How to Convert LoRa to Modbus

How to Convert LoRa to Modbus

📋 Executive Summary

Our gateway solution seamlessly connects LoRaWAN sensor networks with industrial Modbus systems by leveraging Chirpstack's IoT stack. This middleware enables long-range IoT sensors to integrate directly with industrial control systems, providing an efficient bridge between modern LPWAN technology and traditional industrial protocols.
Note: This method is applicable to R1520LG

✨ Key Features & Benefits

💧 LoRaWAN Integration


  1. Chirpstack Compatible: Direct integration with Chirpstack's MQTT events
  2. Automatic Device Registration: Dynamic handling of new LoRaWAN devices
  3. Long Range Coverage: Leverage LoRaWAN's extensive range capabilities
  4. Low Power Operations: Support for battery-operated sensors

🖥️ Device Management

  1. Centralized Dashboard: Monitor all LoRaWAN devices from a single interface
  2. Auto-Discovery: Automatic detection of new devices through Chirpstack events
  3. Health Monitoring: Track device age, signal strength, and connection status
  4. Signal Quality: Monitor RSSI and SNR for each device


🔒 Robust Architecture

  1. Scalable Design: Support for multiple LoRaWAN devices
  2. Error Handling: Comprehensive logging and error recovery
  3. Thread-Safe Operations: Concurrent device handling
  4. Modular Structure: Easy to maintain and extend

🏭 Industrial Integration

  1. Modbus TCP Server: Expose LoRaWAN data to industrial systems
  2. Flexible Mapping: Automatic Modbus register assignment
  3. Data Conversion: Automatic scaling and type conversion
  4. Status Monitoring: Device age and connection status tracking

🛠️ Technical Specifications

System Architecture

  1. LoRaWAN Network Server: Chirpstack
  2. Gateway Interface: MQTT subscription to Chirpstack events
  3. Industrial Interface: Modbus TCP Server
  4. Management Interface: Web-based dashboard

Protocol Support

  1. LoRaWAN Features
  2. Integration: Chirpstack integration via MQTT
  3. Device Support: Handles multiple device types
  4. Decoding: Automatic payload decoding
  5. Monitoring: Signal quality tracking (RSSI/SNR)

Modbus TCP Server

  1. Port Configuration: Configurable settings (default: 5020)
  2. Function Support: Function Code 3 (Read Holding Registers)
  3. Register Allocation: 100 registers per device
  4. ID Management: Automatic slave ID allocation

🔄 Data Processing

  1. Type Conversion: Automatic float scaling (×100 for register storage)a.
  2. Register Organization:
  3. Registers 0-9: Primary sensor data
  4. Register 10: Device age
  5. Remaining registers: Additional metrics
  6. Value Handling: Support for various data types (numeric, string hashing)

💻 Technology Stack

  1. Backend: Python 3.x with Flask
  2. Frontend: Modern JavaScript, CSS3
  3. Storage: JSON configuration files
  4. Architecture: Multi-threaded architecture

💎 Business Value Proposition

💰 Cost Efficiency

  1. Infrastructure: Reduce wiring with long-range LoRaWAN
  2. Power Management: Battery-operated sensors reduce infrastructure needs
  3. Integration: Use existing Modbus systems
  4. Maintenance: Self-managing operation with automatic handling

⚡ Operational Benefits

  1. Coverage: Monitor large industrial areas efficiently
  2. Power Efficiency: Long battery life for sensors
  3. Deployment: Quick setup with automatic registration
  4. Reliability: Built-in error handling and monitoring

📈 Enhanced Monitoring

  1. Range: Cover remote or distributed assets
  2. Data Access: Instant access to sensor readings
  3. Network Health: Comprehensive signal quality monitoring
  4. System Overview: Complete solution monitoring

🚀 Implementation & Support

  1. Deployment Requirements
  2. R1520LG
  3. Compatible LoRaWAN sensors
  4. Remote Modbus Master SW

Configuration Steps

  1. Configure Chirpstack: Gateway Settings, Application Settings, Sensor types (CODEC to be applied)
  2. Install the application and configure the gateway to be accessible by your networ
  3. Set LoRa parameters on the Gateway
  4. Set up Modbus parameters. (Port to be hosted on the R1520LG).
  5. Deploy LoRaWAN sensors
  6. Collect generated Modbus parameters, to be used on the Modbus Master side

🔮 Future Enhancement Opportunities

  1. The types of sensors and their CODECs are being handled individually. If the application doesn't work for your type of sensor specifically CODEC, it will be added with the next patch.

🎯 Conclusion

Our LoRaWAN to Modbus gateway provides an efficient solution for integrating long-range wireless sensors with industrial control systems. By combining the benefits of LoRaWAN technology with traditional industrial protocols, organizations can implement wide-area monitoring while maintaining compatibility with existing systems.

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