BL116 Edge Gateway: Smart Factory PLC Data Acquisition & Cloud Integration

In the stamping and welding workshops of an auto parts manufacturing factory, the following automation equipment is deployed:

• Siemens S7-200SMART PLC: controls the stamping press (Ethernet port, Profinet protocol)
• Mitsubishi FX3U PLC: controls the welding robot (RS422 interface, requires conversion to RS232/485)
• Modbus RTU instruments: including power monitoring meters and temperature/humidity sensors (RS485 interface)
• MES system server: located on the factory LAN, needs to collect PLC data for production monitoring and quality traceability
• Corporate IoT cloud platform: based on the MQTT protocol, requires devices to report data to the cloud and support remote operation and maintenance

Challenges faced:

• Multiple PLC protocols are incompatible (Siemens Profinet vs. Mitsubishi MELSEC vs. Modbus RTU)
• Some devices only have serial ports (RS485/RS232) and cannot be directly connected to the factory Ethernet
• Harsh workshop environment (high temperature, strong electromagnetic interference) – ordinary gateways are prone to crashing or communication errors
• Data must be provided simultaneously to the local MES (Modbus TCP) and the corporate cloud platform (MQTT)
• Future need for remote PLC program download to reduce on-site service trips

After deploying the BL116, the factory achieved the following:

• Real-time data from stamping presses and welding robots (speed, current, temperature, output, etc.) are uploaded to the corporate cloud platform every 2 seconds.
• The local MES system reads data via Modbus TCP, and the production dashboard updates OEE and equipment status in real time.
• When current or temperature exceeds limits, the gateway actively triggers an alarm and can simultaneously activate a local audible/visual alarm.
• Engineers can remotely log into the BL116 via VPN from the office and directly download programs to the Siemens PLC; the average fault handling time is reduced from 4 hours (including travel) to 20 minutes.
• After a summer of high temperatures (exceeding 45°C in the workshop) and multiple thunderstorms, the gateway experienced no crashes or data loss, demonstrating excellent MTBF performance.

What kind of hardware is the BL116 gateway?

• 8 isolated RS485/232 ports, allowing simultaneous connection of devices with different electrical characteristics and avoiding crosstalk
• Dual Ethernet ports (WAN+LAN), isolating the data acquisition network from the office/production network for enhanced security
• 4G + WiFi dual wireless backup-automatically switches when the wired network is interrupted to ensure no data loss
• Wide voltage input (9-36 VDC) with reverse polarity protection, suitable for industrial power fluctuations
• IP30 aluminum alloy housing, resistant to electromagnetic interference, suitable for environments with welding, large motor starts, etc.
• Supports simultaneous data reporting to multiple cloud platforms (e.g., Alibaba Cloud, AWS IoT Core, ThingsBoard)
• Supports offline data retransmission (up to 100,000 data points), preventing loss of critical production data due to network jitter
• Supports TLS/SSL encryption to ensure data upload security

Downlink collection protocols (reading data from devices)

• Siemens: S7-200, S7-200SMART, S7-300/400/1200/1500 (Ethernet)
• Mitsubishi: FX1S/2N/3S/3U/3G, Q series, L series, FX5U (serial/Ethernet)
• Omron: CJ/CS/CP series (Host Link/FINS TCP)
• Delta: DVP series
• Modbus: Modbus RTU Master, Modbus TCP Master

Uplink forwarding protocols (sending data to platforms/systems)

OPC UA, MQTT, Modbus RTU, Modbus TCP, compatible with mainstream cloud platforms such as Alibaba Cloud, AWS IoT Core, Thingsboard, Ignition SCADA, and more.

Why choose BLIIOT BL116 IIoT gateways?

• No need for additional protocol converters-one gateway simultaneously connects to Siemens, Mitsubishi, Modbus, and other devices.
• Saves hardware costs and reduces wiring complexity.  

• Operating temperature range -40°C to +85°C, passes EMC/EMI Level 3 tests (ESD, surge, EFT).
• Independent hardware watchdog-automatically resets on crash, ensuring 7×24 continuous operation.
• Electrically isolated serial ports to avoid ground loops and lightning damage.  

• Dual-core Cortex-A7 1.2 GHz + 512 MB RAM + 8 GB eMMC, capable of locally processing 10,000 data points.
• Supports alarm triggering, data transformation (scaling, formulas), task scheduling, and other edge logic.
• Collects 1,000 data points in just 1.5 seconds, meeting high-speed data acquisition requirements. 

• Supports Modbus TCP Server and OPC UA Server for direct connection to local SCADA/MES.
• Supports MQTT and Sparkplug B for seamless connection to mainstream IoT platforms (Alibaba Cloud, Huawei Cloud, AWS, ThingsBoard).
• 4G/wired dual-link backup with automatic switching ensures uninterrupted data upload. 

• Supports OpenVPN, allowing remote login to the gateway’s local area network for remote PLC program upload/download.
• Supports remote configuration changes and firmware upgrades-engineers can debug and maintain without traveling.
• Provides BLRMS remote management platform to centrally manage thousands of distributed gateways.

• Provides graphical configuration software (Windows)-no coding required; protocol configuration is done through drop-down menus and forms.
• Supports batch import/export of data points via Excel, greatly improving project implementation efficiency.

 With its rich hardware interfaces (multiple isolated serial ports + dual Ethernet + 4G/WiFi), comprehensive protocol compatibility (covering mainstream PLCs and Modbus, uplink supporting MQTT/OPC UA/Modbus TCP and major cloud platforms), and industrial-grade reliability (wide temperature range, EMC Level 3, hardware watchdog), the BLIIOT BL116 high-performance edge gateway is an ideal solution for solving the problems of “difficult data acquisition, protocol incompatibility, and complex cloud upload” in smart factories, smart energy, smart cities, and other fields.

For manufacturing enterprises that are promoting digital transformation and need to uniformly collect data from multiple PLC brands while simultaneously connecting to both local MES and cloud IoT platforms, the BL116 provides a cost-effective, highly reliable, and easy-to-implement all-in-one edge computing solution.