IoT Use Case

Industrial Edge Devices and IoT Gateways

Edge devices, also called edge or industrial IoT gateways, are rugged computers installed close to machines and sensors. They read data from controllers and field devices, translate protocols such as Modbus or S7 into MQTT or OPC UA and preprocess data on site. Only refined values reach the cloud or IoT platform, and local logic keeps running even without a connection.

  • Sr Controls Engineer, ALPS Inspection
  • Project Manager Digital Engineering, Albrecht Bäumer GmbH & Co. KG
  • Sales Manager, nass magnet
  • PLM-Innovation-Consultant, Liebherr-IT Services GmbH
  • Managing Director, BESI Marine Systems GmbH
  • Co-Founder & CTO/CPO, Greenlyte Carbon Technologies

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Who offers it

Edge devices in practice

6 manufacturers from our partner network with 64 solution examples. Those with the most documented use in this category come first.

What it is used for

What they are used for, and with what

Based on these manufacturers' solution examples: the most common use cases and the technologies their solutions speak.

Use cases

What to look for

What an edge device does

An edge device, also called an edge gateway or industrial IoT gateway, is a rugged computer mounted right at the machine or in the control cabinet. It reads data from controllers, sensors and fieldbuses, translates field protocols such as Modbus, PROFINET or S7 into IT-friendly protocols like MQTT or OPC UA and preprocesses values on site: filtering, aggregating, adding timestamps and checking limits. Only the result is passed on to an IoT platform, the cloud or a local database. Many devices also run their own applications in containers, for example Docker apps or Node-RED flows.

Common form factors are DIN rail devices with a 24-volt supply, compact box PCs and industrial PCs with more computing power for machine vision or AI inference.

Edge device, router or security gateway?

The boundaries overlap, so the primary reason for buying is what counts. A router connects networks and forwards data packets but makes no decisions about the data. A security gateway separates OT from IT and secures the connection. An edge device is bought because it converts protocols, preprocesses data and runs local logic. Some edge devices include router functions or a cellular modem. They are still edge devices, because local data processing is their main job.

What to look for when choosing one

Key criteria are the protocols supported on both sides: the field side (Modbus, PROFINET, S7, IO-Link) and the IT side (MQTT, OPC UA, REST). Add to that computing power and memory for the planned applications, support for containers, central device management for updates in the field, and operating temperature range, ingress protection and mounting options. For larger fleets, it matters how easily configurations and software can be rolled out.

To get started, a gateway that connects a single machine and sends data to an IoT platform is often enough. As the project grows, devices that can be managed centrally, updated remotely and query several machines in parallel become important. This way, a pilot can be extended to more machines and sites without replacing hardware.

Examples from the network include the WAGO Edge Controller, the SIINEOS edge operating system from in.hub and the Exor IoT Gate. In solution examples, edge devices are often the first building block for condition monitoring or energy data collection on existing machines.

Frequently asked questions about edge devices

What is an edge device?

An edge device is a computer at the edge of the network, close to the machine or sensor, that collects and processes data where it is generated. In industry, it reads data from controllers and sensors, translates protocols and sends only refined values to the cloud or an IoT platform. This saves bandwidth, shortens response times and keeps raw data inside the plant.

What is an IoT gateway?

An IoT gateway is the link between devices in the field and IT systems. On one side it speaks field protocols such as Modbus or S7, on the other side IT protocols such as MQTT or OPC UA, and it translates between them. Once a gateway also preprocesses data or runs its own applications, it is usually called an edge gateway or edge device.

What is the difference between an IoT gateway and a router?

The difference lies in the job: a router forwards data packets between networks, for example from the machine network to the cellular network, without interpreting the content. An IoT gateway translates between different protocols and data formats and can process the data. In practice, both functions are often combined in one device, so what counts for classification is the main job the device is bought for.

What are examples of edge computing in industry?

Typical examples are vibration analysis directly at the machine, where only key figures instead of raw data are transmitted, collecting energy and consumption data from several plants, machine vision for quality inspection on the line and local alarms when limits are exceeded. What they have in common is that decisions are made without a detour through the cloud and keep working when the connection drops.

What hardware is used for edge computing?

Edge computing hardware ranges from small DIN rail gateways with ARM processors to fanless box PCs and industrial PCs with dedicated GPUs or AI accelerators. The choice depends on the workload: protocol conversion and data aggregation need little computing power, while machine vision or AI inference call for considerably more. Ruggedness, temperature range and long-term availability matter in every case.

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