As of the end of february, the project “modbus-tcp-based optimization of electronic scale communication” (modbus-tcp-based) implemented by the taikura port technical team has been operating steadily for a year. This innovative “zero hardware input” programme not only succeeded in a year-long “zero failure” operation, but also addressed the root causes of the communication disruption that had plagued the company's electronic scales for a long time。
Previously, the taikura port electronic weigh communications relied on gateway equipment for agreement conversion. Since the beginning of 2025, there have been frequent failures in the electronic scales gateway in the discharge process and the replacement of three units within two months, resulting in frequent loss of electronic scales data, which has seriously affected the precision reconciliation of the discharge output。
Faced with the difficulties of frequent hardware failures, the takura port technical team decisively jumped out of the passive cycle of “replacement” and turned to the system architecture to seek cure。
The technical team leader, li jong-taek, who was the project leader, recalled: “every time the gateway is broken, the field data is broken, and the replacement of new equipment is not only costly, but the key is to delay production. We were wondering if we could get rid of this "stop" from the root。
With this in mind, the team innovation proposes a “de-linking” approach, fully exploiting the existing equipment potential, replacing the “hardware gateway” through “software upgrades” and reshaping communication links。
In response to bottlenecks in the modbus-tcp agreement that were not supported by the original programmable logical controller (plc), the technical team independently loaded the dedicated communications extension package and prepared a matching program, successfully equipping plc with the capability to communicate directly with the ethernet and completely eliminating the gateway as a source of failure。
Li zongsai introduced: “we are like helping plc “to unlock” a new skill that allows it to `understand' the language of electronic scales and to speak directly. All the calibrations and fittings in the middle are our own work." the entire retrofit process was carefully designed and implemented step by step, resulting in the seamless transmission and integration of electronic scales through the optimized plc system into a medium-controlled platform and the safe and smooth migration of the data links。
This optimization has brought significant multiple benefits to taikura. At the technical level, the technical team was autonomous throughout the process, with a comprehensive mastery of the core technology from protocol configuration to system commissioning and the formation of complete technical files, such as the debug method, the fault check guide, which achieved full autonomy and control of the communications system. The economic benefits are equally significant, as the project is expected to save approximately $28,000 per year in equipment procurement and maintenance costs, with real gains and losses in terms of reduced and efficiency gains。
