Industrial Automation · Edge Computing & Telemetry
Industrial IoT Solutions & Custom Gateway Engineering
Bridge legacy industrial machinery and enterprise cloud systems with rugged, custom-engineered Industrial IoT gateways. Designed to endure harsh factory conditions: wide temperature ranges, high electrical noise, power fluctuations, and 24/7/365 deterministic uptime.
Engagement Scenarios
When Enterprises Partner With DeviceLab For This Service
We collaborate with forward-thinking enterprises, OEMs, and product innovators navigating critical hardware challenges.
Extracting Data from Isolated Legacy PLCs & Machines
Your industrial equipment operates smoothly, but lacks modern networking capabilities. We build non-intrusive gateway hardware that monitors registers and sensor lines without disrupting PLC control cycles.
Off-the-Shelf Commercial Gateways Are Too Expensive or Rigid
Off-the-shelf industrial PCs (IPCs) are costly, run bloated operating systems, require high power, and lack specific analog inputs or customized protocol conversion algorithms.
Harsh Environmental & Electromagnetic Interference (EMI)
Factory environments with massive motor inrush currents, welding transients, and heavy vibration cause consumer-grade hardware to crash. Our hardware features opto-isolation and wide DC power regulation.
Technical Scope
Core Engineering Capabilities & Specifications
Deep engineering competence verified by laboratory instrumentation and compliant with global manufacturing standards.
✓ Industrial Fieldbus & Protocol Translation
Hardware interfaces for Modbus RTU (RS485), Modbus TCP, CAN 2.0B / CANopen, Profinet, and proprietary serial protocols translated into JSON/MQTT payloads.
✓ Ruggedized Power & Electrical Isolation
Galvanic isolation up to 2.5kV on RS485/CAN communication ports, wide 9-36V DC input, TVS transient surge protection, and reverse polarity immunity.
✓ Edge Computing & Autonomous Buffering
Local telemetry filtering, real-time threshold alarm processing, and non-volatile Flash/SD storage to cache sensor data during cloud connectivity dropouts.
✓ Cellular & Industrial Wireless Backhaul
Integrated 4G LTE Cat-1 / NB-IoT modules with fallback to Ethernet and Wi-Fi, equipped with external SMA antenna ports for metallic enclosures.
✓ DIN-Rail & NEMA / IP65 Enclosure Fit
Custom PCB form-factors engineered to fit standard DIN-rail electrical cabinets or rugged IP65/IP67 waterproof die-cast aluminum enclosures.
✓ SCADA & Enterprise Cloud Connectivity
Direct telemetry integration with enterprise IoT clouds (AWS IoT Core, Azure IoT, ThingsBoard) via secure TLS 1.3 encrypted MQTT channels.
Comparative Advantage
Engineering Partnership vs. Freelancers & Generic Agencies
Commercial hardware cannot be trusted to amateur experimentation. Why B2B enterprises choose DeviceLab.
Methodology
6-Stage Engineering Lifecycle: Concept to Production
A disciplined, milestone-driven framework eliminating technical risk at each stage before committing capital to tooling.
Machine & Interface Audit
Analyzing target PLC protocols, signal voltages, sampling rates, and physical cabinet constraints.
Hardware Architecture & Isolation
Designing power supply stages, optical isolation barriers, and microcontroller selection.
Custom PCBA & DIN Enclosure Fit
Drafting multi-layer PCB layout and mechanical enclosure integration.
Protocol Driver & Cloud Engineering
Developing protocol polling state machines and secure TLS MQTT cloud publishing.
Factory Floor Pilot Testing
Deploying pilot units on actual machinery under electrical noise and vibration.
Full Handover & Scaled Production
Delivering production packages, firmware repositories, and manufacturing batches.
Guaranteed Handover
Production Deliverables & 100% Intellectual Property (IP) Handover
You own 100% of the design source files, Git repositories, and manufacturing packages. Zero royalties or vendor lock-in.
- ✓ Industrial-grade gateway hardware units in DIN-rail enclosures
- ✓ Complete technical datasheets, pinout wiring guides, and mechanical assembly drawings
- ✓ Firmware source code with fieldbus protocol drivers and cloud telemetry routines
- ✓ Protocol documentation and register mapping tables
- ✓ Factory Functional Circuit Test (FCT) jigs and testing procedures
Engineering Clarifications
Frequently Asked Questions
Direct answers to commercial, technical, and operational questions from prospective hardware partners.
Can DeviceLab read data from PLCs without altering the PLC code? +
How does the gateway behave when factory Wi-Fi or 4G disconnects? +
Ready to Engineer Your Custom Hardware System?
Speak directly with senior hardware and embedded engineers. We evaluate your functional specifications and provide technical architecture recommendations within 24 business hours.