cost $4,000–$7,000+. They require proprietary software, specialized programmers, and weeks of downtime when something fails. The entire industry assumes the user can program. ForgeLogic assumes they can’t — and doesn’t need to.
Legacy PLCs Are Dying
Allen-Bradley SLC 500s from the 90s are failing across America. Nobody has the code. The software (RSLogix 500) is discontinued. Replacement means starting from zero.
Programming Is the Bottleneck
Ladder logic, structured text, proprietary software licenses ($500+). Specialized programmers charge $50–$100/hr. A simple machine takes 40–80 hours to program.
No Visibility
Traditional PLCs are black boxes. No run counts, no sensor trending, no failure logs, no maintenance reminders. You find out something’s wrong when the machine stops.
Vendor Lock-In
Each manufacturer’s proprietary ecosystem: different software, different programming languages, different training requirements. Switch vendors = retrain everyone.
Downtime Kills Profit
When a PLC fails, production stops. Hunting for legacy code, legacy software, legacy programmers. Weeks of downtime while the line sits idle.
Tap. Assign. Done.
Every configuration action happens through the touchscreen. Visual pin-out diagram — tap any pin to set it as Input, Output, Analog In, or Analog Out. Color-coded confirmation: green for inputs, red for outputs, blue for analog. Duplicate detection warns of conflicts.
If This, Then That.
No text-based programming. All rules built through touch-friendly UI elements. Conditions and actions from dropdown menus. Rules displayed as visual cards — drag to reorder priority, toggle on/off without deleting, test mode simulates in real-time.
Time It. Count It. Automate It.
Create named timers (on-delay, off-delay, retentive) and named counters (up, down, up/down). Configure through simple numeric fields: duration, target count, reset conditions. Visual status shows running state, elapsed time, and count value on the dashboard.
Verify Before You Deploy.
Before any configuration change goes live, the system runs a simulation showing expected I/O behavior. Conflict detection warns if rules contradict each other. Dry-run mode executes logic against simulated inputs for 60 seconds. Instant rollback to last known-good configuration. Every change saved with timestamp and user ID.
Ready to deploy.
Tell Your Machine What to Do.
In English.
Import your machine documentation into KevAI-OS. Claude reads every manual, every wiring diagram, every sensor spec. Then just describe what the machine needs to do — and get a complete ForgeLogic configuration ready to deploy. No training. No if/then builder. Just say it.
From Documentation to Configuration.
KevAI-OS turns ForgeLogic from a “simplified PLC” into an “intelligent PLC.” Import machine docs → Claude builds a knowledge base → Describe needs in plain English → AI generates complete configuration → Review and deploy.
Your Machine Is Now a Data Platform.
ForgeLogic isn’t just a controller — it’s a complete data system for every machine it controls. Real-time dashboards, historical reporting, automated alerts, and multiple delivery methods.
One Dashboard. Every Machine.
When a facility runs multiple ForgeLogic units, fleet management becomes the killer feature. Single KevAI-OS dashboard showing all units with map view and color-coded status overlays.
ForgeLogic Doesn’t Just Monitor. It Learns.
The AI analyzes cycle time patterns, sensor trends, I/O failure frequency, maintenance correlation, cross-machine differences, energy consumption, and operator behavior. Then it recommends.
The Math Speaks for Itself.
Scenario: Replace a failed Allen-Bradley SLC 500 controlling a simple packaging machine. Factor in hardware, software licenses, programming labor, and monitoring systems.
- Configure through HMI touchscreen
- No AI, no KevAI-OS required
- Full settings screens and rule builder
- Built-in monitoring and reporting
- User login and access control
- Connect ForgeLogic to KevAI-OS
- Import machine documentation into vault
- Claude generates configs from plain English
- User reviews and deploys
- Remote monitoring via KevAI-OS dashboard
- Fleet management and AI optimization
- Send machine specs to Hibb Co.
- We program via KevAI-OS + Claude
- Ship back the configuration file
- 24–72 hour turnaround
- Rush service: same-day at 2x pricing
- Remote support during first commissioning
Custom circuit board with 12V/24V industrial I/O, integrated capacitive touchscreen, ARM/ESP32 RTOS processing, and multiple communication options. Designed for the factory floor.
| Model | Screen | Digital I/O | Analog I/O | Est. MSRP |
|---|---|---|---|---|
| FL-7 (Entry) | 7" capacitive touch | 8 DI / 8 DO | 4 AI / 2 AO | $1,500 |
| FL-10 (Standard) | 10" capacitive touch | 16 DI / 16 DO | 8 AI / 4 AO | $2,200 |
| FL-10P (Pro) | 10" capacitive touch | 24 DI / 24 DO | 12 AI / 6 AO | $2,800 |
| FL-EXP (Expansion) | N/A | 8 DI / 8 DO | 4 AI / 2 AO | $400 |
HMI Application
Settings screens, rule builder, dashboards, reports. What the user sees and touches.
Configuration Engine
Translates settings into executable logic. If/then compiler, pin manager, threshold engine.
Real-Time I/O Engine (RTOS)
Deterministic scan cycle. Reads inputs, evaluates logic, writes outputs. Watchdog timer.
Communication Layer
Ethernet, WiFi, BLE, Modbus, MQTT. KevAI-OS MCP connector. REST API. OTA updates.
Data & Reporting Engine
SQLite database for I/O logs, run counts, timestamps, failures. Report generation and email export.
Walk Up. Tap. Configure.
ForgeLogic broadcasts WiFi or Bluetooth LE. Technician walks up with iPhone/iPad, scans QR or taps NFC, gets full configuration interface on mobile. Deploy new configs with drag-and-drop.
Industrial-Grade Protection.
Hardware watchdog timer puts outputs in safe state if software locks up. Dedicated E-stop input bypasses all logic. Role-based access control with full audit trail. Encrypted config at rest, TLS in transit, works offline.
The Aging PLC Emergency
Packaging plant. Allen-Bradley SLC 500 died. 1998 install. Nobody has the code. RSLogix 500 discontinued. Traditional fix: $8,000+ and 2 weeks. With ForgeLogic: Jason pulls an FL-10, imports the wiring diagram photos into KevAI-OS, Claude generates config in 5 minutes. Machine runs in 2 hours.
The Non-Programmer Tech
Food processing plant, 6 conveyor systems with aging PLCs. Maintenance tech knows the machines inside and out but has zero programming experience. With ForgeLogic FL-7: configure each conveyor through dropdown menus. “Motor runs when start is pressed AND guard is closed.” No code. No programmer. No license fees.
Fleet Optimization
Bottling plant, 12 identical filling machines with ForgeLogic FL-10. After 90 days, KevAI-OS fleet dashboard shows Machine 8 fills 6% fewer bottles per shift. AI identifies fill valve close delay is 0.3s longer. One-tap fix. Machine 8 immediately matches fleet performance.
Done-For-You Service
HVAC company in Ohio needs to replace a rooftop unit controller. They email Hibb Co. the wiring diagram, sequence of operations, and sensor list. KevAI-OS generates the config. Kevin reviews it, emails back. Tech loads via USB. Total turnaround: 36 hours.
| Stream | Model | Price Range | Margin |
|---|---|---|---|
| Hardware Sales | One-time purchase | $1,500–$3,000/unit | 40–60% |
| AI Programming Service | Per-job fee | $200–$1,000/machine | 80%+ |
| KevAI-OS Pro | Monthly subscription | $12–$18/mo | 90%+ |
| Fleet Monitoring | Monthly per machine | $5–$15/mo/machine | 90%+ |
| Custom Configuration | Consulting | $150/hr | Variable |
| Training/Certification | Per student | $500–$2,000 | 70% |
| I/O Expansion Modules | Hardware add-on | $200–$500/module | 40–60% |