Predictive Maintenance Data Gateway

The problem

Maintenance wants vibration, temperature and current trends to plan work, but the data sits in drives and sensors that nobody logs, so failures still arrive as surprises.

Solution overview

MILESGO gateways collect data from vibration and bearing temperature sensors, variable frequency drives (VFD), PT100 / PT1000 temperature probes, 4–20 mA / 0–10 V transmitters over Modbus RTU / Modbus TCP / HART, and deliver it to a historian / database (MySQL, SQL Server, InfluxDB), a cloud platform (MQTT), SMS, email and messaging alarms as MQTT / OPC UA. Field equipment keeps its own protocol and control logic; integration is done by configuration and point mapping, not custom code.

Typical scope

vibration and bearing temperature sensors
variable frequency drives (VFD)
PT100 / PT1000 temperature probes
4–20 mA / 0–10 V transmitters

Protocol path

Modbus RTU / Modbus TCP / HART → MQTT / OPC UA

Implementation checklist for the project manager

For hard-wired signals, list each DI/DO/AI/AO with its type (dry contact, 4–20 mA, 0–10 V, PT1000) and choose I/O modules accordingly.
Agree sensor positions (height, airflow, distance from doors and diffusers) so readings are representative.
Configure NTP so trends, alarms and meter readings carry consistent timestamps.
Confirm local storage so data survives network outages, and define the retention period.
Agree KPI definitions (for example OEE components or kWh per unit) with operations before building dashboards.
Roll out in phases: pilot one site or area, confirm data quality, then replicate.

Project deliverables

Signed point table and protocol mapping
Gateway configuration files and backups
IP address plan and network drawing
FAT and SAT test records
As-built documentation and operator training

System architecture

Field layer: vibration and bearing temperature sensors, variable frequency drives (VFD), PT100 / PT1000 temperature probes, 4–20 mA / 0–10 V transmitters, connected over Modbus RTU / Modbus TCP / HART. Edge and integration layer: MILESGO protocol gateways and edge controllers, mounted on DIN rail in existing panels, polling each device, time-stamping values and buffering them locally. Upper layer: a historian / database (MySQL, SQL Server, InfluxDB), a cloud platform (MQTT), SMS, email and messaging alarms, which receives the data as MQTT / OPC UA. Remote access for maintenance runs over VPN rather than open internet ports.

System composition

Field devices: vibration and bearing temperature sensors, variable frequency drives (VFD), PT100 / PT1000 temperature probes, 4–20 mA / 0–10 V transmitters
Edge / integration: MILESGO protocol gateways and edge controllers
Upper systems: a historian / database (MySQL, SQL Server, InfluxDB), a cloud platform (MQTT), SMS, email and messaging alarms (MQTT / OPC UA)
Tools and commissioning: Web-based configuration, point table import/export (Excel), off-site simulation and on-site diagnostic tools

Software and AI capabilities

Predictive maintenance indicators from equipment trendsPilot
Anomaly detection on trend dataRoadmap

Delivery steps

1
Site survey and point list
Inventory devices, protocols, register maps, panel space, power and network paths.
2
Design and point table sign-off
Map every point to the target protocol and system; agree it with the client and the upper-system contractor.
3
Configuration and FAT
Build the gateway configuration off site, simulate it and test against the signed point table.
4
Installation and wiring
Mount gateways on DIN rail, wire RS-485 / I/O / Ethernet, apply the IP plan.
5
SAT and alarm tests
Verify values against local readings, test every alarm and command end to end.
6
Handover and support
Hand over configuration backups, point table and as-built documents; train operators.

Customer value

Abnormal conditions seen early, before they become failures
Reliable trend data for optimisation and fault diagnosis
Data ready for cloud platforms and analytics
Alarms reach the right person by SMS, email or messaging apps

Tell us about your project

Send the protocols, point count and target system. A sales and engineering pair reviews every submission.

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