Linux-based IoT Gateway
Data acquisition and process automation for mid-sized manufacturing operations
Industry
Manufacturing
Platform
Custom Yocto Linux
Protocols
Modbus, Profinet, OPC-UA
Cloud
Azure IoT Hub + AWS
Deployed
80+ units
Make Legacy Machines Cloud-Ready
Mid-sized manufacturing operations run machine parks that have grown over decades. The equipment is reliable, but it doesn't feed data to modern cloud platforms. Replacing it is economically out of the question.
The goal was a compact solution that acquires machine data over various industrial protocols, preprocesses it locally, and connects bidirectionally to the cloud. Including active control logic for time-critical processes right at the edge.
The Gateway
What the Gateway Does
- Data acquisition via Modbus RTU/TCP, Profinet, and OPC-UA
- Bidirectional connection to Azure IoT Hub, AWS as fallback
- Active process control with PLC-style logic
- Edge computing with local data buffering during network outages
- Secure boot, CVE management, and FOTA updates with automatic rollback
From Linux Distribution to Certification
Embedded Solutions developed the gateway end to end: from the Yocto distribution through the control firmware to CE certification.
Under the Hood
Custom Yocto Distribution
Lean, real-time-capable Linux distribution based on Core Image Minimal. 110 MB image size, boot time under 60 seconds for fast recovery after power loss.
Real-Time Kernel
PREEMPT_RT patches for deterministic latencies. Edge-based control loops continue to run time-critically and independently of the cloud connection.
SBOM & CVE Management
Automatic SBOM generation (SPDX, CycloneDX) from the Yocto build. Continuous CVE scanning of all software components. Patch management across the entire product lifecycle for Cyber Resilience Act compliance.
Multi-Cloud Architecture
Azure IoT Hub as primary with AWS IoT Core as fallback. Automatic x.509 certificate rotation, central management of all devices via the Azure portal.
Security by Design
U-Boot verified boot with chain of trust, automated CVE scanning via SonarQube, SBOM generation for Cyber Resilience Act compliance.
FOTA with Rollback
A/B partitioning for safe over-the-air firmware updates. Automatic rollback on failure. Updates to all 80+ gateways without on-site visits.
Measurable Impact on the Shop Floor
80+
units in continuous production use
35 %
fewer unplanned machine stoppages
20 %
efficiency gain through optimized parameters
60 %
reduction in cloud data volume through edge processing
Want to make existing machines cloud-ready and actively controllable?