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Telecommunication
Industrial interface converter with TCP/IP extension
In the rapidly evolving landscape of Industry 4.0, seamless, reliable, and efficient communication between industrial devices is more crucial than ever. Addressing this demand, our cutting-edge Modbus Ethernet Gateway and RemoteCom technologies bridge the gap between traditional serial communication protocols and modern Ethernet networks. Designed to optimize data transmission, enhance connectivity, and ensure robust performance, these solutions are essential for modern industrial environments.a
Industrial devices use various interfaces that are often incompatible with each other and are unable to communicate without additional equipment. To solve this problem, we have designed a converter whose main function is to enable data exchange between production line controllers, robots, HMI screens, and servers. Basing the project on a microcontroller allows the user to additionally control the data flow and redirect it to the Cloud using network interfaces. This technology is an essential part of building a modern 4.0 Industry system.
Many uses
We have created a universal system ready to perform various functions depending on the software and hardware version.
The use of a fast interface enabling communication with a computer network allows for a wide range of dynamic adaptation of the device to emerging needs and tasks. A wired Ethernet interface solution was used, connected to a socket in the popular RJ45 8-pin standard. Additionally, the system has been expanded by adding the possibility of wireless communication via short-range wireless communication and Wi-Fi modules.
The basic operation of the device provides for two operating modes:
- Direct connection
We have designed software that allows easy control of communication by setting parameters on the server. The entire protocol configuration process takes place in a web browser – the user sets the transmission speed, number of data bits, stop bits, parity and CRC control. - COM port – hub
The desktop application we have created for transparent support of virtual serial ports (COM) enables convenient integration of the device with existing tools using this type of communication. We ensure cross-platform compatibility with MS Windows, Linux and macOS operating systems.
Modbus Ethernet Gateway: Transforming Industrial Communication
The Modbus Ethernet Gateway is a pivotal technology facilitating communication between LAN hosts and serial devices by converting Modbus protocols—specifically Modbus TCP and Modbus RTU/ASCII. As a cornerstone of Industry 4.0 implementation, it enables seamless integration and data exchange across diverse industrial devices.
Key Features and Capabilities:
- Versatile Transmission Modes: The gateway supports two primary transmission modes—Gateway and Router. In Gateway mode, the port communicates with Slave devices, while in Router mode, it communicates with Master devices. This flexibility allows each port to operate in different modes, catering to various industrial communication setups
- Advanced Microcontroller Integration: The devices utilize either the ESP32 Xtensa LX6 microcontroller or the STM32F4 microcontroller, depending on the required ports and interfaces. This ensures high efficiency and reliability in handling a wide range of industrial communication protocols.
- Enhanced ESD Protection: To combat the challenges of electrostatic discharge (ESD) in industrial settings, our gateways are equipped with dedicated EMC integrated circuits. These circuits significantly improve connection quality by reducing industrial interference, ensuring reliable data transmission.
- Comprehensive Connectivity: The gateway supports RS232, RS485, and RS232/RS485 interfaces, allowing for extensive compatibility with various industrial devices. It also features a wide voltage power input (12 – 30 VDC) and low power consumption, making it adaptable to diverse power environments.
- Intuitive Web-Based Configuration: Users can easily configure the gateway via a web interface, allowing for quick adjustments to network settings, protocol configurations, and port assignments, streamlining the setup process and reducing downtime.
RemoteCom: Bridging Serial Communication and Modern Networks
RemoteCom complements the Modbus Ethernet Gateway by offering advanced serial communication capabilities over modern networks. Designed for RS232/RS485 interfaces, RemoteCom leverages the powerful ESP32 and STM32F4 microcontrollers to facilitate robust communication between serial devices and network hosts.
Key Features and Capabilities:
- Web-Based Configuration: Like the Modbus Ethernet Gateway, RemoteCom allows for easy configuration through a web interface. Users can manage LAN settings, TCP/UDP sockets, and UART parameters effortlessly, ensuring a seamless integration process.
- Multiple Connectivity Options: RemoteCom supports both wired (Ethernet) and wireless (WiFi and short-range wireless communication ) communication, providing flexibility in device connectivity and management—crucial for modern industrial setups with varied communication needs.
- USB/UART Conversion: RemoteCom includes a USB/UART converter, enabling the conversion of USB data to UART signals for transmission over RS232/RS485 interfaces. This feature is especially useful for integrating legacy devices into modern network infrastructures.
- Versatile Communication Hub: RemoteCom enables the establishment of a communication hub where TCP clients can interact with RS232/RS485 devices through Ethernet, facilitating seamless data exchange and remote device management.
EMC compatibility, climate tests, safety
The possible importance of the device imposes the obligation to guarantee immunity to electromagnetic disturbances occurring in industrial environments and to meet emission requirements in accordance with the EU EMC directive. Numerous systems are used to decouple both low-frequency and high-speed interference. Added protection against overvoltage and electrostatic discharge on each input/output connection. The device is equipped with additional grounding connections to ensure the highest protection.
We performed climatic tests under the full load of the system in a temperature and humidity range exceeding the requirements of industrial standards. The experience of our engineers allowed us to achieve above-average results and ensure guaranteed reliability in all conditions.
Additionally, the highest security of devices connected to our converter was ensured. Thanks to the introduction of optical isolation of the input/output ports, in the event of a failure of one of the communicating devices, the remaining devices are not exposed to overvoltages not exceeding 3kV. Interfaces that remain in a state of suspended communication or those that have not been connected at all in a given configuration are subject to impedance matching using active terminal termination. This procedure improves the signal quality of other devices on a common bus and provides protection against electromagnetic wave reflection, which carries a potential risk of damaging the signal source.
Mechanics
Thanks to the small size of the device, durable insulating housing, solid screw connections, and practical DIN rail latches, a very convenient and refined mechanical solution has been achieved. Well-thought-out and ergonomic arrangement of input/output sockets allows for flexible connection configuration even in the most difficult-to-access places in the factory. Additionally, the system has been adapted to service work thanks to facilities based on a modular structure.
Front-end
We have designed and developed an intuitive and transparent front-end of the application, which makes using the converter even more enjoyable. We achieved excellent user experience using the following technologies:
Javascript
Vue.js
Bootstrap
Protocol Buffers
Python
Flask
C++
libserialport
Python
Hardware
We decided to adapt two versions of the computing unit – Cortex-M4 STM32 or Xtensa ESP32. The choice of the microcontroller to be installed depends on the configuration of the interfaces used and the software dedicated to the product’s application. Physical support for RS232, RS485, USB, M-Bus, Ethernet, Wifi, and short-range wireless communication standards has been implemented. Such flexibility allows for a convenient selection of technology and optimization of production and operating costs. Operation in a wide range of power supply conditions has been refined, both with DC and AC voltage. Advanced optimization allows for low power consumption and the implementation of battery power.
Firmware
All device processes are controlled based on the FreeRTOS real-time operating system. Network connectivity was implemented by using an open LwIP stack, which means multiple devices can communicate regardless of their physical differences. Additionally, the stack is characterized by automatic connection stabilization in the event of energy or communication problems. Full functionality is restored without the need for user intervention. Support for various TCP/IP protocols has been implemented, including telnet, modbus-tcp, http and https. Modbus-RTU/ASCII was used for asynchronous serial transmission. Google’s Protobuf data sequencing method was also used.
Industrial-Grade Reliability and Safety
Both the Modbus Ethernet Gateway and RemoteCom are engineered to meet the rigorous demands of industrial environments. We’ve incorporated several safety and reliability features:
ESD and Overvoltage Protection
To safeguard devices from electrostatic discharge and overvoltage, we’ve implemented advanced protective measures across all input/output connections, ensuring the longevity and stability of the communication system.
Optical Isolation
Our converters utilize optical isolation for input/output ports, preventing damage from overvoltage in connected devices, ensuring that the failure of one device does not compromise the entire network.
Robust Mechanical Design
The compact, durable housing, combined with practical DIN rail latches and solid screw connections, makes our devices easy to install and maintain, even in the most challenging industrial environments.
Summary
When designing the converter, we wanted to create a system that would have the following features:
- versatility – the ability to be used with various software and hardware;
- dynamics and adaptability;
- stability and safety.
The device we created met all the basic assumptions, and then some more. You can buy it from our client’s online shop!
