Industrial IoT Platform

Platform Overview

MetalCore Industrial IoT transforms legacy machinery and modern CNC lines into data-driven assets. By deploying hardened edge gateways alongside our cloud analytics suite, manufacturers gain real-time visibility into OEE, predictive maintenance windows, energy consumption, and production throughput.

The platform abstracts protocol complexity, enabling seamless integration between legacy PLCs, robotics controllers, and modern MES/ERP systems without disrupting shop floor operations.

Key Features

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Multi-Protocol Gateway

Native support for OPC UA, Modbus, EtherNet/IP, PROFINET, and MQTT over single hardware node.

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Edge Processing

Local data filtering, alarm generation, and model inference at the machine level with <5ms latency.

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Real-Time Analytics

Live dashboards for OEE, cycle times, downtime tracking, and energy utilization per asset.

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Predictive Maintenance

ML-driven vibration and thermal analysis to forecast bearing wear, spindle failure, and motor degradation.

Technical Specifications

Hardware Form Factor	IP65-rated stainless steel enclosure, DIN-rail or wall mount
Processor	ARM Cortex-A72 Quad-Core @ 2.0GHz
Memory / Storage	4GB DDR4 / 32GB eMMC (expandable via microSD)
Connectivity	2× Gigabit Ethernet, 4G LTE Cat.4, Wi-Fi 6, Bluetooth 5.2
Operating System	Linux-based (Yocto), containerized services via Docker
Data Protocols	OPC UA, Modbus TCP/RTU, MQTT 3.1.1/5.0, HTTP/REST, Kafka
Operating Temperature	-20°C to +60°C (industrial grade)
Power Supply	24V DC (industrial standard), 12W typical

Integration Architecture

Our IIoT stack operates on a hub-and-spoke model optimized for manufacturing environments. Edge nodes handle protocol translation and local buffering, while secure tunnels relay aggregated data to the cloud or on-premise servers.

PLCs / CNC

Sensors

Edge Gateway

Cloud / MES

BI Dashboard

Protocol Translation → Edge Buffering → TLS 1.3 Tunnel → Time-Series DB → Analytics Engine

Integration typically requires less than 4 hours per machine line. Our engineering team provides custom protocol adapters for proprietary CNC controllers and legacy robotic cells.

Security & Compliance

Industrial networks demand zero-trust architecture. MetalCore IIoT implements:

Hardware-rooted TLS certificates per device
Network segmentation via VLAN tagging and MAC filtering
Role-based access control (RBAC) with LDAP/Active Directory sync
Automated OTA firmware updates with cryptographic signing
Compliance with IEC 62443, NIST SP 800-82, and GDPR data handling standards

Frequently Asked Questions

Yes. The edge node includes a 24-hour circular buffer (configurable up to 7 days via external storage). Once connectivity is restored, data syncs automatically without duplication or loss.

Absolutely. Our SDK provides C++ and Python bindings for parsing proprietary serial/parallel machine protocols. We also offer managed protocol adapter services under professional services contracts.

Models are trained on aggregated, anonymized vibration and thermal datasets across 12,000+ machine hours. Accuracy typically reaches 89-94% for rolling element bearings and spindle motors, with continuous retraining as new client data is ingested.

We offer per-gateways perpetual licenses with optional annual maintenance, or a subscription model priced per connected asset with tiered analytics features. Volume discounts apply for 50+ node deployments.

Ready to Digitize Your Shop Floor?

Speak with our OT integration engineers to map your current infrastructure and receive a custom deployment roadmap.

Request Technical Consultation