Industrial IoT Solutions
Connect field devices to cloud.
Industrial gateways and smart sensor platforms connecting field devices, PLCs and sensors to cloud analytics. We build the edge layer that translates between factory-floor protocols and cloud platforms, with buffering that survives network outages, plus power-optimized sensor firmware for fleet-scale deployments. Hardened for industrial environments, not lab conditions.
Industrial IoT is the edge layer that reads legacy factory-floor protocols — Modbus, CAN, OPC UA — from PLCs and sensors, converts them to MQTT or a cloud IoT protocol, and forwards telemetry with store-and-forward buffering so plant network outages don't lose data. It also covers the power-optimized firmware that runs on battery sensor nodes and the fleet management needed to keep hundreds of deployed gateways configured and updated.
- Protocol conversion: Modbus RTU/TCP, CAN, OPC UA to MQTT
- Store-and-forward buffering across network outages
- Sensor node firmware with aggressive power optimization and wireless connectivity
- Telemetry ingestion, time-series storage and threshold/trend alerting
- Fleet management: remote configuration, monitoring and OTA updates
1. Discovery
We map your requirements, constraints, existing systems and success criteria before proposing a solution.
2. Architecture
We design the system architecture, interfaces and technology choices, documented and reviewed with your team.
3. Implementation
We build in short iterations with working increments, code review and continuous integration from day one.
4. Validation
We test against real conditions — hardware, load, failure modes — and report measured results, not assumptions.
5. Deployment
We ship to production with monitoring, documentation and a handover that leaves your team in control.
Where benchmarks are required, Gengini documents throughput, latency, test platform, workload, and measurement method.
Technologies
- Gateway software image for your chosen hardware
- Sensor node firmware with a measured power budget
- Protocol mapping and cloud integration (AWS IoT, Azure IoT or self-hosted broker)
- Fleet provisioning and OTA update mechanism
- Site deployment and commissioning guide
What happens to data during an internet outage?
The gateway buffers locally with store-and-forward, then backfills the cloud when connectivity returns. Buffer depth is sized to your outage tolerance, and alarm logic keeps running locally throughout.
Can it read our 20-year-old PLCs?
Usually yes. Modbus, serial and fieldbus interfaces on legacy equipment are exactly what these gateways exist for, and we read data without modifying certified control programs.
How long can battery-powered sensor nodes run?
With duty-cycled firmware and the right radio, years are achievable — we've designed nodes targeting 3–5 year battery life on LoRaWAN. We deliver a measured power budget, not an estimate, as part of every node design.
Does this replace our PLC's control program?
No. The gateway reads data alongside the existing control system without touching certified PLC logic — it's a monitoring and data layer, not a control layer, unless a project explicitly scopes control integration.
How do you manage firmware updates across a large sensor fleet?
Gateways and nodes report a version and health status on check-in, and OTA rollout is staged in batches with an automatic halt if failure rates on early batches exceed a threshold, rather than pushing to every device at once.
Can the gateway run at the edge without any cloud connection at all?
Yes. Local alarm logic, thresholds and store-and-forward buffering run on the gateway itself, so plant operations continue and nothing is lost even if the site has no WAN connection at all for extended periods.
Embedded & Firmware Engineering
Custom Linux BSPs, RTOS firmware and reliable hardware interfaces.