Posts Tagged ‘DeviceMaster UP’

Distribution Center Enabled Via Modbus Communication

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Distribution Center Communication

With the continued growth of online shopping, one large online retailer was interested in improving their operations within their distribution center locations. This online retailer turned to Comtrol when they learned of the DeviceMaster UP’s ability to support Master-to-Master communication. Traditionally, Modbus communication takes place between a master and a slave; the master gives out the command, and the slave answers back with the necessary information: weight, size, temperature, etc. Although many industry experts believed Master-to-Master communication wasn’t possible, Comtrol has discovered a way!

Distribution Center Communication

Through the purchase of Comtrol’s DeviceMaster UP 2-Port 1E Modbus, the DeviceMasters support multiple functions within the distribution center, including a scanning, labeling, and printing process. Orders are weighed before they receive their appropriate shipping label, and to ensure accuracy, the DeviceMasters communicate with one another sending information regarding the size, weight, contents, etc. to ensure the package is receiving the correct shipping label.

Impressed with the improvements in their distribution center, the large integration project was given the go ahead and is now being implemented in additional warehouses in Europe, North America, and Canada.

To learn more about this solution, CLICK HERE

Creative Solutions for Industrial Automation

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In an industry as unique as industrial automation, it can be difficult to find the products to fit your business’ needs. Comtrol’s products have many applications in the industrial space. Our DeviceMaster UP, RocketLinx Industrial Ethernet switches, and IO-Link Masters have been utilized in manufacturing and distribution centers, connecting multiple production processes, and in making efficient applications run seamlessly.

With its feature rich options, Comtrol’s DeviceMaster UP provides EtherNet/IP™, Modbus/TCP, Modbus RTU/ASCII, and PROFINET connectivity to a wide variety of devices. Easily connect your PLCs to serial and Ethernet TCP/IP devices such as barcode scanners, RFID readers, weigh scales, vision systems, printers, encoders, and sensors. DeviceMaster UP has been used in many industrial automation settings to improve the efficiency of assembly lines, communication between different automated systems, and more.

The RocketLinx Industrial Ethernet switches are designed to meet the performance and environmental demands for applications requiring extended operating temperatures, rugged housings and high performance and reliability. With both managed and unmanaged models available, the RocketLinx ES series of switches provide cost-effective networking solutions delivering the industry’s best Ethernet switch technologies.

Offering advanced industrial protocol gateways such as IO-Link masters, to ruggedized Ethernet and PoE switches, power supplies, and media converters, Comtrol has a solution for your industrial manufacturing application.

DeviceMaster’s Security Features

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Recent data security breaches have put an emphasis on security. Customers of the medical, financial, and government industries have increasing worries that their confidential information may be stolen. Comtrol’s DeviceMaster RTS, PRO, and Serial Hubs enable secure data communication across connected serial devices.

Comtrol’s DeviceMaster family of products offer the enhanced security features of SSL and SSH encryption. With these additions, DeviceMaster is able to effectively serve an even greater range of roles, reliably enabling serial to Ethernet communications while protecting sensitive data.

For users with demanding security requirements, there are two options that the DeviceMaster can provide. The first involves a free software download from Comtrol’s website called Secure Port Redirector. This software creates COM ports that redirect data between the host application and DeviceMaster using encrypted SSL data streams. For the second option, DeviceMaster can itself be locked down, giving full control over communication ports to administrators only.

Read more HERE

Custom DeviceMaster for Product Organization

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A large company approached Comtrol with a tricky situation. Because the client’s primary business required the rapid and efficient movement of merchandise, they were continuously sorting thousands of barcode labels every day. The client’s current sorting platforms could not process any barcodes longer than 10-digits, and with such large volumes of barcodes, they needed a way to upgrade their system. This urgent need for a cost efficient and timely solution brought the company to Comtrol Corporation.

Comtrol was able to design and implement a custom solution for this client. Using a DeviceMaster UP, Comtrol created custom message routing, custom diagnostic and configuration pages, and full documentation on the custom product.

Read more HERE

Customer Solution: Industrial Brewery Production and Diagnostics

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A major American brewing company was in need of a solution for its production facilities that could network multiple production processes together  and be able to withstand temperatures in excess of 140°F without failing. Multiple controllers and production machines needed to be seamlessly connected, and it had to work flawlessly.  After extensive research and testing, the company chose to deploy Comtrol’s DeviceMaster® UP.

Loaded with Modbus/TCP firmware, the DeviceMaster UP provides the brewery a flexible, easy-to-use and highly robust solution.  Controllers include SCADA systems communicating over Modbus/TCP and PLCs communicating via Modbus/TCP, serial Modbus/RTU or serial Modbus/ACSII.  The production machines communicate via ASCII data, Modbus/RTU or Modbus/ASCII.  Further complicating the situation, the ASCII data machines need to communicate to each controller independently.

The DeviceMaster UP seamlessly networks the controllers to the production machines. The automatic Modbus protocol conversion functionality enables multiple Modbus controllers to communicate to the serial Modbus machines.  The industry’s first command/response mode enables multiple controllers to independently communicate to the ASCII production machines.


Product Spotlight: DeviceMaster® UP

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The DeviceMaster UP industrial Ethernet gateways are designed to provide EtherNet/IP, Modbus/TCP, Modbus RTU/ASCII, and PROFINET PLC connectivity to a wide variety of devices.

Advanced features include:


  • Protocol Flexibility – EtherNet/IP, Modbus/TCP, PROFINET IO
  • DualConnectPlus™ Technology – connect raw/ASCII devices (serial and/or Ethernet) to PLCs and/or applications simultaneously.  String, RFID, and barcode data filtering eliminates redundant data while extracting the RFID and barcode parameters
  • Web-based Configuration – makes configuration changes quick and easy
  • Diagnostic Capabilities – informative message logs, communication, and status pages
  • Unique protocol-specific features – Peer-to-Peer Modbus/TCP, Write-to-Tag EtherNet/IP, etc.
  • Temperature rated for extreme conditions 
  • Rugged Housing – with panel, rack and DIN rail mounting options
  • PortVision™ Plus – remote monitoring and management software to automatically locate DeviceMaster UPs on the network, enable user to view status, update firmware and resolve issues remotely
  • …and more!


Energy Substation Surveillance & Power Monitoring

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With rising value of scrap metal and struggling economies throughout the world, theft of copper and other materials is on the rise.  Surveillance is increasing at energy substations, power plants and other critical infrastructure locations in attempt to deter thieves from cashing in stolen copper wiring, aluminum doors and other materials at scrap yards or metal melting facilities.

Comtrol and a few other companies have collaborated to create a solar-powered security system to monitor critical infrastructure around the world.  The system is responsible for monitoring the power grid and establishing surveillance to prevent material theft and protect critical operations.  As seen in the diagram, security cameras in each location record live feed from the grounds to send via Ethernet to Comtrol’s RocketLinx® ES8105 industrial Ethernet switch.  The data travels via Ethernet to a wireless bridge, which communicates the data to a remote control center network.



Aircraft Part Manufacturing Automation

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A large sensor and measuring instrument manufacturer has teamed up with Comtrol to offer an innovative factory automation capability to industrial manufacturers and warehouse distribution centers.  Optimizing efficiency and increasing productivity through mechanization and industrial innovation is the goal.

An industrial production company creating aircraft parts received a plan from a factory automation integrator to streamline a floor process in the warehouse.  The specific assembly process was responsible for etching numbers onto finished parts and readying them for shipment.

Included in the assembly, the sensor manufacturer’s laser marking machine etches part numbers on the completed projects.  A robotic arm then receives each etched piece and packs it properly for shipping.  This configuration is integrated and controlled by a PLC, PC application and Comtrol’s DeviceMaster® UP 2-Port 2E with its DualConnectPlus™ feature.  This manufacturer needed to connect the raw/ASCII laser marker over serial RS-232 to an EtherNet/IP enabled PLC.

keyence laser marker industrial automation factory automation


Ethernet Over Fiber-Optics: As clear as glass!

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As the demand for Ethernet connectivity increases in the market, so do the demands on Ethernet connectivity.  By transmitting Ethernet signals over fiber-optic cabling, users are able to extend the distance Ethernet signals will reach, protect against external Electro-Magnetic Interference (eliminating internal), and shield products from electrical surges.  All in all – by transmitting your data through light in a glass cable, fiber-optic connectivity is a great way to get more out of your Ethernet connections!

While the sales pitch on fiber above certainly sounds appealing, there are many aspects to consider during a migration to fiber-optic connectivity.  In order to select the best fiber optic connectivity solution, we must address:

1. Type of fiber-optic communication
2. Bandwidth
3. Fiber-optic connection type

Relating directly to these concerns, users must ask themselves

1. Type of fiber-optic communication

How do I want my data to be sent over fiber?

fiber-optic communication Fiber-optic communication is available in two different forms: Single-Mode and Multi-Mode.  Single-Mode, generally associated with longer distance capabilities, provides a hyper-efficient mode of transportation for the data-carrying light signals.  Multi-Mode fiber, while less expensive, is a less efficient method of fiber transmission.  As data travels across Single-Mode fiber it will degrade less than it would over the same distance with Multi-Mode fiber.

Furthermore, each fiber strand is designed to support a specific wavelength of fiber transmission.  Wavelength, measuring the distance between successive crests of a light wave, also influences efficiency and distance fiber can be transmitted.


Efficiency in Energy Management

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An energy meter manufacturing company based in Cairo, Egypt discovered that there is an economical solution to the extra time and cost that can be accrued by sending out company personnel to manually read electrical meters and log energy usage from each floor of a commercial building.

Property management and energy companies can reduce time and expenses by adding a DeviceMaster® Ethernet gateway to their physical system configurations as well as a corresponding software program on their networks.

Comtrol’s DeviceMaster UP 1-Port has been used by the energy meter manufacturing company to complement its meters and provide as a package to property management companies.  The DeviceMaster UP 1-Port has the capability to connect the energy meters together for remote reading and monitoring.device master ethernet gateway energy connectivity



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