IoT gateways basically fulfill a seemingly simple (minimum) task: they must be easy to integrate into existing or new systems and transfer machine and process information, which is collected directly or via local sensors, to the cloud via the internet. The challenges lie in the details - and lead Jonas Schuster, Head of Marketing & Sales at Grossenbacher, to believe that individually developed gateways are usually the better and more economical choice in the long term: "Basically, standard products are rarely the best choice - the applications and the type and scope of data to be collected are simply too individual for that." In addition, "0815 gateways" are simply overwhelmed by the integration of different wireless standards and their global use through roaming, says Schuster.

The function: who needs what?

The amount of data to be collected and the type and bandwidth of the connection determine whether the gateway needs an edge function to pre-process the data. It requires significantly more computing power, which, together with the interface/sensor equipment and data transmission technology, determines whether battery operation is possible. With modern, energy-efficient embedded hardware and especially when using low-power networks, battery operation is an option. The number of data points for monitoring and the transmission frequency remain manageable. Jonas Schuster comments: "Applications such as condition monitoring, preventive maintenance and servicing according to usage intensity or data-based spare parts management can often be implemented sensibly - and particularly economically - with battery-powered gateways."

However, if you want to equip gateways with extended remote functions for updates, calibration or simple control, you generally need powerful hardware in addition to a mains power supply. The latter may initially seem more expensive, but it often makes economic sense: remote updates in particular are becoming increasingly important and cover a spectrum ranging from firmware updates for individual gateways to field device management and functional enhancements. For example, updates to the system software including the soft PLC runtime systems, the application programs including recipes or parameter sets or even the safety-relevant elements are possible. Today, it must also be possible to adapt all of this to new threats from hackers during operation and in the field - keyword "cyber security". The updates required for this must be communicated securely in order to prevent gateways for malware.

Jonas Schuster, Head of Marketing & Sales at Grossenbacher.

© Grossenbacher systems

Another area of application for high-performance gateways "à la Grossenbacher" is remote calibration as a service tool. Here, a gateway becomes a mobile, compact measuring and calibration station that checks devices in industrial use from time to time to ensure that they are functioning properly and that measured values are being adhered to, and provides adjusted parameters if necessary. This eliminates the need for costly travel.

Ultimately, IoT gateways provide data access for existing equipment. But how do you proceed with new machines and systems? Grossenbacher believes that the way forward here is to redesign the machine operation and control system so that a gateway function is directly integrated. New smart panels with touch displays for operation and machine control via soft PLC can be expanded to include comprehensive gateway functions. Jonas Schuster: "With the right overall architecture, both worlds can be combined in such a way that digitalization is driven forward and the safety of the connected devices is guaranteed."

Consulting, development and production from a single source

Visitors to the trade fair stand can find out what customized smart panels with PLC and gateway function can look like: after all, a new generation of compact operating panels is the second focus of Grossenbacher Systeme at SPS. However, according to Jonas Schuster, visitors to the trade fair should take away the following above all: "Whether battery-operated economy gateway or integrated high-end solution: Ultimately, it is important that suppliers are able to advise their customers competently as early as the definition phase and implement the jointly found solution in development and production economically and in line with the desired business model."