Factory IoT Data Bridge
Connect legacy equipment to IT systems without modification
Solution Description
We develop interactive communication systems based on standard equipment protocols, bridging OT equipment to IT management platforms. Our solution adapts to diverse integration methods, including enterprise proprietary protocols. Without modifying machine software, legacy equipment can be quickly upgraded for cloud connectivity, expanding factory IoT dashboards and advanced data applications
Field Challenges
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Equipment Disparity
Legacy machines lack communication capabilities, and mixed brands create a gap between old and new equipment, making integration difficult. -
Format Chaos
With thousands of different communication protocols and non-standardized formats, integrating production data is complex and challenging. -
High Modification Risks
Modifying original equipment often voids warranties, incurs high costs, takes a long time, and poses potential operational risks.
Solutions and Value
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Non-Intrusive Implementation
Achieve standardized communication capabilities directly from the signal end without the need to modify the original machine's software or hardware, enabling rapid deployment. -
Standardized Data
Converts diverse arbitrary formats into unified standards, fully supporting mainstream industrial platforms and protocols like MQTT and SEMI. -
Industrial-Grade Reliability
Designed with anti-interference capabilities and signal isolation protection, ensuring stable operation even in harsh industrial environments.
Application Scenarios
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Manufacturing Site
Instant data capture, tracking, and process visualization to optimize on-site decision-making. -
SMT Production Line
Enables non-standard interface equipment and older SMT machines to join the smart manufacturing network seamlessly. -
Automation Workstation
Connects PLCs, robots, and controllers, bridging the gap between automated logic and information systems.
Supported Equipment Brands
Leveraging I/O module parsing, we expand PLC card communication capabilities to enhance connectivity efficiency and reduce costs. Supported brands include FANUC, Siemens, Mitsubishi, Omron, Panasonic, and more.
FANUC CNC
FANUC Robot
SIEMENS PLC / NC
MITSUBISHI PLC
FATEK PLC
KEYENCE PLC
OMRON PLC
PANASONIC PLC
PC/ HMI
Empowering Strategic Transformation through Comprehensive Integration
Sunjsong provides expert system integration services, seamlessly merging EMS, AI, IoT, and edge computing. We empower enterprises to implement intelligent applications and achieve cross-domain synergy, creating high-efficiency, visualized environments that drive strategic value and informed decision-making.
Hardware Function Overview
Integrating hardware capabilities and interface features to quickly grasp the key functions of the product.
Multiple I/O
Supports DI/DO, AI/AO, and Sensor Input, allowing easy integration of various device types.
Communication Flexibility
Provides industrial control protocols such as TCP/IP, Modbus, MQTT for quick connection to edge or cloud systems.
Module expansion
Modules can be added based on production line needs, forming a flexible data acquisition architecture.
Cross-brand PLC integration demonstration
Understand at a glance how Smart Remote I/O supports different devices.
Smart Remote I/O × KEYENCE PLC
Quickly capture KEYENCE equipment I/O status
This video demonstrates how Smart Remote I/O quickly integrates signal acquisition and communication with KEYENCE PLC. Through the corresponding method of DI/DO terminals, it can read the input and output status of the PLC in real-time and display it synchronously through the Web I/O interface. In practical tests, it can be seen that device signal online is completed with minimal wiring, suitable for traditional machines, mixed-line environments, or expanded I/O needs. This method does not require changes to the PLC program and will not affect existing control logic, making it the fastest way to implement smart monitoring with KEYENCE PLC.
Smart Remote I/O × FANUC NC
Connect to the network without modifying the program FANUC NC
This video demonstrates how Smart Remote I/O captures equipment signals from the FANUC NC controller, including start, stop, alarm, and I/O changes. By using a simple terminal correspondence method, the status of the FANUC machine can be transmitted in real-time to the backend system, and viewed remotely through the Web I/O Monitor. This method does not require modification of the FANUC program logic to complete the equipment networking, making it particularly suitable for CNC machining areas, automated workstations, and centralized management fields for multiple FANUC NCs.
Smart Remote I/O × Panasonic PLC
Quick integration of Panasonic PLC I/O data
This video demonstrates the I/O integration of Smart Remote I/O with Panasonic PLC. By wiring the DI/DO, the real-time status of the PLC can be captured and displayed synchronously on the Web I/O interface without the need to install additional software for monitoring. This solution is particularly suitable for automated equipment controlled by Panasonic PLCs, such as assembly lines, testing stations, and dispensing stations. Its features of rapid deployment, no program modification, and flexible expansion make Smart Remote I/O an ideal solution for monitoring and networking Panasonic equipment.
Smart Remote I/O × OMRON PLC
Support OMRON multi-point I/O signal acquisition
This video demonstrates the process of equipment signal acquisition using Smart Remote I/O with OMRON PLC. By using standard terminal wiring methods, the PLC I/O status can be fully read and displayed synchronously on the Web I/O Monitor, allowing engineers to remotely check on-site signals. This solution enables OMRON PLC to quickly integrate into multi-brand production line structures, enhancing the overall data visualization in the field and reducing labor costs for maintenance and debugging.
Smart Remote I/O × Modbus TCPTCP and WEB
Easily upload device data via Modbus TCP
This video demonstrates the Smart Remote I/O transmitting device data using the Modbus TCP protocol. The system can convert I/O signals into standardized communication formats in real-time, facilitating uploads to MES, SCADA, ESM, databases, or cloud platforms. This method is compatible with most industrial control devices and is easy to set up, making it the lowest threshold, most stable, and most universal integration method for creating links between OT and IT data.
Detailed specifications
| Transistor model | LJ-SRIO-X32Y32 | LJ-SRIO-X32Y32 | LJ-SRIO-X16 | LJ-SRIO-Y16 |
|---|---|---|---|---|
| Input Voltage | 24 VDC ± 20% | 24 VDC ± 20% | 24 VDC ± 20％ | 24 VDC ± 20% |
Input points |
PNP or NPN
Change through COM |
PNP or NPN
Change through COM |
PNP or NPN
Change through COM |
|
| Input Type |
PNP or NPN (transistor)
Change through web settings |
PNP or NPN (transistor)
Change through web settings |
PNP or NPN (transistor)
Change through web settings |
|
| Output Voltage | 32 points | 16 o'clock | 16 o'clock | |
Maximum output current |
PNP Mode : 500 mA
NPN Mode : 300 mA High-Side : 1500 mA |
PNP Mode : 1200 mA NPN模式 : 810 mA High-Side : 1200 mA |
PNP Mode : 1200 mA NPN Mode : 810 mA High-Side : 1200 mA |
|
Output Protection |
Overcurrent, overvoltage Short circuit (error warning light) |
Overcurrent, overvoltage, overtemperature Short circuit (individual error warning light) |
Overcurrent, overvoltage, overtemperature Short circuit (individual error warning light) |
|
| Electrical isolation method |
2500 Vrms optical isolation 2500 Vrms communication isolation |
2500 Vrms optical isolation 2500 Vrms communication isolation |
2500 Vrms optical isolation 2500 Vrms communication isolation |
2500 Vrms optical isolation |
| Installation method | DIN-Rail | DIN-Rail | DIN-Rail | DIN-Rail |
| Size | 123mm×122mm×50mm (length × width × height) | 123mm×122mm×50mm (length × width × height) | 116mm×78mm×45mm (length × width × height) | 116mm×78mm×45mm (length × width × height) |
| Relay model | LJ-SRIO-RY8 |
|---|---|
| Input Voltage | 24 VDC ± 20％ |
| Input points | |
| Input Form | |
| Rated output withstand voltage | 32 points |
| Output format | Relay output (1 CO SPDT) |
| Rated output current | 10 A (MAX : 16A) |
| Relay model | FINDER 43.41 |
Electrical isolation method |
2500 Vrms optical isolation 6000 Vrms communication isolation |
| Installation method | DIN-Rail |
| Size | 55mm×122mm×50mm (length × width × height) |
| Relay model | LJ-SRIO-X4Y4-CE1 | LJ-SRIO-X8Y8-CE1 |
|---|---|---|
| Input voltage | 24 VDC ± 20% | 24 VDC ± 20% |
| Input points | 4 o'clock | 8 o'clock |
| Input Form | PNP or NPN change through COM | PNP or NPN change through COM |
| Output voltage | 24 VDC ± 5% | 24 VDC ± 5% |
| Output format | PNP or NPN changes through COM | PNP or NPN change through COM |
Maximum output current |
PNP Mode : 1200 mA NPN Mode : 810 mA High-Side : 1200 mA |
PNP Mode : 1200 mA NPN Mode : 810 mA High-Side : 1200 mA |
| Output Protection | Overcurrent, overvoltage, overtemperature short circuit | Overcurrent, overvoltage, overtemperature short circuit |
Electrical isolation method |
2500 Vrms optical isolation 2500 Vrms communication isolation |
2500 Vrms optical isolation 2500 Vrms communication isolation |
| Installation method | DIN-Rail | DIN-Rail |
| size | 90mm×54mm×61mm (length × width × height) | 121mm×38mm×100mm (length × width × height) |
Activate global smart integration
Shengjie Song provides smart system integration services, integrating electronic manufacturing services, AI, IoT, and edge computing technologies, assisting enterprises in implementing smart applications and cross-domain integration to create an efficient and visual decision-making environment.
