Modbus/RS-485 Industrial Controller
A ruggedized I/O controller board bridging legacy factory-floor Modbus RTU instrumentation into a modern Ethernet-based SCADA system.
The client's factory equipment relied on a mix of legacy RS-485 Modbus RTU instrumentation that their new Ethernet-based SCADA system couldn't natively communicate with, risking a costly full instrumentation replacement across their production line.
We designed a ruggedized protocol-bridging controller board with isolated RS-485 Modbus RTU ports on one side and industrial Ethernet with Modbus TCP on the other, built around an STM32 with a dedicated real-time protocol translation layer. The board included surge protection and galvanic isolation rated for the client's electrically noisy production environment.
The client integrated their existing instrumentation into the new SCADA system without replacing a single field sensor, avoiding an estimated large-scale instrumentation replacement cost and multi-week production line downtime.
“We were bracing for a full instrumentation replacement. Autoematio's bridge controller let us keep every sensor we already had installed. That alone paid for the entire engagement many times over.”
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