Most sites are a museum and a showroom at the same time: a twenty-year-old controller on one wall and a brand-new analyser on the other. Our hardware integration service connects both into one coherent system, without forcing you to abandon equipment that still works. Integration happens at two levels — the physical link and the protocol on top of it.
The physical layer: serial, network, wireless
- Serial communication — RS-232 and RS-485 remain everywhere in industry. We handle wiring topology, termination, biasing, and addressing on multi-drop RS-485 buses where one wrong resistor can corrupt a whole segment.
- Network communication — Ethernet/IP networks with proper segmentation between control and business traffic, managed switches, and addressing plans that survive expansion.
- Wireless communication — Wi-Fi, cellular, and low-power radio for nodes where cable runs are impractical, designed with link budgets and interference in mind rather than hope.
The protocol layer
- Modbus (RTU over serial, TCP over Ethernet) — the lingua franca of industrial devices. We build and document register maps, handle byte/word ordering quirks between vendors, and tune polling so the bus is busy but never saturated.
- OPC DA — for integrating legacy Windows-based SCADA and historian systems that still expose classic OPC servers.
- OPC UA — the modern, platform-independent successor: secure, structured, and our default for new SCADA-to-enterprise and IoT integration.
- JSON strings — for talking to web services, cloud platforms, and modern APIs; clean payload design makes dashboards and databases straightforward downstream.
- Buffer arrays / raw frames — some devices speak nothing standard at all. We parse proprietary byte streams directly — framing, checksums, scaling — and wrap them in a protocol the rest of the system understands.
The integration mindset
Good integration is mostly disciplined documentation: a signal list, a register map, and a test record for every connection. That is what makes the system maintainable after we leave site — and it is included in every integration job we do.
Two systems that refuse to talk? That is usually a Tuesday for us. Describe the gear and we'll propose the bridge.