PLC to MQTT Gateway
Problem
Headquarters wants production data from every plant in the cloud, but opening PLC networks to the internet is not acceptable to the plant’s IT and safety teams.
Opis rozwiązania
MILESGO gateways collect data from PLCs, production counters and machine state signals, electricity meters over S7 / Modbus TCP / EtherNet/IP, and deliver it to a cloud platform (MQTT), a historian / database (MySQL, SQL Server, InfluxDB) as MQTT. Field equipment keeps its own protocol and control logic; integration is done by configuration and point mapping, not custom code.
Typical scope
- PLCs
- production counters and machine state signals
- electricity meters
Protocol path
S7 / Modbus TCP / EtherNet/IP → MQTT
Implementation checklist for the project manager
- Keep OT networks segregated and use VPN for remote access instead of opening ports to the internet.
- Do not modify validated PLC programs; read existing data areas or add gateway-side mapping instead.
- Confirm local storage so data survives network outages, and define the retention period.
- Check 4G signal and the SIM data plan at every site before committing to cellular backhaul.
- Fix a site / asset naming convention before the first site so data from all sites can be compared.
- Standardise one configuration template per equipment type so further sites are copied, not rebuilt.
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
Architektura systemu
Field layer: PLCs, production counters and machine state signals, electricity meters, connected over S7 / Modbus TCP / EtherNet/IP. 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 cloud platform (MQTT), a historian / database (MySQL, SQL Server, InfluxDB), which receives the data as MQTT. Remote access for maintenance runs over VPN rather than open internet ports.
Skład systemu
- Field devices
- PLCs, production counters and machine state signals, electricity meters
- Edge / integration
- MILESGO protocol gateways and edge controllers
- Upper systems
- a cloud platform (MQTT), a historian / database (MySQL, SQL Server, InfluxDB) (MQTT)
- Tools and commissioning
- Web-based configuration, point table import/export (Excel), off-site simulation and on-site diagnostic tools
Możliwości oprogramowania i AI
- Anomaly detection on trend dataW planach
- Predictive maintenance indicators from equipment trendsW planach
Etapy wdrożenia
- 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.
Korzyści dla klienta
- Data ready for cloud platforms and analytics
- Data kept locally during network outages
- Monitoring added without changing existing control programs
- Configuration templates reused across sites
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