When high-precision manufacturing machines generate 70+ GB of telemetry per machine per year across 100+ machines, protocol complexity quickly becomes a growth bottleneck. This case study shows how a multi-protocol IIoT gateway ecosystem, deployed across 80+ industrial hardware gateways, unified machine data into real-time analytics and predictive maintenance insights.
The increasing adoption of Industrial IoT (IIoT) in manufacturing has revolutionized how machines communicate, offering significant potential for predictive maintenance, enhanced machine uptime, and production monitoring.
This case study details the development of an IoT gateway solution that enables bi-directional communication between wire processing machines and cloud infrastructure.
This solution features capabilities for handling high-end enterprise machines through a unified IoT gateway architecture for optimizing machine performance and implementing seamless data communication.
Azure IoT Enabled Machine Data Transmission
Real-time Machine Telemetry Data Processing
Multi-protocols Support – HTTPS, MQTT, OPCUA
Monitoring and Predictive Maintenance
Admin Interface for Machine Configuration
Secure & Scalable Azure Cloud Operations
The client is a pioneer and market leader in automated wire processing solutions with over 40+ years of industry expertise. The company operates globally across 60+ countries.
We developed a comprehensive IoT gateway solution that bridges the gap between manufacturing equipment and cloud infrastructure, enabling real-time monitoring, configuration management, and high-volume machine data analytics.
Machines connected via a scalable IoT gateway ecosystem
GB telemetry per machine per year processed in real time
Lenovo M90N1 G2 & G3 gateways managed across the network
The manufacturing high-precision wire processing machines are utilized across top-tier automotive firms. These machines are essential for managing all wire-processing-related tasks in industrial applications, ensuring precise cutting and processing of wires with unparalleled accuracy.
The implemented IoT gateway solution provides a comprehensive machine data communication and analytics that enables seamless integration between wire processing machines and cloud infrastructure.
→ Each machine is integrated with an IoT edge device, facilitating seamless communication between the Hardware-enabled IoT edge device and a central configuration platform.
→ The configuration platform serves as the intermediary, enabling manufacturing operations engineers to connect machines via LAN.
The integration of IoT with traditional manufacturing processes represents a transformative shift towards data-driven decision-making.
Manufacturers can significantly improve their operational efficiency and reduce maintenance costs.
The solution centers around an IoT gateway that serves as a middleware proxy between manufacturing equipment and Azure Cloud.
→ Azure device provisioning is utilized for automatic gateway certification, ensuring streamlined registration and validation.
→ The gateway implements multiple communication protocols to support various machine types.
IoT hardware monitoring is supported via Azure metrics collector modules, ensuring real-time visibility into operational health. Comprehensive monitoring of gateway devices involves capturing the following metrics:
→ Resource consumption, CPU and memory usage.
→ Gateway uptime, downtime, and service disruption count.
→ Disk space usage.
Telemetry data collected from machines is analyzed for actionable insights. Key parameters include:
→ Machine status, job states, and outputs.
→ Current and completed batch overviews.
→ Machine performance indicators such as availability, effectiveness, and quality.
→ Detailed status monitoring for operational and non-operational machines.
We have integrated Microsoft Data Fabric to streamline data operations, ensuring efficient management, scaling, and governance within their technology ecosystem. This provides actionable insights for decision-making, including:
→ Real-time visualization of production outputs for comparisons and predictions.
→ Automated reports and centralized quality management.
→ Fully traceable production and quality metrics.
Mender provides a robust control panel for IoT gateways, enabling efficient troubleshooting and updates. Key functionalities include:
→ Custom deployment configurations, including release names and artifact types.
→ Firmware and software updates for specific IoT edge devices.
→ Scalable deployment for multiple gateways using Linux-based automation.
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