Protocol Converter

Automation systems consist of many components and subsystems from different manufacturers, which often use different industrial communication standards or protocols - from fieldbus systems to real-time Ethernet protocols and proprietary systems. This diversity can lead to problems when trying to integrate these components into a coherent automation system. Protocol converters bridge this gap by translating data between different protocols so that different devices can communicate effectively. They therefore play a very important role in the seamless integration and exchange of data, control commands and status information between different industrial devices, systems and networks that use incompatible communication protocols.

Protocol converters come with features like compact size, DIN rail or wall mounting options, wide operating temperature ranges, and isolated interfaces to withstand harsh environments. They enable, among other things, the integration of legacy serial devices into modern Ethernet-based control systems, as well as the connection of field devices to higher-level control networks.

By using protocol converters, industrial automation systems can achieve greater flexibility, scalability, and interoperability, allowing for the seamless exchange of data and the optimization of production workflows.

Just as the landscape of automation systems and industrial communication is diverse, so too is the range of protocol converters designed to integrate these heterogeneous networks.

1. Different Types

   While gateways and switches are often the first devices that come to mind when discussing protocol conversion, the options extend beyond these. Other types include embedded solutions, software-based converters, and modular I/O systems with integrated protocol conversion capabilities, all tailored to meet specific application needs.

2. Protocol Translation

   The primary function of protocol converters is to translate between various industrial communication protocols. This capability enables devices utilizing different protocols—such as Modbus, CANopen, EtherCAT, PROFINET, and DeviceNet—to seamlessly exchange data, control commands, and status information. The converter acts as a bridge, transforming the data format, encoding, and framing from one protocol to another.

3. Media Conversion

   Certain protocol converters can transform the data transmission medium itself, facilitating conversions between copper cables, fiber optic cables, and even wireless communication. This capability significantly extends the reach and flexibility of industrial networks, allowing for the integration of devices across various physical media.

4. Enabling Legacy Device Integration

   Protocol converters are essential for integrating legacy serial devices into modern industrial automation systems. They enable these older devices to communicate with newer Ethernet-based controllers and software, thus preserving valuable investments in existing equipment while enhancing system capabilities.

5. Supporting Real-time Communication

   Some protocol converters are engineered to meet real-time and deterministic communication requirements in industrial applications, including robotics and motion control. This ensures timely and reliable data exchange critical for dynamic processes.

6. Closing the Gap Between OT and IT

   Edge gateways represent a groundbreaking form of protocol conversion that bridges the gap between Operational Technology (OT) and Information Technology (IT). These gateways serve as vital interfaces in the Industrial Internet of Things (IIoT), laying the groundwork for fully networked production environments in line with Industry 4.0 principles.

Given their critical functions, protocol converters are ubiquitous across all areas of automation. Their role will continue to be indispensable in driving efficient and innovative automation solutions into the future.

Protocol converters find applications across various industries and scenarios where there's a need to bridge communication between devices or systems using different protocols. 

• Building Automation

  Protocol converters enable communication between different building systems such as HVAC, lighting, access control, and security. This allows for integrated and efficient building management. They enable seamless communication between devices using protocols like BACnet, LonWorks, KNX, and Modbus, allowing centralized management and control of building functions.

• Industrial Automation

  Protocol converters allow devices and machines from different manufacturers to exchange data and instructions, facilitating centralized monitoring and control. They facilitate communication between PLCs (Programmable Logic Controllers), HMIs (Human-Machine Interfaces), sensors, actuators, and other devices that may use different fieldbus or industrial Ethernet protocols such as PROFIBUS, Ethernet/IP, and DeviceNet. They ensure interoperability and enable data exchange for efficient control and monitoring of manufacturing processes.

• Energy Management

  Protocol converters ensure that data from diverse sources like smart meters and renewable energy sources can be integrated and utilized for effective energy monitoring and optimization. They also enable communication between meters, sensors, SCADA (Supervisory Control and Data Acquisition) systems, and energy management software. They enable real-time monitoring, control, and optimization of energy usage in utilities, substations, and industrial facilities.

• Transportation Systems

  In transportation applications, protocol converters facilitate communication between different subsystems, such as signaling, passenger information, and fleet management, ensuring smooth operation and management. They integrate devices such as barcode scanners, RFID readers, weigh scales, and conveyor systems. They enable communication between these devices and warehouse management systems (WMS) or enterprise resource planning (ERP) systems, improving efficiency and accuracy in inventory management, order processing, and shipment tracking.

• Oil and Gas Industry

  Protocol converters are employed to integrate equipment and systems with different communication protocols, enabling centralized monitoring and control of operations. It is used to integrate devices such as sensors, actuators, PLCs, and SCADA systems in remote monitoring and control applications. They support different protocols and enable efficient management of production, refining, and distribution processes.

• Telecommunications

  In telecommunications networks, protocol converters facilitate communication between different network elements and protocols, such as converting between synchronous optical networking (SONET) and Ethernet protocols. They enable interoperability between legacy and modern telecommunications equipment, supporting network upgrades and expansions.

• Smart Grids

  Protocol converters play a crucial role in smart grid systems by enabling communication between smart meters, distribution automation equipment, SCADA systems, and utility control centers. They enable real-time monitoring, control, and optimization of power distribution networks.

Protocol converters find widespread applications across various industrial sectors, enabling seamless communication, data exchange, and integration of disparate systems and devices, ultimately improving operational efficiency, flexibility, and cost-effectiveness in industrial automation and control.

Enabling Interoperability: Protocol converters bridge the gap between different industrial communication protocols, allowing devices and systems using incompatible protocols to exchange data, control commands, and status information. This enables greater interoperability and integration of diverse industrial equipment. This interoperability facilitates the integration of diverse devices from different vendors into a unified system.

Integrating Legacy Devices: Protocol converters play a crucial role in integrating legacy serial devices into modern Ethernet-based industrial automation systems. They allow these older devices to communicate with newer controllers and software, preserving investments in existing equipment. It also helps to facilitate the integration of heterogeneous devices and equipment into a cohesive automation system by translating data formats and protocols, protocol converters. They ensure that disparate components can communicate effectively with each other, enabling efficient data exchange and coordination.

Improving Flexibility and Scalability: Protocol converters provide flexibility by allowing existing devices to communicate with newer equipment and systems that may use different protocols. They enable the integration of a wide range of devices and systems, allowing for the optimization of production workflows and the implementation of more advanced control and monitoring strategies. This flexibility reduces the need for costly upgrades or replacements, extending the lifespan of existing infrastructure and supporting scalability as the industrial environment evolves.

Efficiency: While protocol converters require some configuration and mapping effort, they significantly reduce the engineering effort compared to custom-built solutions for protocol conversion. This can lead to faster deployment and reduced project timelines. They also optimize data transmission by performing tasks such as data compression, encryption, or filtering, improving network efficiency and reducing bandwidth consumption. They ensure that data is transmitted reliably and securely, even in demanding industrial environments with high levels of noise and interference.

Cost-effectiveness: Protocol converters offer a cost-effective solution for achieving interoperability and integration within industrial automation systems. Instead of replacing existing equipment or investing in expensive upgrades, organizations can use protocol converters to enable communication between legacy and modern devices, minimizing costs and maximizing return on investment.

Enabling Media Conversion and standardization: Protocol converters can transform the data transmission medium, converting between copper cables, fiber optic cables, and even wireless communication. This extends the reach and flexibility of industrial networks. On the other hand, it also helps standardize communication by translating proprietary protocols into widely accepted industry standards. This standardization simplifies system integration and maintenance, promotes interoperability across different vendors and platforms, and reduces dependency on vendor-specific solutions.

Overall, protocol converters play a crucial role in enabling the seamless integration and interoperability of diverse industrial devices, systems, and networks, ultimately enhancing the flexibility, scalability, and efficiency of industrial automation and communication systems. It eventually makes them indispensable tools for optimizing and enhancing industrial processes.

Hilscher is a company that specializes in industrial communication and networking solutions. They are known for their extensive range of products and services designed to enable communication between various devices and systems. Protocol converters play a significant role in Hilscher's offerings, as they are essential for bridging the gap between different communication protocols used in industrial automation.

Hilscher's broad gateway portfolio offers a suitable solution for every application: from cost-optimized devices for dedicated and simple applications to flexible high-end devices for demanding and individual conversion tasks. The company has devices for control cabinet mounting as well as connectors for direct mounting. They offer a cost-effective and simple solution for any type of data conversion - whether in use with fieldbus, Ethernet, Real-Time Ethernet systems or a mixture of these. This enables efficient integration of devices and system components into existing structures as well as the connection of systems and network components. Hilscher's edge gateways with container management also serve as intelligent computing platforms at the edge and enable sensor-to-cloud communication.