Real-Time, Linux-Based Industrial Communication Gateway

A global leader in industrial automation and connectivity solutions engaged PSI to re-engineer the embedded software for a key gateway product used in process and factory automation environments. The gateway, a critical component in enabling field device interoperability, needed to support seamless communication with a wide range of industrial sensors, meters, and controllers using WirelessHART. The system also had to reliably handle protocol translation for upstream server communications over Modbus and HART IP via TCP/UDP.

PSI was tasked with refactoring the legacy gateway system to improve performance, reduce complexity, and enhance long-term maintainability. The engagement involved a comprehensive redesign of approximately 80% of the original codebase. Through careful optimization and modernization of the system architecture, PSI reduced the total source code size by 50%, significantly improving efficiency while maintaining full protocol compatibility and support for expanding field device types.

By applying its deep expertise in embedded development and industrial communication protocols, PSI delivered a streamlined, scalable solution that extended the product’s lifecycle and adaptability. The result was a more robust and maintainable platform that continues to evolve — nearly a decade later — as new features and capabilities are added to meet the demands of modern industrial networks. PSI’s long-term partnership with the client underscores the reliability and flexibility of the solution, supporting their broader mission of advancing digital connectivity and automation across industrial environments.