CODESYS MODBUS TCP communication via a CODESYS Gateway with Factory IO

This project simulates an automated assembly and sorting line that classifies parts based on color — Green, Blue, and Gray. I used:

🔹 CODESYS V3 for PLC programming
🔹 Soft PLC (CODESYS Control Win SL)
🔹 MODBUS TCP communication via a CODESYS Gateway
🔹 Full I/O mapping between the soft PLC and Factory I/O

One of the biggest challenges was getting some of the actuators, limit switches, and robotic mechanisms in Factory I/O to work with external PLC control. That meant writing a PLC program to manage not just the conveyors and sensors, but also control a robotic pick-and-place system — all from CODESYS!

💡 While recording the video, I encountered a few issues — and I decided to leave them in. I walk through some of the troubleshooting steps, hoping it gives others insight into the debugging process when working with virtual automation systems.

🛠️ Even though it was a virtual factory, I still had to tweak my logic, reposition limit switches and actuators, and revise parts of the code — just like in the real world. It's a great reminder that no matter how solid the program looks on paper, we always need real-time testing and iteration on the ground (or on screen!).

⏩ Skip to minute 6:00 to see the system running. The beginning covers an overview and the CODESYS program setup.