In-depth Explanation of Multi-Protocol Support in Cellular Router: How to Achieve Seamless Integration Between PLCs and Sensors?
In the wave of Industry 4.0, the core of smart manufacturing lies in data interconnection and collaboration among devices. However, industrial sites often face protocol barriers: Programmable Logic Controllers (PLCs) and sensors cannot directly interact with data due to the use of different communication protocols.
For example, the Siemens S7-1200 PLC does not natively support Modbus RTU master station functionality, preventing it from directly reading data from temperature sensors using the Modbus protocol. In an automobile factory, the Automated Guided Vehicle (AGV) experienced a 30% decrease in navigation accuracy due to protocol incompatibility between the PLC and sensors. How can the multi-protocol support of cellular router break this deadlock? This article provides an in-depth analysis from three dimensions—protocol compatibility, data conversion logic, and typical application scenarios—and offers actionable solutions.
Scenario 1: Mismatch between PLC and Sensor Protocols
A chemical enterprise uses a Siemens S7-1200 PLC to control the temperature of a reaction vessel, but the temperature sensor uses the Modbus RTU protocol. Since the PLC does not support Modbus RTU master station functionality, data collection requires additional configuration of a Modbus-to-PROFINET gateway, increasing system complexity by 30%.
A smart factory simultaneously uses PLCs from Siemens, Mitsubishi, and Omron, along with sensors supporting different protocols (e.g., SICK laser distance sensors supporting EtherNet/IP and Banner flow sensors supporting Modbus TCP). Protocol incompatibility leads to data silos, necessitating the use of multi-protocol routers for unified access.
A new energy enterprise needs to upload equipment data from a battery production line to the cloud for AI analysis, but the (on-site) equipment uses diverse protocols (e.g., PLCs use PROFINET, while sensors use Modbus RTU). Data must be converted to the MQTT protocol via a cellular router before uploading, but traditional routers only support single-protocol conversion, failing to meet demand.
Scenario 2: Mixed Use of Multi-Brand Devices
Scenario 3: Edge Computing and Cloud Collaboration
Cellular routers achieve data mapping between different protocols through built-in protocol conversion engines. Taking the USR-G809s as an example, its core functions include:
Protocol Conversion: Supports over 20 industrial protocols, including Modbus RTU/TCP, PROFINET, EtherNet/IP, and DeviceNet, enabling bidirectional conversion between protocols. For example, it can convert data from a Modbus RTU sensor into PROFINET format for PLC reading.
Data Preprocessing: Supports edge computing functions, allowing local operations such as data filtering, threshold judgment, and data compression. For example, it can convert raw temperature sensor data into "normal/alarm" status, reducing PLC computational load.
Network Management: Supports VLAN division, QoS policies, and multi-link backup to ensure data transmission reliability and real-time performance. For example, dual-SIM card design enables automatic switching between 4G/5G and wired networks, with network interruption time <50ms.
Requirement: An automobile factory needs to integrate vibration sensor data (using the Modbus RTU protocol) into a Siemens S7-1200 PLC (supporting PROFINET) for equipment condition monitoring.
Solution:
Hardware Connection: Connect the vibration sensor's RS485 interface to the RS485 terminal of the USR-G809s in a daisy-chain manner. Use an industrial Ethernet cable to connect the router's PROFINET interface to the PLC's PN port.
Protocol Configuration:
In the USR-G809s's Web management interface, set Modbus RTU parameters (baud rate 9600, 8 data bits, 1 stop bit, no parity) and map sensor register addresses (e.g., vibration values stored in register 40001) to the PROFINET input area (e.g., IB0-IB1).
In the PLC's TIA Portal project, import the USR-G809s's GSDML file, add it as a PROFINET IO device to the network, and allocate input/output address spaces.
Data Interaction: The PLC reads real-time vibration values by accessing the router's input area via the PROFINET protocol. Simultaneously, the PLC can send control commands (e.g., start/stop sensor collection) to the router via the output area.
Effect: Achieves millisecond-level data interaction between the sensor and PLC, reducing equipment fault diagnosis response time from minutes to seconds.
Requirement: A smart factory needs to uniformly access Siemens PLCs (PROFINET), Mitsubishi PLCs (CC-Link IE), Omron PLCs (EtherNet/IP), and Modbus RTU-compatible sensors for centralized production data monitoring.
Solution:
Network Topology: Adopt a star topology, connecting all devices to the LAN ports of the USR-G809s via an industrial switch. The router connects to the enterprise intranet via its WAN port.
Protocol Conversion:
Configure multi-protocol conversion rules in the USR-G809s: Convert CC-Link IE and EtherNet/IP protocols into Modbus TCP, then communicate with upper-computer software supporting this protocol.
For Modbus RTU sensors, directly connect them via the router's RS485 interface and convert them into Modbus TCP format.
Data Integration: The upper-computer software reads all device data through a unified interface (e.g., OPC UA), enabling production dashboards and abnormal alarms.
Effect: Reduces wiring costs by 30% and shortens equipment integration cycles from 2 weeks to 3 days.
Scenario 3: Edge Computing and Cloud Collaboration
Requirement: A new energy enterprise needs to upload equipment data (e.g., voltage, temperature, pressure) from a battery production line to the cloud for AI analysis, but the on-site equipment uses diverse protocols (PLCs use PROFINET, while sensors use Modbus RTU).
Solution:
Data Collection: Connect Modbus RTU sensors via the USR-G809s's RS485 interface and PLCs via its PROFINET interface for centralized data collection.
Edge Processing: Configure edge computing rules in the router:
Data Filtering: Remove abnormal temperature sensor values outside ±5℃.
Threshold Alarms: Trigger local relay outputs and generate alarm logs when voltage exceeds thresholds.
Data Compression: Compress raw data within 1 minute into average, maximum, and minimum values to reduce uploaded data volume.
Cloud Upload: Upload processed data to the cloud platform via the MQTT protocol, supporting real-time monitoring and historical data queries.
Effect: Reduces cloud data volume by 90% and improves AI model training efficiency by 50%.
Comprehensive Protocol Support: Covers mainstream industrial protocols such as Modbus RTU/TCP, PROFINET, EtherNet/IP, DeviceNet, and OPC UA, supporting bidirectional conversion between protocols.
Robust Hardware Performance:
Rich Interfaces: 1x 100Mbps WAN port, 4x 100Mbps LAN ports, 1x RS232, 1x RS485, 2x DI/2x DO, supporting independent subnet division.
High Protection Level: IP30 protection, EFT electrical fast transient testing, ESD electrostatic protection, built-in hardware watchdog, and adaptability to harsh environments (-20℃~70℃).
Network Redundancy: Supports dual-SIM cards and wired/WiFi primary-backup link switching, with network interruption time <50ms.
Intelligent Software Functions:
Edge Computing: Supports local processing such as data filtering, threshold alarms, and data compression.
Remote Management: Enables device status monitoring, firmware upgrades, and parameter batch configuration via the USR Cloud platform.
Security Encryption: Supports 5 VPN protocols (PPTP, L2TP, IPSec, OpenVPN, GRE), ensuring financial-grade data transmission security.
Smart Agriculture Weather Monitoring: The USR-G809s integrates routing, DTU, and network IO functions, enabling a single device to connect temperature and humidity sensors, wind speed sensors, and light sensors, uploading data to the cloud platform for real-time farmland environment monitoring.
Smart Store Real-Time Monitoring: The USR-G809s collects data from cameras, temperature and humidity sensors, and smoke sensors in stores, uploading it to the cloud platform for unified management, supporting 7×24-hour device status monitoring and abnormal alarms.
Industrial Automation Production Line: In an automobile parts factory, the USR-G809s achieves multi-protocol interconnection between PLCs, sensors, robots, and AGVs, supporting real-time production data collection and remote equipment control, improving production line efficiency by 20%.
Multi-protocol support in cellular routers is key to breaking communication barriers between devices, but specific selection must align with enterprise needs. We offer the following services to facilitate rapid implementation:
Free Requirement Diagnosis: Fill out an online form, and our technical team will provide a preliminary solution within 24 hours, including protocol compatibility analysis, network topology design, and equipment selection recommendations.
Sample Testing Service: Submit your application requirements to obtain the opportunity for sample testing, verifying device performance in real environments with remote debugging and technical support.
Customized Development: For special scenarios (e.g., explosion-proof, intrinsic safety requirements), we offer ODM/OEM services, supporting protocol stack customization and hardware interface expansion.
In the wave of the Industrial Internet, choosing a multi-protocol cellular router is not just a technical decision but a strategic investment. The USR-G809s provides a stable, efficient, and secure industrial network foundation for enterprises with its comprehensive protocol support, robust hardware performance, and intelligent software functions. Submit the form now to embark on your digital transformation journey!
