Modbus Conveyor Simulator Project
Build a complete Modbus-controlled conveyor simulation with status, speed command, fault and reset registers.
Learning objective
Build a complete Modbus-controlled conveyor simulation with status, speed command, fault and reset registers.
Components and tools
- Development board
- Current-limited low-voltage supply
- Digital multimeter
- Oscilloscope or logic analyser
- Emergency power disconnect
Safety before motion
- Use a virtual or low-voltage indicator-only conveyor.nReject out-of-range writes.nSeparate normal control from emergency stop.
Practical procedure
- Define a documented register map.nImplement read-only status and bounded speed setpoint.nRequire start permissive and acknowledgement.nSimulate jam/overcurrent fault.nRequire stop, cause removal and explicit reset.
Measurement checkpoints
| Checkpoint | Expected | Instrument | Safety limit |
|---|---|---|---|
| Register map | Values/types match documentation | Modbus client | Bounded writesnFault reset |
Troubleshooting
| Symptom | Check | Corrective action |
|---|---|---|
| Illegal address | Client offset mismatch | Align zero/one-based mapnUnsafe restart |
Engineering sizing tools
Calculate before powering
Mandatory pre-start gate
Machine safety checklist
The simulated enable button remains locked until every item is confirmed.