Navigating Communication Protocol Conversion in Industrial Automation

Oct 22

Since industrial automation emerged with the advent of the Modbus communication protocol, automation companies have each developed their own methods for data transmission, usually in completely different ways.

This evolution has produced numerous communication protocols and technologies over the years: Modbus RTU, Modbus TCP, Ethernet/IP, OPC, OPC-UA, Profibus, Profinet, MQTT, Sparkplug B, MTConnect, and countless proprietary protocols depending on your hardware and software.

Even as certain protocols have gained market dominance and become standards like OPC-UA, Ethernet/IP, and MQTT, you'd expect seamless integration to be straightforward. The reality? Even if the latest PLC from any major brand supports all these protocols out of the box, you'll inevitably encounter legacy hardware that requires integration.

This is where communication protocol conversion becomes essential. In our decades of experience across multiple industries and technology platforms, communication protocol conversion is arguably the most challenging aspect of any automation project.

Managing communication between devices is one area where experience makes all the difference. The more protocols you've encountered throughout your career, the better equipped you are to handle them as modern technology is deployed.

This post explores the challenges and solutions related to communication protocol conversion.

Integrating Legacy and Modern Hardware from the Same Vendor

Let's face it: a complete rip-and-replace of an existing process control system is daunting and extremely costly. Beyond the expenses for hardware and labor, you'll likely face significant downtime during installation, testing, and commissioning.

A more practical approach? Add modern hardware to your existing control system using protocol converters where needed.

Working with a single hardware vendor makes this process considerably easier than mixing vendors.

Typical examples include:

DataHighway+ to Ethernet/IP cards for Allen Bradley/Rockwell hardware
Profibus to Profinet converters for Siemens hardware
Modbus RTU to Modbus TCP converters for Schneider Electric PLCs

The advantages of this approach:

Everything is thoroughly tested within the same hardware ecosystem
Single point of contact for technical support
Fewer integration complexities

Integrating Legacy and Modern Hardware from Different Vendors

When your legacy and modern equipment come from different vendors, you can still build an effective solution—but the complexity increases significantly.

This scenario typically requires third-party hardware devices. For example, connecting a modern Allen Bradley/Rockwell PLC with a Modbus RTU/TCP device or a Siemens Profibus/Profinet device requires a bridge solution like a Red Lion Data Station Plus or a Prosoft module. Depending on your needs and Opto 22 groov EPIC or RIO might also fit the bill.

While this adds another component to your system and potentially another support contact, it's often the most practical solution.

A recent Corso Systems success story: We integrated legacy Profibus communications from an existing Siemens PLC into an Allen Bradley ControlLogix PLC. Using Prosoft modules to handle the Profibus communication and convert the tags to an Ethernet/IP device, we created a seamless mapping solution in the ControlLogix PLC. Compared to using non-Profibus devices, this added approximately one week of research, development, and implementation time, and the system has been running flawlessly ever since.

Have questions about hardware options for your new control system? We're here to help!

Hardware vs. Software Communication Protocol Conversion

Another viable option is using software tools like Ignition, Kepware, or Node-RED to bridge your devices.

Why this approach works: These software platforms typically offer extensive connectivity options for legacy devices, allowing you to configure tags that your modern hardware can read using protocols like OPC-UA.

Considerations:

Adds licensing costs and an additional system component
Requires expertise for setup and maintenance
Minimal ongoing maintenance once properly configured

Important caveat: Software solutions rely on PC hardware, which typically isn't as rugged as industrial-grade equipment for indefinite operation in harsh environments. You're also exposed to risks like Windows updates causing disruptions. For these reasons, we favor hardware-specific solutions whenever possible, using software approaches as a last resort.

Need guidance on software options for your control system integration? Chances are we've tackled similar challenges before, please reach out and see how we can help!

Why Communication Protocol Conversion is Critical for Unified Namespace (UNS) Integrations

As manufacturing increasingly adopts the Unified Namespace (UNS) methodology, communication protocol conversion has become more important than ever for system modernization.

Since most UNS integrations use MQTT as their backbone, you need the proper communication protocols to convert data to MQTT for your UNS—or adopt a hybrid approach using tools like Ignition to bridge legacy devices and your UNS.

Corso Systems has helped numerous companies build the infrastructure needed for comprehensive UNS integration. Have questions about getting started? Reach out—we're ready to help!

Partner with Experts Who Understand the Complexity

Communication protocol conversion can be the most challenging part of any system integration project. This is where partnering with trusted experts like Corso Systems makes all the difference. We take the worry out of getting everything set up and make the process as seamless as possible.

While there may occasionally be something we haven't encountered before, we've successfully handled a vast array of protocol conversion combinations. Ready to get started? Drop us a line, and we'll help you get everything you need for a successful integration!