Platform IIOT: Why is universal compatibility with market instrumentation crucial?

INTRODUCTION: The objective of Operational Intelligence via IOT

In the dynamic scenario of industry 4.0, the search for operational efficiency, cost reduction and optimized maintenance drives the adoption of Internet Solutions of Industrial Things (IIOT). The ultimate goal is clear: transforming raw data, generated by machines and processes, into a good intelligence, remotely accessible and in real time. Whether in a vast industrial plant, a remote sanitation station or a complex commercial building, the ability to monitor, analyze and act based on accurate information is an undeniable competitive differential.

However, the journey to achieving this connected operational intelligence often bumps into a fundamental technological decision: which platform iiot adopts? The choice directly impacts the viability, cost and flexibility of the solution, especially with regard to integration with instrumentation (sensors, PLCs, meters, etc.) existing or necessary.

The connectivity dilemma: integrate the legacy or start from scratch?

When considering an IOT platform, companies are usually in one of these two main scenarios:

1. Existing Automation Infrastructure: Many operations already have full operational automation systems , composed of programmable logic controllers (PLPs) and a variety of sensors (temperature, pressure, vibration, level etc.). This operational instrumentation represents significant investments made over time. The challenge, in such cases, is how to connect these often isolated systems to a cloud -centralized platform to add remote analysis, intelligence and access, making the most of the existing functional infrastructure .
2. Points not monitored or without automation: There are numerous assets or measuring points that historically did not justify the high cost of a complete PLC -based automation system. Isolated pumps, specific engines, remote tanks, among others, could benefit greatly from monitoring, but the complexity and cost of traditional automation were prohibitive. The challenge, in this case, is to find a cost-effective way to implement monitoring and data collection at these points.

The choice of the IIOT platform should consider how it is effectively addressing both scenarios.

The risk of platforms with proprietary instrumentation

Some IIOT solutions on the market adopt a model based on proprietary instrumentation . That is, the platform works primarily or exclusively with a limited set of sensors and devices developed by the solution supplier itself. Although they may argue simply in certain cases, this approach has significant limitations:

1. Limited measurement scope: No proprietary instrumentation supplier can cover the vast range of variables and operating conditions found in the industry. Specific parameters sensors (thermography, particular gas types, complex vibrations, etc.) may simply not exist in the supplier portfolio.
2. Technological Dependence (Lock-in): The company is tied to the supplier's ecosystem. Any expansion or need to monitor new variables that are not covered by proprietary sensors will require the search for other platforms or solutions, creating data silos and management complexity.
3. Functional Assets Disposal: For measurements covered by the proprietary platform, the company can be forced to replace perfectly functional and already installed market sensors (connected to PLCs) with the specific instrumentation of the supplier, generating unnecessary costs and underutilizing previous investments.
4. Restricted Flexibility: Choosing the best sensor technology for a specific application is limited to what the supplier offers, not always being the technically ideal or more economical option available on the large market.
5. Total Cost of High Property (TCO): The potential need for multiple platforms, the replacement of existing sensors and the lack of negotiation power with a single supplier may inflate the total cost of the long -term solution.

It is crucial to note that the idea of ​​“replacing any instrumentation existing with proprietary sensors” is, in most cases, technically unfeasible and economically prohibitive, being a mistake in understanding the real problem imposed by these limited platforms.

The strategic advantage of universal compatibility

On the other hand, an IIOT platform designed with a focus on universal compatibility with market instrumentation offers a more flexible, strategic and economic approach:

1. Legacy Use: Allows the connection and integration with the vast majority of PLCs, controllers and sensors (analogical, digital, with standard protocols - such as Modbus, MQTT, etc., already existing in the plant, protecting the investments made.
2. Freedom of choice: The company can select the best instrumentation for each specific measurement need among millions of options available in the market, ensuring technical adequacy and optimizing costs.
3. Unified Solution: enables the centralization of monitoring various variables and active in a single platform, regardless of the origin of the sensor or local automation system, eliminating data silos.
4. Easy expansion of new monitoring points: Monitoring isolated points that did not justify the installation of a dedicated PLC now becomes an economically viable option by using market sensors connected directly to smart communication gateways.
5. Scalability and Future Proof: The platform can grow organically, incorporating new measurement verticals or new instrumentation technologies as they arise, without being trapped in a single supplier.
6. Interoperability: They are usually built on standard industry protocols (MQTT, OPCI etc.), facilitating integration with other corporate systems (ERP, SCADA, CMMS).

Demystifying the “plug-and-play”

The argument that the proprietary instrumentation offers a higher plug-and-play experience needs to be critically analyzed. The ease of integration does not reside in the sensor to be the owner, but the capacity of the IOT Platform of connection and interpretation of signal signals and protocols of the industry.

Traditional Industrial Sensors (Analogs 4-20MA, 0-5V, Digital On/Off) and those using widely widespread open protocols (such as Modbus) can be integrated as “plug-and-play” as any proprietary sensor as long as the chosen solution is designed for it . Compatible converters and gateways make this integration a standard reality on a platform with universal connectivity. Complexity or simplicity lies in the intelligence of the solution, not the origin of the sensor.

Bridgemeter: Universal connectivity and integrated intelligence

Bridgemeter, developed by Above-Net , is the definitive IOT platform solution that combines universal connectivity and shipped intelligence . It is designed to overcome the existing limitations of restrictive solutions and meet the real needs of critical applications:

1. Comprehensive compatibility:
   • Natively connects to clps and controllers of the most diverse manufacturers and generations.
   • It integrates directly with a wide range of market sensors: analog, digital and intelligent (supporting more than 150 industrial protocols).
   • It allows to monitor both complex infrastructures already automated and simple points, cost-effective.
2. Unified horizontal platform: consolidates data from multiple and vertical sources (electrical, mechanical, hydraulic, environmental, etc.) in a single environment, providing a holistic view of the operation.
3. Artificial intelligence and predictive analysis: Goes beyond simple data collection, using IA to:
   • Detect anomalies and predict faults based on multiple parameters.
   • Calculate key indicators such as OVERALL EQUIPMENT Effectiveness).
   • Allow the creation of complex business rules and calculated functions.
   • Optimize processes and firing predictive or prescriptive maintenance actions.
4. Agile implementation: Despite its robustness, the platform allows quick configuration through intuitive web interface, often in a few days, without interruption of existing processes.
5. Model SAAS with Integrated IAAs: Eliminates the need for large initial investments in communication/processing and software hardware, offering the complete solution as a predictable monthly service.

Conclusion: The intelligent choice for the future of the industry

The decision on which Platform IOT adopts has long -term implications for a company's flexibility, cost and innovation capacity. Platforms that impose the use of proprietary instrumentation may seem simple initially to a very limited scope, but create technological dependencies, limit horizontal expansions, can lead to hidden costs and information silos.

The universal connectivity approach, incorporated by Bridgemeter , offers a higher strategy. It respects the investments already made, provides freedom of choice for better market instrumentation, unifies operational vision and enables intelligent monitoring in a scalable and cost-effective manner. True agility and plug-and-play concept come from the platform's intelligence in dealing with industry standards, not proprietary restrictions.

In the age of industry 4.0, the ability to integrate the legacy with the new, flexibly and intelligently, is critical. Bridgemeter represents this view, offering the most robust and adaptable path to the digital transformation of industrial operations.

Ready to turn your operations with a truly flexible and intelligent IIOT platform?

Find out how Bridgemeter can integrate perfectly with its existing infrastructure, taking advantage of its current instrumentation while offering advanced AI predictive analysis. Request a personalized demonstration today and see how we can reduce your operating costs as we increase the efficiency and reliability of your equipment.