Alok A Chauhan et al.
/ (IJAEST) INTERNATIONAL JOURNAL OF ADVANCED ENGINEERING SCIENCES AND TECHNOLOGIES
Designing of MODBUS for Continues Process
Control
Alok A Chauhan
M.E.(PERSUING),DEPT. OF CSE
G.H.Raisoni College of Engineering
NAGPUR, INDIA
e-mail: chauhanalok9@gmail.com
Abstract — In order to achieve real-time diagnosis and
accurate calibration, an Master/Slave System based on
Modbus Communication Protocol is to be designed which is
capable of gathering LM35 signals or the 4~20 mA industry
standard signals. It can save pre-defined parameters, gather
the analog data on-site and convert them into digital data for
processing, with rich communication functions to the main
computer. Designed primarily to ensure interoperability
between multi-vendor systems, this protocol also simplify
integration and commissioning of data communication
networks, reduce the installment costs, and allow for
independent testing and validation, which in turn leads to
more efficient designs.
I.INTRODUCTION
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Keywords- Modbus Communication, Continues Process Control
Communication protocols and standards were
introduced to the industry since late 1970‟s. These standard
protocols were quickly adopted for continues process
control applications and gradually replaced their
proprietary counterparts. In addition, communication
systems designed in accordance with these standards can
be more easily upgraded or modified in the future. This is
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especially important, since the advances and innovations in
the field of communication networks often outpace the
frequency of modifications in the continues process control
infrastructure. Therefore, the designed communication
network must be adjustable to continue process automation
designs with the least amount of effort possible.
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One of the communication protocols efficient in
connection with continues process control is described.
MODBUS Master / Slaves protocol principle :
Modbus is a field bus protocol in advanced
manufacturing infrastructure environment, which is not
dependent on the specific type of network, due to its
simplicity, easy implementation and high performance; it
has been a wide range of applications in industrial control
field.
ModBus a kind of master-slave communication, in the
same network, there is a master device and up to 255 sets
of equipments, slave device's address is encoded as I ~
255. Usually, master device only communicate with one
slave device, but when the master device sends 0 address
code which means using broadcast to communicate, and
ISSN: 2230-7818 @ 2011 http://www.ijaest.iserp.org. All rights Reserved.
Vol No. 3, Issue No. 1, 024 - 028
Dr. A.R.Mahajan
DEPT.OF CSE
G.H.Raisoni College of Engineering
NAGPUR, INDIA
sends a message to all the slaves. Standard ModBus using
the RS232C serial interface, so frame is seemed as one unit
in ModBus communication, data structure of frame is the
the same as RS-232C's frame. The communication of
ModBus is consist of a number of frames that include send
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and receive data packets, the meaning of these frames is
defined by the protocol, as long as the controller explained
that the frame data it receives and sends according to the
protocol, the same protocol controller can communicate
with others in the same network.
There are two communicate modes about ModBus
protocol ASCII mode and RTU (Remote Terminal Unit)
mode. ASCII mode is a byte into two ASCII characters to
send, while RTU mode is in hexadecimal form to transmit
data, a byte is one frame, so efficiency of data transmission
is more than ASCII mode, the majority of industrial
controllers are using RTU mode. At present, commonly
transmission rate of ModBus protocol is 1200 bit/s ~ 1
9200 bit/s. The master node issues a MODBUS request to
the slave nodes in two modes _ In unicast mode, the master
addresses an individual slave. After receiving and
processing the request, the slave returns a message (a
'reply') to the master. In that mode, a MODBUS transaction
consists of 2 messages: a request from the master, and a
reply from the slave. Each slave must have an unique
address (from 1 to 247) so that it can be addressed
independently from other nodes.
II. AIM AND OBJECTIVE
The basic aim of this project is to provide advanced
automation in the communication of a continues process
with the implementation of modbus communication
protocol for acquiring data such as temperature and
speed for manufacturing of bakery products and pass it
to connected intelligent device.
By implementing this following are the objectives to
achieve:
 Better real-time diagnosis
 Remote calibration accuracy
 Process aware devices
This will lead to the reduction in industry production
cost and unplanned shutdown .
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Vol No. 3, Issue No. 1, 024 - 028

III. LITERATURE REVIEW
The protocol defines a message structure that can be
recognized and used by a controller, no matter they
communicate through any kind of network. It describes
the process that a controller requests and accesses other
devices, and also it establishes the public format of
message fields and contents. The various work done on
modbus communication protocol in different areas are as
follows:
A connection scheme of a cascade PLC
communication was proposed to solve the defects of
decreasing transmission speed because of long distance
in communication [2]. The communication software of
PLC was also optimized to reduce the cycle treatment
time of PLC CPU, and greatly improve the
communication efficiency and response speed in a fire
water system of hydropower station.
before starting the data processing. The checking may
result in an error, for example a reply from an unexpected
slave, or an error in the received frame. In case of a reply
received from an unexpected slave, the Response time-out
is kept running. In case of an error detected on the frame, a
retry may be performed.
4) If no reply is received, the Response time-out expires,
and an error is generated. Then the Master goes into "Idle"
state, enabling a retry of the request. The maximum
number of retries depends on the master set-up.
5) When a broadcast request is sent on the serial bus, no
response is returned from the slaves. Nevertheless a delay
is respected by the Master in order to allow any slave to
process the current request before sending a new one. This
delay is called "Turnaround delay". Therefore the master
goes into "Waiting Turnaround delay" state before going
back in "idle" state and before being able to send another
request.

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The voltage acquisition system based on modbus
industrial bus and single chip is designed and its prototype 6) In unicast the Response time out must be set long
is also implemented. It consists of MCS51 single chip and enough for any slave to process the request and return the
multichannel voltage acquisition card [1]. And the single response, in broadcast the Turnaround delay must be long
chip. enough for any slave to process only the request and be
able to receive a new one.
In order to improve the efficiency and production of
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continues process contol used in industry, I propose
implementation of de-facto standard i.e modbus
communication protocol for communication between
various devices which are related to each other in a
continues process.

IV.PROPOSED PLAN OF WORK

7) Frame error consists of: 1) Parity checking applied to
each character; 2) Redundancy checking applied to the
entire frame. The state diagram is intentionally very
simple. It does not take into account access to the line,
message framing, or retry following transmission error, etc.

Proposed work can be divided into following steps:

1) Master unit is configured for desired parameter

(Temperature and Speed).
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2) These parameter values are send to slave unit through
Modbus.
3) Sensor are planted at slave unit will sense according to
set values.
4) Upon the request from Master the sensed data of slave
is sent to master unit.
5) If data received is according to set data then the job
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piece will be selected otherwise rejected.

Master State diagram

The following fig no. 2 explains the Master behavior:
Fig No 2 Master State diagram
1) State "Idle" = no pending request. This is the initial state
after power-up. A request can only be sent in "Idle" state. Slave State Diagram:-
After sending a request, the Master leaves the "Idle" state,
and cannot send a second request at the same time. Some explanations about the above state diagram :
2) When a unicast request is sent to a slave, the master 1) State "Idle" = no pending request. This is the initial
goes into "Waiting for reply" state, and a “Response Time- state after power-up.
out” is started. It prevents the Master from staying
indefinitely in "Waiting for reply" state. Value of the 2) When a request is received, the slave checks the
Response time-out is application dependant.
packet before performing the action requested in the
3) When a reply is received, the Master checks the reply

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 Alok A Chauhan et al. / (IJAEST) INTERNATIONAL JOURNAL OF ADVANCED ENGINEERING SCIENCES AND TECHNOLOGIES
Vol No. 3, Issue No. 1, 024 - 028

packet. Different errors may occur: format error in the
request, invalid action, In case of error, a reply must be
sent to the master.
3) Once the required action has been completed, a
unicast message requires that a reply must be formatted
and sent to the master.
4) If the slave detects an error in the received frame, no
V.RESEARCH METHODOLOGY TO BE EMPLOYED:
According to the suggested block diagram and
proposed plan of work this project can be divided into
following phases:-
1) Selection of Hardware and its implementation
2) Selection of Software and its implementation
3) Hardware Software Co-design

respond is returned to the master. 4) Simulation of Result

5) MODBUS diagnostics counters are defined and 5) Actual Working Project

should be managed by any slave in order to provide Selection of Hardware and its implementation

diagnostic information. In this phase various hardware modules are identified

according to the requirement of the project. Another issue
which is to considered while selecting hardware as well as

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software is cost of implementing in specific domain. If cost
of implementing any module is less in hardware then it is
more preferable to implement it in hardware. . Processor
selection is depends on the optimal cost, system
performance, memory space require and testability.
Considering all these parameters following are the list
ES of hardware components which are used in this project.




Microcontroller AVR At mega 16
Differential bus transceiver IC 75179
Temperature Sensor LM35
IC L293 Driver for Motor
 LCD Keypad IC
 Speed Sensor
Fig 3 Slave State Diagram
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Microcontroller AVR Atmega 16
BLOCK DIAGRAM OF PROPOSED SYSTEM
The ATmega16 is a low-power CMOS 8-bit
microcontroller based on the AVR enhanced RISC
architecture. By executing powerful instructions in a
single clock cycle, the ATmega16 achieves
Microcontroller AVR

TEMP, throughputs approaching 1 MIPS per MHz allowing

Atmega16
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SPEED the system designed to optimize power consumption

SENSO
Micr R versus processing speed.
ocon Differenti Salient features of Atmega 16 microcontroller
trolle al Bus
r Transceiv High-performance,Low-power AVR® 8-bit
AVR er IC Microcontroller
Atm 75179
High Endurance Non-volatile Memory segments
Microcontroller AVR

ega1 LCD
6 IC TEMP,
 16K Bytes of In-System Self-programmable
Display
Atmega16

SPEED
SENSO Flash program memory
R
 512 Bytes EEPROM
 1K Byte Internal SRAM
MASTER UNIT  Write/Erase Cycles: 10,000 Flash/100,000
SLAVE UNITS EEPROM

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 Alok A Chauhan et al. / (IJAEST) INTERNATIONAL JOURNAL OF ADVANCED ENGINEERING SCIENCES AND TECHNOLOGIES
 Data retention: 20 years at 85°C/100 years at
25°C
 Optional Boot Code Section with Independent
Lock Bits
JTAG (IEEE std. 1149.1 Compliant) Interface
 Boundary-scan Capabilities According to the
JTAG Standard
 Extensive On-chip Debug Support
Peripheral Features
 Two 8-bit Timer/Counters with Separate
Prescalers and Compare Modes
 One 16-bit Timer/Counter with Separate
Prescaler, Compare Mode, and Capture Mode
Real Time Counter with Separate Oscillator
Four PWM Channels 8-channel,
 10-bit ADC 8 Single-ended Channels
 Programmable Serial USART ES
 Master/Slave SPI Serial Interface
 ProgrammableWatchdogTime
The ATmega16 AVR is supported with a full suite of
program and system development tools including: C
compilers, macro assemblers, program
debugger/simulators, in-circuit emulators, and evaluation
kits
 Urge to move over from CISC to RISC
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 Our project requires the use of ADC which is
inbuilt in AT mega 16.
 Requirement of larger code space.
 8 channel 10 bit ADC
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 Noise Suppression Circuitry Rejects Spikes on
Bus Lines
 Ease in coding due to availability of standard
libraries.
 Flexibility in selection of various baud rates for
UART transmission.
Differential bus transceiver (SN75176):-
The SN75176A differential bus transceiver is a
monolithic integrated circuit designed for bidirectional data
communication on multipoint bus-transmission lines. It is
designed for balanced transmission lines and meets ANSI
Standard EIA/TIA-422-B and ITU Recommendation V.11.
The SN75176A combines a 3-state differential line driver
and a differential input line receiver, both of which operate
from a single 5-V power supply. The driver and receiver
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Vol No. 3, Issue No. 1, 024 - 028
have active-high and active-low enables, respectively, that
can be externally connected together to function as a
direction control. The driver differential outputs and the
receiver differential inputs are connected internally to
form differential input/output (I/O) bus ports that are
designed to offer minimum loading to the bus whenever
the driver is disabled or VCC = 0.
Temperature Sensors LM35 Precision Centigrade
The LM35 series are precision integrated-circuit
temperature sensors (fig no 5), whose output voltage is
linearly proportional to the Celsius (Centigrade)
temperature. The LM35 thus has an advantage over linear
temperature sensors calibrated in ° Kelvin, as the user is
not required to subtract a large constant voltage from its
output to obtain convenient Centigrade scaling. The LM35
does not require any external calibration or trimming to
provide typical accuracies of ±1⁄4°C at room temperature
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and ±3⁄4°C over a full −55 to +150°C temperature range.
Features of Temperature Sensor:-
 Calibrated directly in ° Celsius (Centigrade)
 0.5°C accuracy guarantee able (at +25°C)
 Rated for full −55° to +150°C range
 Suitable for remote applications
 Low cost due to wafer-level trimming
 Operates from 4 to 30 volts
 Low self-heating, 0.08°C in still air
 Low impedance output, 0.1 W for 1 mA load
L293 QUADRUPLE HALF-H DRIVERS (Driver for
Motor):-
The L293 and L293D are quadruple high-current half-
H drivers. The L293 is designed to provide bidirectional
drive currents of up to 1 A at voltages from 4.5 V to 36 V.
The L293D is designed to provide bidirectional drive
currents of up to 600-mA at voltages from 4.5 V to 36 V.
Both devices are designed to drive inductive loads such as
relays, solenoids, dc and bipolar stepping motors, as well
as other high-current/high-voltage loads in positive-supply
applications. All inputs are TTL compatible.
Selection of Software and its implementation
Simultaneously in second phase according to our
embedded system. It is required that software for
hardware must be tested using some sort of simulator .
As per the hardware implementation and compatibility
of that hardware we would select the software.
a) AVR Studio (Assembler/ Simulator)
b) Win AVR ( C-Cross Compiler)
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Vol No. 3, Issue No. 1, 024 - 028

 Automatic „follow me‟ wire routing and junction

Proteus Design Suite dot placement/removal.
The Proteus Design Suite combines schematic capture,
SPICE circuit simulation, and PCB design to make a
complete electronics design system. Add to that the VI. APPLICATIONS
ability to simulate popular micro-controllers running This project can be used in industries where there is a
your actual firmware, and you have a package that can
dramatically reduce your development time when need of continues process control such as:
compared with a traditional embedded design process. 1. Paper and Pulp Industry
2. Soft Drinks and Mineral Water Production
3. Packing Industry
4. Bakery Product Industry

VII.REFERENCES

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[1]Chen Lin ”Research on Voltage acquisition system
based on Modbus Industrial Bus and Single Chip” 2009
International Conference on Signal Processing Systems.
[2]FENG Lei-hua, GUI Wei-hua, YANG Feng
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Fig No 6 Circuit Diagram of Master Units
“Application of Communication Optimization Strategy
Based on Cascade PLC MODBUS in Fire Water System of
Hydropower Station” 2009 Second International
Conference on Intelligent Computation Technology and
Automation.
[3]Daogang Peng, Hao Zhang, Jiannian Weng, Hui Li, Fe
Xia “Design and Development of Modbus Master
A
Monitoring System Based on Embedded PowerPC
Platform” IEEE International Symposium on Industria
Electronics (ISlE 2009).
[4]ZHANG Zhi-qiang, ZHANG Yu-lin “Realization of
Communication between DSP and PC Based on Modbus
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Protocol” 2009 International Conference on Multimedia

Fig No.7 Circuit Diagram of Slave Unit
Features of Proteus Design Suite:
 Produces publication quality schematics.
 Style templates allow customization of supplied
library parts.
 Mouse driven, context sensitive user interface.
Information Networking and Security.
[5] M. Casares*, A. Pinto*, and A. Sainchez”Development
of a NO3-N Analyser for Real-Time Nitrate Control in a
Pilot Urban Wastewater Treatment Plant” 0-7803-9419-
4/05/$20.00 ©2005 IEEE .
[6]Bo Cui, Guangbin Xu “Design and realization of
Intelligent Data Acquisition and Display System Based on
AT89C52 and Modbus” 2009 ISECS International 2007 .

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