IoT gateways: The innovative solution for seamless connectivity in mechanical engineering

IoT gateways: the innovative solution for seamless connectivity in mechanical engineering

1. Introdution

The ongoing digitalization of production requires flexible, end-to-end connectivity. Production control systems such as MES, ERP or monitoring systems can only perform their tasks efficiently with the right data. But how can machines, sensors and IT systems be connected securely and flexibly? This is where IoT gateways play a crucial role.

IoT gateways combine hardware and software to integrate IT interfaces, process data and transfer it flexibly to downstream systems. They enable flexible solutions that can be tailored to the requirements of any modern production. In this article, you will find out what advantages IoT gateways offer and what to look for when selecting a suitable solution.

2. IoT gateway: A new generation for a connected future  

Modern IoT gateways combine robust hardware in the form of an industrial-grade box PC with powerful software. This combination allows even the most complex IT interfaces to be integrated.

The role of hardware

The Box PC serves as a platform and connection point for various devices and systems. Machines, sensors and actuators can be connected via LAN, serial interfaces such as COM1 or GPIO. The GPIO interfaces are suitable, for example, for simple automation tasks such as monitoring limit switches or recording signals at maintenance terminals.

The importance of software

Only the right software turns the box PC into a fully-fledged IoT gateway. A good example is FabEagle®Connect, a software for interface integration. The software connects various protocols such as OPC UA, MQTT, TCP/IP or REST, translates data formats, buffers data and can be used for local processing (edge computing). Local processing minimizes latency and makes data formats and structures seamlessly compatible with cloud systems.

3. Origin and relevance through the ages

With the introduction of IoT technologies in automation technology, the requirements for interfaces and data communication have become increasingly complex. Sensors and devices not only provide simple measured values, but also status reports and alarms from structured data models.

While Profibus, Profinet and TCP/IP have long been the classics in industrial communication, modern applications require more versatile solutions. Protocols such as OPC UA, MQTT, REST or ActiveMQ enable the transmission of complex data structures and formats. However, this requires efficient conversion and processing directly locally - a task that IoT gateways are ideal for.

Decentralized machines that are to be connected to cloud systems pose additional challenges. In such cases, IoT gateways not only act as translators between protocols, but also use firewalls and anti-virus software to create a secure separation between local IT and the internet.

4. Use and benefits in practice

IoT gateways offer practical solutions for various applications in mechanical engineering. They enable both the connection of modern IT systems and the retrofitting of older machines.

Machine connection to cloud solutions

• Increased network security: IoT gateways separate devices and PLC´s from the cloud, which means that security measures such as firewalls and antivirus scanners on the IoT gateway significantly minimize security risks.
• Data buffering and edge computing: Data can be processed locally before being transferred to the cloud to optimize bandwidth and response times.
• Secure transmission: Protocols such as REST ensure reliable encrypted communication between devices and systems.

Connection of older existing machines

• Acquisition of digital signals: GPIO enables the connection of signal lights or maintenance signals.
• Data aggregation: Combination of multiple data from sensors to create status information. 

Solutions for series machine manufacturing

• Connectivity as added value: Standardized IoT gateways offer a cost-effective way to equip machines from series production with a variety of interfaces.

5. What to look out for when selecting the solution 

The market for IoT gateways offers a wide range of hardware and software solutions. To make the right choice, companies should consider the following aspects:

Hardware availability

Reliable hardware is the foundation of a stable system. The long-term availability of replacement devices and the longevity of the devices are essential for trouble-free operation.

Software updates and security

Security updates are essential to protect IoT gateways against potential cyber threats. A good provider will provide regular updates and ensure the long-term functionality of the solution.

Support and Service

An experienced provider with a competent support team is particularly important when it comes to integrating complex systems. Proximity to the customer for queries and project support when connecting complex systems can save considerable time and therefore money.

Trust and quality

Devices that manage critical production data should come from trustworthy manufacturers. Aspects such as supply chains (manufacturing location), design (development location) and software security should not be underestimated.

6. Our solution

The Kontron susietec®® Connect IoT Bundle is ideal for companies looking for a reliable and flexible solution for networking machines and systems. This combination of the powerful KBox A-250 box PC and the intuitive FabEagle®Connect integration software provides an ideal basis for efficiently connecting a wide variety of machines, sensors and IT systems.

The KBox A-250 is characterized by its versatile connection options and its good price-performance ratio. It has serial interfaces (RS232/RS485), which are particularly suitable for simple devices such as scanners, while TCP/IP and optional WiFi modules enable seamless integration into IT networks. In addition, the KBox A-250 offers a GPIO interface that can be used for simple automation tasks such as controlling signal lights or reading out maintenance signals. For applications that rely on wireless connections, the KBox A-250 also supports LTE (4G) and GSM (2G/3G) as an option. 

On the software side, FabEagle®Connect enables simple and efficient integration between machines and IT systems. The software ensures standardization of the interfaces and thus significantly reduces the effort required for integration and maintenance. Even for specific, non-standardized protocols, FabEagle®Connect offers a flexible solution through freely programmable components that support companies in the seamless integration of individual systems. In addition, the regular provision of updates ensures the long-term security and functionality of the software.

The interaction of hardware and software in this Bundle offers companies numerous advantages. The KBox A-250 takes on the central role as an IoT gateway and enables secure and flexible data transmission, while FabEagle®Connect simplifies the integration of various protocols and systems. Together, these components offer a reliable solution for efficiently networking production environments and successfully mastering the challenges of Industry 4.0.

7. IoT gateways in a nutshell 

IoT gateways are the key to digitalization in mechanical engineering. They offer a powerful combination of hardware and software to efficiently network different machines, sensors and IT systems. Whether for connecting older machines, processing large volumes of data or integrating modern cloud solutions - IoT gateways such as the KBox A-250 with FabEagle®Connect create a reliable and flexible basis for innovative production environments.

Rely on IoT gateways to future-proof your production and benefit from the advantages of 
Industry 4.0.