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Capabilities · Industrial IoT

Machine data, floor to cloud, connected and secured.

Machine connectivity, edge gateways and edge-to-cloud, data acquisition, MES integration, IIoT security and brownfield retrofit: the data layer of Industrie 4.0, with the test and programming tools to prove every hop.

  1. 01 What we build
  2. 02 How we work
  3. 03 The stack
01

Six pieces of the Industrie 4.0 data layer, built by GSAS.

Underneath the dashboards, Industrie 4.0 is a connectivity and data problem. Each card lights the point in the plant where that work sits, from the machine on the floor to the MES and the cloud.

A plant's data path: a PLC, a drive, a legacy machine with a retrofit tap and a DAQ on the floor, all reporting to an edge gateway, which feeds the MES and dashboards and, over an encrypted link, the cloud Modbus CAN-FD OPC-UA OPC-UA · REST MES · DASHBOARDS CLOUD MQTT · TLS EDGE GATEWAY PLC RUN DRIVE LEGACY MACHINE SCAN DAQ 1. Protocols: Machine connectivity over Modbus, OPC-UA, MQTT and CAN-FD 1 Protocols 2. Edge: Edge gateway firmware that filters, buffers and pre-processes before the cloud 2 3. DAQ: Machine and process data acquisition, time-stamped for dashboards 3 4. MES: Production data into the MES over OPC-UA and REST 4 5. TLS: TLS transport, secure boot and IEC 62443-aligned architecture 5 6. Retrofit: Non-intrusive data capture on machines that already run 6 Retrofit
  • 1. Protocols: Machine connectivity over Modbus, OPC-UA, MQTT and CAN-FD
  • 2. Edge: Edge gateway firmware that filters, buffers and pre-processes before the cloud
  • 3. DAQ: Machine and process data acquisition, time-stamped for dashboards
  • 4. MES: Production data into the MES over OPC-UA and REST
  • 5. TLS: TLS transport, secure boot and IEC 62443-aligned architecture
  • 6. Retrofit: Non-intrusive data capture on machines that already run
Hover, tap or focus a numbered point or a card to see where each capability sits.
  1. Machine connectivity and industrial protocols

    Getting data off the machine is the first problem of Industrie 4.0. GSAS implements the protocol layer so PLCs, drives, sensors and meters speak to the gateway reliably.

    • Modbus RTU, ASCII and TCP with SEGGER emModbus, master or slave
    • OPC-UA and MQTT, with MQTT over SEGGER emNet
    • CAN and CAN-FD

    SEGGER emModbus · emNet · Arm

  2. Edge gateways and edge-to-cloud

    The edge is where raw machine data becomes useful. Gateway firmware filters, buffers and pre-processes at the edge and sends only what matters, cutting bandwidth and latency.

    • Gateway firmware for filtering, buffering and pre-processing
    • Docker containers at the edge on AutoPi CM4-based units
    • Only what matters sent upstream, cutting bandwidth and latency
    • Edge-to-cloud over MQTT and REST

    Edge AI and vision

    AutoPi · SEGGER emNet

  3. Machine data acquisition (MDE)

    You cannot optimise what you do not measure. GSAS captures machine and process data, time-stamps it and feeds live dashboards for OEE, energy and condition monitoring.

    • Voltages, currents, temperatures and cycle times
    • Multi-channel acquisition with the GW Instek DAQ-9600
    • Time-stamped data for OEE and energy dashboards
    • Condition monitoring of machines and processes

    GW Instek DAQ-9600

  4. Production and MES integration

    On the factory floor, machine data has to reach the MES. GSAS wires production programmers and stations into it, so serialisation, traceability and pass/fail flow straight through.

    • MES links over OPC-UA and REST
    • ProMik XTL-i inline programming, managed by FlashTask Pro production software
    • Serialisation and traceability records
    • Pass/fail and yield into Industrie 4.0 data systems

    ProMik FlashTask Pro · XTL-i

  5. IIoT security and DevSecOps

    A connected machine is an attack surface. GSAS secures the data path and shifts security left into the firmware itself.

    • TLS transport with SEGGER emSSL (TLS 1.3), integrated with emNet
    • Secure boot and IEC 62443-aligned architecture
    • Klocwork static analysis (SAST) in a DevSecOps pipeline
    • Hardware secure element on the AutoPi CAN-FD Pro (NXP SE051)

    Security engineering

    SEGGER emSSL · Perforce Klocwork

  6. Digital retrofit of brownfield lines

    Many plants run machines that were never built to be connected. The value is in connecting machines that already run, without re-engineering the line.

    • Non-intrusive data capture on legacy equipment
    • Protocol-bridging gateways for older fieldbuses
    • Older machines joined to the same data layer as new ones
    • Connected without re-engineering the line

    Gateway and DAQ, sized to the machine

02

From one machine’s signal to a plant-wide dashboard.

One reading’s path from the machine to the dashboard, hop by hop, and the three stages GSAS works through to build it. Hover a stage to see its hops.

Connect · Secure · Scale
  1. Sense Machine, meter or DAQ channel
  2. Fieldbus Modbus, CAN-FD, OPC-UA
  3. Edge Filter, buffer, pre-process
  4. Encrypt TLS on the uplink
  5. Publish MQTT to the cloud
  6. MES OPC-UA and REST
  7. Dashboard OEE, energy, condition
  1. 01

    Connect

    Survey
    The machines, their controllers and the protocols they already speak
    Protocols
    Modbus, OPC-UA, MQTT and CAN-FD on the device side
    Capture
    Non-intrusive taps and multi-channel DAQ where a machine has no data port

    Brownfield machines joined without replacing them

  2. 02

    Secure

    Transport
    TLS from gateway to cloud with SEGGER emSSL
    Device
    Secure boot and IEC 62443-aligned architecture
    Code
    Klocwork static analysis on the firmware, every change

    Security built into the firmware, not added at the network edge

  3. 03

    Scale

    Edge
    Filter, buffer and pre-process so only what matters leaves the plant
    Systems
    MES over OPC-UA and REST, dashboards for OEE, energy and condition
    Proof
    Test and programming tools to validate every hop

    One data layer from the sensor to the dashboard

Related: Embedded software · Edge AI and vision · Security engineering · Test and measurement

03

The IIoT stack the work is built on.

Connectivity middleware, edge compute, acquisition, production systems and security analysis: partner tools GSAS supports in India. Specifications come from each product page.

Partner lines on this page

04

Three ways to start, depending on what you run.

A plant connecting the machines it has, a builder putting connectivity into its product, and a line feeding its MES each start differently. Pick yours.

  1. 01

    Brownfield plants

    Machines that already run

    Non-intrusive data capture and protocol-bridging gateways on the machines you have, so older equipment joins the same Industrie 4.0 data layer as the new, without re-engineering the line.

  2. 02

    Machine and equipment builders

    Connectivity inside the product

    The protocol stack and gateway firmware inside your controller: Modbus, OPC-UA, MQTT and CAN-FD on embedded targets, TLS on the uplink, and static analysis on the firmware before it ships.

  3. 03

    Electronics production lines

    Programming and test into the MES

    Production programmers and test stations wired into the MES over OPC-UA and REST, so serialisation, traceability and pass/fail flow straight into your Industrie 4.0 data systems.

05

Bringing a line or a fleet of machines online?

Tell us the machines, the protocols and where the data needs to go. GSAS scopes the connectivity, edge and security layers, validates them with real test and programming tools, and supports them across Bengaluru, Hyderabad, Chennai, Pune, Mumbai and Delhi NCR.

sales@gsasindia.com +91 80 6590 1783

Industrial IoT work with GSAS in India

What does GSAS build for industrial IoT?

The data layer of Industrie 4.0: machine connectivity and protocols, edge gateway firmware, machine data acquisition, MES integration, IIoT security and brownfield retrofit, from the sensor on the machine to the dashboard, with the test and programming tools to validate every hop.

Which industrial protocols do you work with?

Modbus RTU, ASCII and TCP (SEGGER emModbus), OPC-UA, MQTT (over SEGGER emNet), and CAN and CAN-FD.

Can you connect machines that have no network port?

Yes. Brownfield retrofit is a core part of the work: non-intrusive data capture and protocol-bridging gateways bring legacy machines into the same data layer, and a multi-channel DAQ such as the GW Instek DAQ-9600 captures signals directly where a machine exposes no data at all.

How is the data path secured?

TLS transport with SEGGER emSSL (TLS 1.3), integrated with emNet, secure boot and an IEC 62443-aligned architecture, with Klocwork static analysis in a DevSecOps pipeline so the gateway firmware itself is checked on every change.

Can production programmers feed our MES?

Yes. GSAS integrates production programming into the MES over OPC-UA and REST. ProMik FlashTask Pro offers a REST API and built-in SQL traceability, and the XTL-i inline system connects over OPC-UA, REST and OPCON/ITAC.

Where do you work?

Engineering is led from Bengaluru, with GSAS offices across India including Hyderabad, Chennai, Pune, Mumbai and Delhi NCR, so plant visits and support run in the same time zone as the line.