Solution for Integrated PLC Data Acquisition IoT System

Source: Dev.to

Overview

Whether in large-scale factories or small and medium-sized enterprises, efficient automated production can be achieved through the replacement of automation equipment or automation retrofitting. However, these automated devices may not be integrated, resulting in data silos that significantly hinder improvements in efficiency, performance, and safety.

Programmable Logic Controllers (PLCs) serve as controllers for many non‑standard automated devices, varying greatly depending on production processes and equipment parameters. They may be supplied by numerous different vendors, each with varying communication protocols and interfaces, making data integration challenging. In response, WideIOT offers a widely compatible PLC data acquisition gateway that swiftly enables PLC data integration, management, and analysis.

By deploying the data acquisition gateway at the production site and connecting it to PLCs, protocol parsing and data collection are performed. The data is then transmitted via 5G/4G/Wi‑Fi/Ethernet to cloud platforms or upper computers, facilitating functions such as visual monitoring of equipment and production data, abnormal alerts, remote control, and remote maintenance, providing reliable support for production management and data analysis.

Functional Characteristics

Data Acquisition

The gateway can real‑time collect various types of data from within PLCs, such as analog quantities, digital quantities, and switch quantities, converting them into standardized data formats.

Data Processing

Collected data may require processing—filtering, amplification, compression—to meet the needs of external systems and alleviate server computational load.

Data Transmission

Processed data is transmitted through the gateway to external systems, supporting multiple communication protocols and transmission methods (e.g., Ethernet, wireless communication) to ensure rapid and stable data delivery.

Protocol Conversion

Since PLCs from different manufacturers may adopt varying communication protocols, the gateway includes protocol conversion capabilities to transform data into a unified standard format for easy reception and processing by external systems.