Next-Generation Universal PROFINET Gateway System

A global industrial device manufacturer specializing in automation and control systems partnered with PSI to design and develop a next-generation Universal PROFINET Gateway System. The goal was to create a high-performance, flexible platform capable of transmitting and analyzing large volumes of industrial data across complex network topologies, while supporting future compliance with Safety Integrity Level (SIL) standards.

PSI engineered a Linux-based, object-oriented gateway solution that provides a PROFINET interface to up to eight PROFIBUS network segments. Each segment supports up to 32 devices (with some configurations scaling to 250), allowing communication with as many as 256 dynamic field devices — including sensors and controllers — through a high-speed, 1-millisecond control loop. The system enables seamless transmission of input and output data between industrial control systems and field devices managed by PROFIBUS PA masters.

Designed for use in demanding industrial environments, the gateway system supports both redundant and non-redundant configurations, offering failover capability and dynamic hot-swap support at every level. The architecture emphasizes reusability, testability, and portability across different operating systems, making it a foundational platform for a family of gateway products across various fieldbus protocols.

To ensure software quality and maintainability, PSI implemented a comprehensive suite of approximately 100 unit tests targeting internal libraries, which led to early bug detection, improved reliability, and better long-term support. Throughout the design, PSI focused on building a robust and modular platform with an eye toward eventual SIL-1 and SIL-2 compliance.

By combining real-time performance with architectural flexibility and system-level redundancy, PSI delivered a reliable and scalable gateway solution that supports industrial automation at scale — helping the client accelerate innovation while ensuring high availability, reliability, and safety.