Enterprise-Class Managed Switch Design

Project in a Nutshell: We developed a remote access device for an international automation solutions provider, enabling PLC and industrial system monitoring through Ethernet, RS232/485, and MPI. Built on the NXP IMX6ull SoC, the device supports remote troubleshooting and software updates for clients’ systems worldwide, streamlining operations and enhancing support efficiency.

Client & Challenge

A provider of comprehensive automation solutions, such as advanced electrical cabinets with PLCs, servo drives, and custom PC software solution applied in various industrial processes worldwide, including hydraulic presses, industrial robots, and image processing projects.

Promwad was assigned to design a device enabling remote access to the client's projects through Ethernet, RS232/485, and MPI protocols. Also, a new modular PCB design should incorporate a SOM and run one of the ARM Linux distributions.

Solution

1. Hardware Design

We designed hardware for this project on the NXP IMX6ull SoC. Our engineers integrated the EG25-G LTE module by Quectel to enable cellular connectivity. Also, they incorporated a WiFi module (ESP32-S2-WROOM by Espressif Systems) into the controller to enhance its connectivity capabilities.

2. Software Development

The software was based on Buildroot Linux with the Linux kernel version 5.14.14.

Promwad developed a BSP package for the device, including several key components and features:

RS485/RS232 interface driver to support seamless communication,

WiFi firmware and driver to enable wireless connectivity,

EG25-G QMI interface support for data transfer,

bring-up of DDR and EMMC components.

Our engineers implemented A/B software updating using the RAUC tool to facilitate the updates. We also enabled Ethernet via IP through USBIP and Serial via Ethernet using the socat utility.

As part of the buildroot customisation, the Promwad team added new packages such as SoftEther VPN, USBIP, and esp32 tools.

To ensure device certification, we created specialised testing scripts.

Business Value

Our client received a new remote access device for PLCs. With remote access options, the client can efficiently troubleshoot, maintain, and update software without physical access to their systems. This makes the new solution stand out with its enhanced customer service.

Reach Out

More of What We Do for Industrial Automation
Industrial Solutions: explore our expertise in developing industrial automation solutions that keep networks running smoothly and resiliently.
Digital Twins Design: a case study of development based on Xilinx Kria SoM and using real-time modelling for an oil and gas company.
MTP Integration: Check out how we propose to address modular interoperability using the Module Type Package standard

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