Modbus Device Detection via Communication Gateway
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Solution Overview
Problem
Industrial control systems face complexity in detecting and identifying equipment connected via Modbus communication protocol across multiple networks, particularly due to long discovery times and inability to identify devices connected downstream of communication gateways.
Innovation Solution
A method implemented in a communication controller that searches for IP addresses of devices with open ports, sends Modbus identification requests, and creates lists of responding devices, including a database to differentiate between communication gateways and terminal equipment, allowing for efficient detection and identification across Ethernet and serial Modbus networks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a technician manually detects and identifies all connected equipment in a large industrial control system, then complete validation of system conformity can be achieved, but the process becomes complex and time-consuming
Solution Approach 1:
The system performs automatic self-detection and self-identification of all connected equipment. The communication controller autonomously scans the network, sends identification requests, and compiles equipment lists without requiring manual intervention, thereby achieving complete detection while significantly reducing the time and expertise required
Solution Approach 2:
The manual mechanical process of technician-based detection is replaced by an automated electronic system. The communication controller uses automated message exchange protocols to detect and identify equipment, substituting human labor with an electronic automation system that operates faster and more consistently
2Measurement precision
If all connected equipment is subjected to recognition attempts using fragmentary data comparison, then equipment identification can be achieved, but the discovery time becomes extremely long and cannot be evaluated a priori
Solution Approach 1:
The system performs preliminary actions by first discovering all equipment with open ports and creating an initial list before proceeding to detailed identification. This preliminary discovery phase allows the system to evaluate the total discovery time a priori and structure subsequent identification steps efficiently
Solution Approach 2:
The identification process is segmented into distinct phases: first discovering equipment with open ports, then sending specific identification requests, and finally comparing responses with reference values. This segmentation allows each phase to be optimized independently and provides better time estimation capability
3Device complexity
If a single communication protocol is used for equipment discovery and identification, then the process is simplified, but equipment connected downstream of communication gateways cannot be identified
Solution Approach 1:
The communication controller is designed with multi-functionality to handle multiple communication protocols and network topologies. It can operate as both a Modbus TCP server and client, and communicate via both TCP/IP and serial Modbus protocols, allowing it to adapt to different network configurations including those with communication gateways
Solution Approach 2:
The communication gateway acts as an intermediary between different network segments. The controller uses the gateway to reach downstream equipment by sending requests through the gateway, which then forwards them to the appropriate serial Modbus devices on the second network
Data Source
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AI summary
The present invention relates to a method for detecting and identifying communicating equipment (12, 13, 14, 22, 23, 24) using a Modbus communication protocol, connected via a first Ethernet communication network (11) and at least one second communication network (21), the first and second communication networks being linked by a communication gateway (12). The invention also relates to a communication controller (10) implementing such a method.