SC2SC
Sensor Connector to Siemens Control
Date: 2023/2024
Programs: Siemens TIA Portal | EPLAN | Visual Studio Code | Arduino DIE
Technologies: TCP/IP | Ethernet | Wi-Fi | ESP32 micro controller | Siemens PLC
About the Project
The “SC2SC” (abbreviation for Sensor Connector to Siemens Control) project aims to develop a flexible, costefficient data interface for connecting ESP32-based sensor modules to Siemens S7 PLC systems. In view of the significantly increasing relevance of individual IoT solutions in an industrial context, a TCP/IP-based communication between microcontrollers and programmable logic controllers was designed. The project was carried out as part of the Industry 4.0 Masterclass in collaboration with Mr. Philipp Kyr, BSc. and took place over a period of two semesters. The focus was not only on implementing the interface, but also on designing standardized processes to minimize user errors during integration. The project work thus forms the basis for modular extensions to industrial systems using freely configurable sensor technology and addresses key challenges such as interoperability, efficiency and safety in industrial communication.
Technical Appropach
The technical basis of the system is a specially developed communication protocol via TCP/IP. Communication is bidirectional between Siemens S7-1200/1500 controllers and various ESP32 models, which are connected via WLAN or Ethernet. A standardized data structure, which includes initialization, directive and sensor data headers, ensures consistency and expandability. In this context, the PLC acts as a data broker whose task is to analyze and process the incoming information in real time. Particular attention was paid to validating and securing the data by means of checksums (CRC), time stamps and user access control. Configuration is carried out via a user-friendly web interface on the ESP modules, making integration easier even for less experienced users. The project also integrates concepts for scalability, error detection and redundancy and was developed iteratively using evolutionary prototyping.
Retrospective
The system met the functional requirements and demonstrated stable communication in laboratory conditions. The prototype developed has the ability to reliably transmit sensor data to Siemens PLC systems, creating a solid foundation for industrial IoT applications. The implementation of the configuration interface and standardized data structures proved to be particularly successful and enables efficient integration of additional sensors. Problems in the initial configuration were solved through code optimization. The initial challenges in terms of network stability and hardware management were successfully addressed through the use of structured tests and iterative improvements. The project results offer significant potential for further developments, for example through the integration of additional protocols such as Profinet or cloud-based analysis modules. The simple expandability, low costs and openness make the concept interesting for retrofit applications and for extending existing systems with special solutions.
