We connect directly to your machines' PLCs, collect production, quality and maintenance data in real time, and sync it into any custom software, database or ERP, then put it on screens, dashboards and the iPad, iPhone or Android phone in your pocket.
Every PLC on your floor already knows how many parts it made, how many it scrapped, when it stopped and why, how hot it ran and how much energy it used. In most plants, that information never leaves the machine. It is copied onto clipboards, typed into spreadsheets at the end of the shift, or simply lost.
The result is decisions made on yesterday's numbers, downtime nobody can explain, maintenance done by the calendar instead of by use, and ERP systems that do not know what production actually did.
ExaSystems closes that gap. We connect to the controllers you already have, speak their native industrial protocols, and move the data into the software and databases your business runs on, reliably, securely and in real time.
A proven four-layer approach that keeps your control network safe and your data flowing.
Your existing PLCs, drives, meters and sensors stay exactly as they are. We connect over Ethernet or serial without changing machine logic unless you ask us to.
An ExaSystems connector service speaks each machine's protocol, polls or subscribes to the tags you need, scales and validates values, and timestamps every reading.
Readings are written to a structured SQL database with history, and buffered locally if the network drops, so nothing is lost.
Your custom software, ERP, dashboards, reports and mobile apps read from that database or receive the data through APIs.
We work and communicate with the industrial protocols used by the major PLC and automation brands, and we choose the right one for each machine.
The most widely supported industrial protocol. We read and write holding registers, input registers, coils and discrete inputs over Ethernet (TCP) or RS-485 serial (RTU), including scaling, byte order and 32-bit values that span two registers.
A vendor-neutral, secure standard. We browse the server's address space, subscribe to tag changes instead of polling, and use certificate-based security and user authentication where the server supports it.
Older plants often expose data through classic OPC servers. We connect to them locally or bridge them to OPC UA, so existing investments keep working with modern software.
Direct reads and writes to data blocks (DB), inputs, outputs, flags and timers without extra hardware. On S7-1200 and S7-1500 this requires PUT/GET access and non-optimised blocks, which we configure with your integrator.
Tag-based communication with Rockwell and other CIP controllers. We read controller and program tags by name, including arrays and user-defined types (UDTs).
Read and write device memory such as D data registers, M relays and X/Y inputs and outputs over Ethernet using the SLMP / MC protocol, in binary or ASCII mode.
Access DM, CIO, W and H memory areas over FINS/UDP or FINS/TCP. Newer Omron NJ/NX controllers can also be read by tag name over EtherNet/IP.
Fieldbus networks are normally reached through the controller or a gateway. We collect the data at the PLC or gateway level so your real-time network is never disturbed.
Lightweight publish/subscribe messaging for sending machine data to brokers and cloud services. Sparkplug B adds defined topics, birth and death certificates and state awareness.
Read temperatures, set points, alarms and equipment status from building automation systems, alongside your production data.
Many machines only talk serially. We use serial connections and serial-to-Ethernet converters for Modbus RTU, Allen-Bradley DF1 and ASCII devices such as scales and printers.
On the software side we deliver data wherever it is needed: directly into SQL databases, through REST APIs and webhooks, or as CSV and Excel exports.
Brand and product names are trademarks of their respective owners and are used only to describe compatibility.
Eight typical projects, showing the machine, what we read, where the data goes and what it changes for the business.
Allen-Bradley CompactLogix · EtherNet/IPSiemens S7-1200 · S7 / OPC UATemperature controllers · Modbus TCPPower meters · Modbus RTU over RS-485Mitsubishi iQ-R · MC ProtocolOmron NJ · EtherNet/IP tagsAny PLC · run-hour & cycle countersiPad, iPhone & AndroidBefore we connect anything, we agree a tag map: which values to read from each machine, how to scale them and where each one lands. Here is what part of a typical map looks like.
| Business name | Machine / PLC | Protocol | PLC address or tag | Type & scaling | Destination |
|---|---|---|---|---|---|
| Line 1 good parts | Press 01 · S7-1500 | OPC UA | ns=3;s="DB_Prod".GoodCount | DINT | production_counts.good |
| Line 1 machine state | Press 01 · S7-1500 | OPC UA | ns=3;s="DB_Prod".State | INT · 0 stop, 1 run, 2 fault | machine_state.state |
| Press 02 hydraulic temp | CompactLogix | EtherNet/IP | Press02_HydTemp | REAL · °C | process_values.value |
| Filler 04 fault code | CJ2M · Omron | FINS | DM 200 | UINT | downtime_log.fault_code |
| CNC 03 recipe speed | iQ-R · Mitsubishi | MC Protocol | D100 | INT · ÷10 = m/min · write | from work_orders.speed |
| Main feeder energy | Power meter | Modbus TCP | HR 3203–3204 | FLOAT32 · kWh | energy_readings.kwh |
Collected values are stored in clean, documented structures, so your developers, ERP and reporting tools can use them immediately. Two illustrative examples:
CREATE TABLE production_counts (id BIGINT IDENTITY PRIMARY KEY,machine_id INT NOT NULL,order_no NVARCHAR(30),good INT NOT NULL,scrap INT NOT NULL,cycle_time_s DECIMAL(8,2),recorded_at DATETIME2 NOT NULL);
{"machine": "Press 01","order": "WO-10482","state": "running","good": 4812,"scrap": 37,"hydraulicTempC": 47.6,"timestamp": "2026-09-27T14:05:00Z"}Connect to your machines' PLC data from anywhere. Supervisors and managers see live status, counts and alarms on a secure mobile app or web dashboard, and alarms reach the right person the moment they happen.
Where you want it, authorised users can also send approved commands and set points from a tablet, always with confirmation, limits and a full audit log. Control at your fingertips, without giving up safety.
Connecting to production equipment demands care. These principles apply to every project.
We only read data unless writing is specifically required, approved and tested.
Machine networks are kept separate from office IT, with only the connections that are needed.
Readings are buffered locally during network outages and delivered when the link returns.
Any value written to a PLC is checked against limits, confirmed by a user and recorded.
Every configuration change and every write is logged with who, what and when.
We coordinate with your controls engineer or machine builder and never change PLC logic without approval.
A structured process that starts with your machines, not with a product.
We list each machine, its PLC model, firmware, available protocols and network, and agree what data matters.
Together we document every tag, its scaling and its destination, and design the database and integrations.
We build the connector, database and dashboards, test against live machines and validate the numbers with your team.
We roll out machine by machine, train your staff and support and extend the system as you add equipment.
No. We connect to the controllers you already have using their native protocols. New hardware is only needed for very old machines, and even then it is usually a small gateway or converter.
Many older machines can be reached over RS-232 or RS-485 serial, using Modbus RTU, Allen-Bradley DF1 or ASCII protocols, often through a serial-to-Ethernet converter.
Data collection is designed to be light on the controller. We tune polling rates, use subscriptions where the protocol supports them, and read at the PLC level so fieldbus networks are not disturbed.
Yes. We write into SQL databases your systems already use, or deliver the data through APIs, webhooks, MQTT or file exports, whichever your software supports.
Yes, where it is safe and approved. Writes are limited to agreed tags, validated against limits, confirmed by a user and logged.
Not unless you ask. Sometimes a PLC needs small configuration changes, such as enabling PUT/GET on a Siemens S7-1200/1500, and we coordinate those with your integrator.
Either. Data can stay on a server in your plant, go to a cloud database, or both.
Send us a list of your machines and PLC models. We will tell you how we can connect them, what data you can collect and how it can reach your software.
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