Design and implementation of Modbus TCP/RTU industrial gateway

Abstract

The rapid advancement of industrial automation necessitates reliable and efficient communication protocols to ensure seamless integration and operation of diverse control systems. This project presents the design and implementation of an Industrial TCP/RTU Modbus Gateway, aimed at bridging the gap between Modbus RTU (Remote Terminal Unit) and Modbus TCP (Transmission Control Protocol) networks. The gateway facilitates bi-directional data exchange between Modbus RTU and Modbus TCP devices, enabling enhanced interoperability and centralized control in industrial environments. The objective of this project is to develop a robust and efficient TCP/RTU Modbus Gateway solution to address the challenge of the communication gap between different Modbus devices, ensuring seamless and real-time data exchange. This report addresses the design and implementation of both the hardware and software aspects of the gateway, in addition to an application for configuration and diagnostics, incorporating advanced error-checking mechanisms and diagnostic tools to maintain data integrity and facilitate troubleshooting. Ultimately, this project aims to deliver a scalable and adaptable solution that can be easily integrated into existing Modbus-based infrastructures, thereby improving the efficiency and productivity of industrial automation systems. The results of this project demonstrate the successful development and implementation of the TCP/RTU Modbus Gateway. Testing confirmed that the gateway effectively facilitates seamless and real-time data exchange between Modbus RTU and Modbus TCP devices, achieving low-latency and high-throughput communication. The advanced error-checking mechanisms and diagnostic tools proved effective in maintaining data integrity and simplifying troubleshooting processes. Overall, the gateway met all design objectives, providing a scalable, adaptable, and reliable solution that enhances the interoperability and efficiency of industrial automation systems.