In many factory networking upgrades, a fundamental disconnect exists between legacy device protocols and modern system requirements. Field devices like PLCs, smart instruments, and remote I/O modules commonly use Modbus TCP, while newer SCADA, MES, and data platforms demand OPC UA for standardization and security. This article explores a proven solution using Kepware as a middleware data hub and the OPM-820 hardware gateway to bridge this gap. The approach enables secure, efficient data transfer without replacing existing equipment, significantly reducing costs and downtime. For engineering teams working on industrial IoT or smart manufacturing initiatives, this integration pattern offers a pragmatic path to achieving centralized control and real-time visibility. The commercial value is high, as it directly supports digital transformation in manufacturing environments.
A practical guide to connecting legacy Modbus TCP devices to modern OPC UA systems using Kepware and OPM-820, addressing a key challenge in factory digitization.