Modbus Simulator System for High-Speed Data Transmission
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Solution Overview
Problem
The Modbus protocol faces limitations in data transmission speed and scalability, particularly with increased cable length, which restricts its use in large-scale industrial applications, and existing solutions fail to effectively address data query speeds and event handling.
Innovation Solution
A Modbus simulator system comprising a master node and slave nodes with simulators that optimize data transmission by storing and transmitting only changed register data, using high-speed connections for direct device communication and low-speed connections for node communication, allowing for efficient data transfer and scalability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If standard Modbus connection with cable is used, then data transmission can be achieved, but transmission speed drops quickly as cable length increases
Solution Approach 1:
The patent introduces slave simulators as intermediary devices between the master station and actual slave devices. These simulators cache register data locally and serve the master station directly, eliminating the need for long cable connections while maintaining protocol compatibility. The simulator acts as a local proxy that responds to master requests without requiring physical connection to distant slave devices.
Solution Approach 2:
The system segments the Modbus network into multiple functional layers: master station, slave simulators, and actual slave devices. Each layer handles specific functions independently - the simulator manages local caching and protocol translation, while the master handles high-level data requests. This segmentation allows the master to communicate with simulators at high speed while simulators handle device-specific protocols at lower speeds.
2Reliability
If all slave devices are queried to detect changes, then event detection is possible, but data transmission time increases significantly
Solution Approach 1:
The slave simulator performs preliminary actions by continuously monitoring and caching register data from slave devices in the background. This pre-caching allows the simulator to immediately respond to master requests without requiring real-time queries to actual devices. The simulator prepares data in advance, so when the master requests data, it receives cached values instantly rather than triggering device queries.
Solution Approach 2:
The patent extracts the data caching and protocol translation functions from the main communication path and places them in the slave simulator. The simulator extracts only the necessary register data from slave devices and maintains it locally, separating the time-consuming device interaction from the time-critical master communication. This extraction allows the master to operate at high speed while the simulator handles device-specific timing separately.
3Adaptability or versatility
If Modbus protocol is used for large-scale systems, then device connectivity is achieved, but data transmission speed and event handling capability deteriorate
Solution Approach 1:
Slave simulators serve as intermediary devices that enable large-scale system deployment without sacrificing speed. Each simulator manages a subset of slave devices locally, allowing the master to communicate with multiple simulators in parallel. This intermediary layer enables scalable architecture where the master can rapidly query multiple simulators while each simulator independently manages its connected devices at appropriate speeds.
Solution Approach 2:
The patent adds a temporal dimension to data transmission by implementing time-based caching strategies. The simulator maintains historical register data over time, allowing the master to retrieve data at high speed from the cache rather than triggering real-time device queries. This temporal buffering separates the timing requirements of master communication from slave device interaction, enabling scalable systems with varying speed requirements.
Data Source
AI summary
A data transmission system may include a master node and a slave node. Both the master node and the slave node may comprise modbus simulators. The master node may initialize by receiving register data into its status repository from a status repository on the slave modbus simulator. After initialization, historical events may be transmitted from a historical repository of the slave modbus simulator to a historical repository of the master modbus simulator.


