Case Study

Bringing 1,000+ Elevators Online: A CANBUS/MODBUS to SCADA Gateway

More than a thousand units went live and have been running 24x7. The success of this rollout led directly to a follow-on connected-IoT program.

Industry

Industrial IoT & OT

Time Frame

8 Months

Services We offer

Embedded & Firmware

Industrial Connectivity

IIoT

Edge Data

About the client

A global manufacturer of elevators and vertical-transport systems.

Problem Statement

Thousands of elevators in the field generated rich diagnostic signals over industrial buses, but that data never reached the systems that could act on it. Faults were found after they happened, not before.

The Challenges

Two industrial buses, one real-time path

Reading CANBUS and MODBUS while guaranteeing the critical fields reached SCADA in real time required careful scheduling on a constrained controller.

Never lose a record

Local SD buffering with battery-backed timestamps means field data survives connectivity gaps and power events.

Approach

We built a rugged edge controller and the firmware around it:

32-bit controller with CANBUS, SPI and I2C interfaces
Battery-backed real-time clock for accurate timestamping
100 Mbps Ethernet and RS-485 to feed SCADA
Local buffering to an SD card so nothing is lost during outages

The Solution

The gateway continuously reads signals from the elevator's buses, routes the critical fields straight to SCADA, and stores a high-resolution local record, up to 180 bytes per record at 10 records per second, for later analysis.

Critical alerts let operators address issues immediately, while the stored history is mined to prevent breakdowns before they occur.

The impact we delivered

1+

Units live, running 24x7

1/s

Sensor records per second, per unit

1 mo

Concept to deployed fleet

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Get Detailed Case Study

Bringing 1,000+ Elevators Online: A CANBUS/MODBUS to SCADA Gateway

A rugged edge controller that reads elevator signals over CANBUS and MODBUS, routes critical fields to SCADA in real time, and buffers data locally, deployed across 1,000+ units running 24x7.

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