Smart IoT Gateway
Designed and scaled a rugged IoT gateway with optimized BOM and remote update capability.
This project showcases how Chipsemantics bridged the gap between legacy industrial infrastructure and modern cloud-connected operations. By combining ruggedised hardware design, multi-protocol firmware, and edge AI capabilities, we delivered a production-ready IoT gateway in just 16 weeks — enabling real-time visibility, predictive maintenance, and secure remote management across an entire device fleet.
Overview
Unlike simple LLM wrappers, this gateway is built with RAG and metadata-trained embeddings to deliver secure, accurate, context-aware answers from your data stack at scale.
The Problem
A mid-sized industrial automation company serving manufacturing and energy clients across APAC. The organization required a reliable, field-deployable IoT gateway to modernize legacy equipment and enable predictive maintenance initiatives without overhauling existing infrastructure.
The Challenge
The client faced several systemic constraints:
- Fragmented Legacy Systems: PLCs and sensors operating on Modbus RTU/TCP, CAN, and proprietary protocols.
- Limited Real-Time Visibility: Data was batch-processed, resulting in delayed insights.
- Security Vulnerabilities: No secure device authentication or encrypted cloud communication.
- Harsh Deployment Environments: High temperature, vibration, and EMI conditions.
- Scalability Constraints: Existing hardware could not support edge analytics or OTA updates.
→ The objective was to engineer a rugged, industrial-grade IoT gateway capable of protocol translation, edge computing, and secure cloud integration.
Our Solution
Chipsemantics designed and delivered a Smart Industrial IoT Gateway with the following capabilities:
- Multi-Protocol Support: Modbus (RTU/TCP), CAN, MQTT, OPC-UA
- Edge Processing: On-device filtering, rule engine, and lightweight ML inference
- Secure Architecture:
- Hardware root of trust
- TLS 1.3 encryption
- Secure boot & OTA firmware updates
- Cloud Integration: Native compatibility with AWS IoT Core and Azure IoT Hub
- Remote Device Management: Fleet monitoring dashboard and diagnostics
Our Process Timeline
Results We Delivered
89%
Accurate Results
Achieved 89% protocol translation accuracy across Modbus, CAN, and MQTT in live industrial deployments, reducing data loss and misrouted packets significantly.
10,000+
Users Worldwide
The gateway platform is now actively deployed across 10,000+ connected devices in manufacturing facilities spanning APAC, Europe, and the Americas.
100%
Customer Satisfaction
Delivered on time and within budget. The client reported full satisfaction with the product quality, documentation, and post-deployment support provided.
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