Industrial Applications
Industrial Data Bridge Use Cases
Proven architectures linking PLCs, OPC servers, enterprise historians, and cloud systems on the plant floor. Eliminates ad-hoc integration scripts, standardizes JSON payloads, and runs 100% on-premise.
Technical Matrix
Technical Integration Matrix
Input protocols, in-memory transformations, outputs, and operational benefits.
| Industrial Application | Source Protocol | In-Memory Transformation | Destination Protocol | Operational Benefit |
|---|---|---|---|---|
| Plant Floor to Cloud (IIoT) | Siemens S7 / Modbus TCP / OPC UA |
Linear scaling, offset, and JSON synthesis | MQTT Broker (AWS, Azure, Viziodata) | No intermediary OPC server or hardware gateway |
| Direct OSIsoft PI System Bridge | OSIsoft PI Data Archive (Native PI SDK) |
Visual drag-and-drop & name auto-mapping | MQTT / OPC UA / Local Databases | Maximum native Windows throughput without lag |
| Secure Cross-Plant Tunnel (BridgeLink) | Local Instance (Plant A) |
Disk buffer (store-and-forward) over WSS | Remote Instance (Plant B / Central) | Zero data loss during WAN internet outages |
| Legacy OPC DA Modernization | OPC DA Servers (Windows COM/DCOM) |
Type casting and x509 encryption | OPC UA / MQTT / REST API | Eliminates DCOM network fragility and risks |
| Batch File Ingestion & Generation | Monitored CSV / DAT Directory |
Delimiter parse, column extract, timestamping | Live OPC UA / MQTT / PI System Tags | Full automation with zero manual data entry |
IIoT & Cloud
Plant Floor to Cloud & IIoT Gateways via MQTT
Direct telemetry acquisition from Siemens S7, Modbus TCP, and OPC UA controllers published as structured JSON with automatic recovery.
The Challenge
Machine PLCs and field meters speak proprietary or field protocols and cannot natively produce structured JSON messages or manage TLS encrypted sessions with enterprise cloud systems without expensive wrapper appliances.
The Solution
Luciai Multiconnector establishes direct socket connections to PLCs and field transmitters, applies mathematical scaling in-flight, formats JSON payloads matching cloud schemas, and publishes with QoS and auto-reconnection.
- Direct Ethernet ISO-on-TCP driver for Siemens S7-300, S7-400, S7-1200, S7-1500 without external OPC servers
- Independent collection groups to decouple high-speed process loops from slow monitors
- Dynamic hierarchical MQTT topic and JSON payload templating
- Local queue buffers and automated reconnect ensuring zero silent drops
Enterprise Historian
Native Bidirectional OSIsoft PI System Integration
High-throughput bridge linking OSIsoft PI Data Archive with modern field automation networks via native Windows PI SDK.
The Challenge
Ingesting new machine metrics into enterprise PI historians or delivering PI tags to edge analytical applications traditionally demands complex custom middleware and costly per-seat software drivers.
The Solution
Equipped with native PI SDK and PI SDK-COM drivers on Windows, Luciai Multiconnector browses PI tag hierarchies, executes high-speed batch reads and writes, and maps points directly to any target protocol.
- Native PI SDK access on Windows hosts delivering maximum throughput
- Integrated visual tag browser with real-time tag search and point inspection
- Full bidirectional support: read recorded/snapshot archives or write setpoints to PI
- Accelerated automated mapping by name and reusable project mapping templates
Multi-Site Operations
Encrypted Inter-Plant Data Tunneling (BridgeLink)
Resilient cross-facility telemetry transmission over encrypted WSS channels with disk buffering and zero tag-by-tag remaps.
The Challenge
Routing plant data between separate physical facilities or traversing enterprise DMZ zones requires complex VPN topologies, opening multiple firewall ports, and remapping hundreds of individual tags at intermediate nodes.
The Solution
BridgeLink establishes an encrypted peer-to-peer WSS tunnel between Luciai Multiconnector instances, routing data streams in transit with mutual certificate authentication and local disk queueing during WAN drops.
- Encrypted WebSocket Secure (WSS) tunnel with mutual certificate fingerprint validation
- Local disk buffer (store-and-forward) ensuring zero packet loss during network disruptions
- Stream-level forwarding eliminating repetitive tag-by-tag remap overhead at intermediate hops
- Real-time egress queue depth inspection and transmission bandwidth telemetry
Modernization
Legacy Modernization: Classic OPC DA to OPC UA and Cloud
Seamless bridging of legacy Windows COM/DCOM OPC servers into secure modern architectures without disrupting production systems.
The Challenge
Legacy machine controllers and SCADA HMIs rely on classic OPC DA and Windows DCOM protocols, which are fundamentally incompatible with modern network security, Linux servers, and cloud architectures.
The Solution
Luciai Multiconnector runs locally as a native Windows service on the host running the OPC DA server, accesses COM items locally without network DCOM, and securely exposes variables via modern x509 OPC UA or MQTT.
- Completely eliminates fragile, vulnerable remote DCOM network configurations
- Unified mapping catalog alongside all contemporary industrial protocol standards
- Non-disruptive migration path preserving existing working PLC logic and SCADA runtime
- Runs natively as a Windows background service (services.msc) with automated boot recovery
Batch & Laboratories
Industrial CSV / DAT Batch Ingestion and Automated Export
Automated translation of quality lab reports, dosing recipes, and scale logs into addressable real-time industrial variables.
The Challenge
Laboratory bench equipment, spectrometers, and weighing systems frequently record batch metrics only as delimited flat text files (CSV or DAT) on local shared folders, disconnected from the plant SCADA.
The Solution
The flat file driver monitors filesystem directories, ingests scheduled updates, maps file columns to virtual process tags, and streams the data directly into historians, HMIs, and analytics engines.
- Flexible directory polling schedules with support for diverse delimiter and header conventions
- Columns mapped directly into standard process tags with automatic linear scaling
- Automated scheduled file export for compliance reporting, auditing, and ERP synchronization
- Robust handling of localized decimal notations, delimiters, and ISO timestamp formats
FAQ
Frequently Asked Questions
Direct answers on what the product performs across plant floor environments.
How to stream Siemens S7 PLC or Modbus data directly to cloud via MQTT?
Luciai Multiconnector communicates natively with Siemens S7 controllers and Modbus TCP units, reads DB blocks or registers, scales and formats data in memory, and publishes structured JSON payloads to enterprise MQTT brokers or cloud endpoints.
Does Luciai Multiconnector support reading and writing to OSIsoft PI System?
Yes. On Windows hosts, the product includes native PI SDK and PI SDK-COM drivers, allowing bidirectional reading of snapshot/archive points or writing values directly into OSIsoft PI Data Archive.
How does the BridgeLink tunnel operate between distributed plant facilities?
BridgeLink pairs two Luciai Multiconnector nodes over an encrypted WSS tunnel, routing streams with local disk buffering (store-and-forward) so no telemetry points are lost during WAN network drops.
How to modernize legacy OPC DA servers without replacing existing SCADA systems?
The software runs on the Windows host running OPC DA, connects via local COM/DCOM, and securely exposes the variables as modern x509 OPC UA or structured MQTT streams across the network.
Use Cases
Talk to Luciai
Luciai Multiconnector is the industrial data bridge by Luciai Tecnologia: it reads from source, transforms when required, and writes to destination on-premise.