When should I choose EtherCAT for PLC replacement?

Choose EtherCAT when your machine requires deterministic, high-speed synchronization across distributed nodes, such as multi-axis servo control or real-time distributed I/O.

Is RS485 still practical in migration projects?

Yes. RS485/Modbus is common in brownfield equipment and serves as a practical compatibility bridge during PLC migration. It's cost-effective and widely supported.

Can multiple protocols be supported in one board?

Yes, our board architecture can combine field-level protocols (CAN, RS485) with Ethernet gateway functions in a single platform for maximum flexibility.

Protocol Guide

PLC Replacement by Communication Protocol

Communication architecture is a primary decision point in any PLC migration project. The right protocol choice affects real-time performance, system complexity, BOM cost, and long-term maintainability.

Unlike PLC module systems where protocol support requires purchasing separate communication modules, custom board solutions integrate protocol stacks directly on the controller, reducing both cost and wiring complexity. Here's how to evaluate each protocol for your migration project.

Protocol	Typical Use	Migration Note	IdeatorTech Board
EtherCAT	Servo and distributed high-speed control	Best for deterministic real-time network requirements	✅ EtherCAT F429
CAN/CANopen	Automotive and distributed industrial nodes	Cost-efficient for robust multi-node control	✅ F407, H743, F103ZE
RS485/Modbus	Process instruments and legacy systems	Good compatibility for brownfield equipment	✅ All series
Ethernet	Gateway and data integration layer	Useful for MES/SCADA connectivity and diagnostics	✅ F407, H743, EtherCAT

FAQ

Protocol Selection Questions

Can EtherCAT and standard Ethernet coexist?

Yes, many systems use EtherCAT for control loops and Ethernet for diagnostics or upper-layer integration. Our EtherCAT F429 board supports both simultaneously.

Which protocol has lower migration complexity?

RS485/Modbus often has lower migration complexity in existing legacy installations, since most existing field devices already support it. CAN is next in complexity, while EtherCAT requires more architectural planning.

Do protocol choices affect BOM significantly?

Yes. PHY and isolation component choices can influence BOM and should be evaluated with target production volume. EtherCAT requires dedicated PHY hardware, while RS485 transceivers are very cost-effective.

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