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Topic Walkthrough

Integration of Multi-Protocol Industrial Data Sources (Modbus ASCII, OPC UA) into Node-RED for Unified Data Acquisition and Visualization

1. Books

Free Book
Advanced Industrial Automation - A great book for PLC Programmer at beginner level
  • ​It Includes Basics of PLC Programming, How to start writing ladder logic
    • it has more than 100 examples to solve
    • It has all the basics covered that you will require to become plc programmer
  • ​We are giving it for free for students Who are desperete to Learn
    • You need to Sign In First to access the download page in the menu
  • Click Here to download the E-book directly to your device if logged in

 2. System Architecture Overview

ISPSoft + CommGR (Delta PLC Simulation)

  • Purpose: Simulate a Delta PLC communicating via Modbus ASCII.

  • CommGR acts as the Modbus communication gateway.

  • Kepware OPC server is used as a Modbus client to read data from the simulated PLC.

Siemens PLC Simulation (with Inbuilt OPC UA Server)

  • Purpose: Simulate a Siemens PLC that exposes process variables directly through its OPC UA server.

  • Node-RED acts as an OPC UA client, connecting directly to the Siemens OPC UA endpoint to read tag values.

OPC UA Simulation Server

  • Purpose: Generate additional simulated process data (e.g., temperature, pressure, flow rate) using an OPC UA simulation server.

  • This adds diversity to the dataset and allows testing of data handling from multiple OPC UA sources.

Node-RED (Data Aggregation Layer)

  • Purpose: Serve as the unified data acquisition and visualization layer.

  • Flows in Node-RED collect data simultaneously from:

    • Kepware (via Modbus/OPC)

    • Siemens OPC UA server

    • OPC UA Simulation Server

  • Data is then processed, combined, and displayed in a dashboard or published to MQTT/Database


  • Source Protocol Middleware Node-RED Connection Type
    ISPSoft + CommGR Modbus ASCII Kepware OPC DA/UA Client
    Siemens PLC OPC UA OPC UA Client Node
    OPC UA Simulation Server OPC UA OPC UA Client Node


Results

All three simulated systems successfully provided data to Node-RED simultaneously.

Data was synchronized, combined, and visualized in real-time.

The unified structure allowed easy scalability—additional OPC UA or Modbus sources could be added without major flow redesign.

Demonstrated the power of Node-RED as a protocol-agnostic integration layer for Industry 4.0 applications..

 Future Enhancements

  • Store data into a time-series database (InfluxDB or MongoDB).

  • Use Grafana for advanced visualization.

  • Add MQTT or HTTP API for cloud connectivity.

  • Implement data analytics or machine learning for predictive maintenance.