Unlocking OT Data for Modernization and Digitalization
Access to machine and controller data is essential for predictive maintenance, energy management, production dashboards, machine learning, and MES and SCADA applications. However, many PLCs and CNC machines were not designed to share their data with modern IT systems, edge applications, or cloud platforms.
Legacy protocols, proprietary interfaces, different controller generations, and the absence of standardized communication can make industrial data integration complex. Suitable connectivity solutions overcome these barriers by securely accessing OT data and making it available through standard interfaces such as OPC UA and MQTT.
The Role of Connectivity in OT/IT Integration
Reliable machine connectivity provides the link between automation systems on the shopfloor and higher-level IT applications. It enables existing machines and controllers to become part of modern data architectures without requiring extensive changes to the installed automation environment.
Typical connectivity challenges include:
- Machines and controllers from different manufacturers and generations
- Legacy protocols and proprietary interfaces
- Limited access to PLC, CNC, NC, and drive data
- Different technical skills across teams and production sites
- Integration requirements ranging from individual machines to scalable, plant-wide architectures
Industrial connectivity solutions must support the relevant PLCs and CNC controllers while providing standardized access to their data. Depending on the application, this may include process values, machine status, alarms, production programs, tool data, axis information, and drive data.
The data can then be made available to SCADA, HMI, MES, historian, analytics, edge, and cloud applications.
Connectivity Designed for the Shopfloor
Industrial environments differ in their existing infrastructure, technical requirements, and available IT expertise. Machine connectivity must therefore be available in different deployment formats.
Windows-based software
Windows-based connectivity software is suitable for users operating industrial PCs or standard Windows systems. A graphical user interface simplifies configuration and operation without requiring extensive knowledge of container or cloud technologies.
This approach is particularly well suited to conventional OPC communication, protocol conversion, and the integration of machine data into SCADA, HMI, MES, historian, and IoT applications
Docker-based software modules
Containerized connectivity software is designed for teams working with Docker, virtualization, industrial edge platforms, or cloud environments. Individual software modules can be deployed close to the data source and integrated into scalable edge architectures.
This approach provides flexibility for centralized management, automated deployment, and the gradual expansion of industrial data integration across multiple machines, production lines, or sites.
Hardware gateways
Industrial hardware gateways provide a dedicated, low-maintenance connectivity solution that can be installed independently of existing PC and IT systems. They are suitable for applications requiring an appliance that can be configured and operated with minimal installation effort.
Hardware gateways are particularly useful when machine data needs to be accessed reliably without installing additional software on an industrial PC or controller.
Softing Expertise in Controller and Machine Connectivity
Softing Industrial provides connectivity technology for accessing data from PLCs, CNC machines, and other industrial controllers. The solutions connect installed automation equipment with modern OT and IT applications while supporting both brownfield and new-build environments.
Depending on the selected solution, users can:
- Connect PLCs and CNC machines from different manufacturers and generations
- Access controller, NC, machine, tool, axis, alarm, and drive data
- Convert proprietary controller protocols into OPC UA, OPC Classic, MQTT, or REST
- Integrate machine data into SCADA, HMI, MES, historian, analytics, and cloud applications
- Deploy connectivity as Windows software, containerized software, or an industrial hardware gateway
- Scale data integration from an individual machine to production lines and multiple sites
This range of technologies allows companies to select the deployment model that best matches their automation environment, IT architecture, and available technical expertise.
Solutions for Controller Connectivity and Industrial Data Integration
From OPC communication to secure shopfloor data exchange, Softing offers software solutions for every stage of industrial data integration.
SDEX Suite - Comprehensive platform for secure shopfloor data exchange and OT/IT integration
SDEX Suite is a scalable integration platform for collecting, aggregating, governing, and distributing industrial data across heterogeneous automation environments. It is available for Windows-based, Docker-based, and hardware gateway deployments, allowing companies to select the deployment model that best fits their infrastructure, technical expertise, and integration requirements.
It extends beyond individual controller connections by supporting standardized data exchange between the shopfloor, enterprise systems, and cloud applications. Its modular architecture is designed for companies that want to establish secure, manageable, and scalable data flows across machines, production lines, and sites.
dataFEED OPC Suite - Universal all-in-one software for OPC communication and data integration:
dataFEED OPC Suite is a Windows-based software solution for connecting PLCs and CNC machines with OPC UA, OPC Classic, MQTT, REST, and cloud applications.
It provides direct access to controller and machine data and supports protocol conversion between installed automation systems and modern applications. This makes it particularly suitable for users who need a configurable, GUI-based solution for integrating individual machines or defined groups of controllers into SCADA, HMI, MES, historian, and IoT environments.
Learn more about dataFEED OPC Suite
Support for Leading PLC and CNC Manufacturers
Softing connectivity solutions support a wide range of PLCs, CNC machines, and industrial controllers from leading manufacturers. This enables companies to integrate heterogeneous automation environments and make data from existing and new equipment available through standardized interfaces.
Videos
Introducing dataFEED OPC Suite - Your All-in-One Industrial Edge Solution
Webinar: Machine connectivity in brownfield projects: How to unlock Siemens SINUMERIK 840D Solution Line CNC controllers with the dataFEED OPC Suite
Webinar: Simple Integration of Brownfield Machines Into Standardized OPC UA Solutions for Unified Namespaces