Sensor mismatch
The wrong sensor type or signal range produces unusable data, costing time and credibility before the first report is generated.
Custom Edge Connectivity Solution
Industrial monitoring requirements often do not fit a pre-packaged solution. Melqart Systems engineers the complete connectivity stack to defined requirements: selecting the right industrial sensors, choosing the telematics gateway that fits the environment, developing the gateway application for the protocol stack and data pipeline, combining the right communication interfaces, and connecting everything to an existing dashboard or deploying one that works from day one.
The Problem
Generic IoT kits fail real industrial requirements.
Industrial environments are not homogeneous. The required sensors, equipment protocols, site connectivity mix, and reporting platform all vary. Off-the-shelf IoT solutions are designed for common requirements and often do not address edge cases. The result is wasted integration effort, unreliable data, and expensive rework when the environment changes. Melqart Systems scopes each engagement to actual requirements rather than average assumptions.
Wrong gateway for the environment
Processing requirements, I/O count, and environmental ratings differ by use case. A single gateway SKU does not fit all.
Single-interface connectivity fails
LTE-only fails at sites with poor coverage. WiFi-only fails on mobile assets. Most real deployments require a primary and a fallback interface.
Dashboard integration is never trivial
Connecting a new data source to an existing platform always requires protocol translation, schema alignment, and authentication work that off-the-shelf kits do not handle.
The challenge
Where current approaches fall short
Sensor selection is a technical decision, not a product choice
Temperature, vibration, pressure, current, flow: every measurement type has multiple sensor technologies with different signal types, accuracy classes, and mounting requirements. Choosing the wrong one invalidates the data before it reaches the gateway.
The gateway model must match the use case
Telematics gateways differ in I/O count, processing power, connectivity options, and environmental ratings. Specifying the wrong model means under-provisioning for the workload or over-specifying and inflating unit cost across the deployment.
Connectivity environments are rarely uniform
A machine that moves between a factory floor with strong WiFi and an outdoor yard with LTE coverage needs a gateway application that manages both interfaces, handles handover, and buffers data during transitions rather than a device that simply drops packets.
Architecture
How Melqart Systems engineers the solution
Melqart Systems follows a structured process from requirements to production deployment, reducing uncertainty, over-specified hardware, and integration risk.
- 01
Assess
Define measurement requirements, environment constraints, protocols, and target platform
- 02
Specify
Select sensor types, gateway model, and connectivity interface combination
- 03
Develop
Build the gateway application with the required protocol stack, data pipeline, and connectivity management logic
- 04
Integrate
Connect to your existing dashboard or deploy and configure the provided one
What's included
What the Solution Delivers
A complete, production-ready connectivity system, not a development kit, prototype, or starter project.
Industrial Sensor Integration
Validated sensor selection and integration for your specific measurement requirements. Signal conditioning, wiring guidance, and calibration verification included.
Telematics Gateway, Selected for the Use Case
A telematics gateway sized to the I/O count, processing needs, connectivity, and environmental constraints of the use case. The custom application runs on it from day one.
Gateway Application Development
A purpose-built application developed for your gateway that handles your protocol stack, data normalization logic, local processing rules, and connectivity management including multi-interface failover.
Multi-Interface Connectivity Stack
The appropriate combination of WiFi, LTE, and Ethernet interfaces configured for the environment. Primary and fallback interfaces include intelligent switching and offline data buffering.
Dashboard Integration or Deployment
Integration into an existing SCADA, IoT platform, or analytics tool, or deployment of a ready-to-use dashboard with the required data, naming conventions, and alert thresholds.
OTA Management and Remote Diagnostics
Remote firmware updates, configuration changes, and live diagnostics without physical access. The gateway application is maintainable from day one.
Technical specifications
Gateway Options
Telematics gateway selected and sized by I/O count, processing needs, connectivity, and environmental constraints, from compact low-I/O units to high-I/O models for complex edge logic.
Connectivity Interfaces
WiFi 802.11 a/b/g/n, LTE/4G cellular with SIM management, 10/100 Ethernet. Any combination supported: WiFi primary with LTE fallback, Ethernet primary with LTE failover, tri-interface for maximum resilience.
Protocol Support
CAN bus, Modbus RTU/TCP, RS232, RS485, I2C, SPI, analog 4 to 20mA, digital I/O, NMEA 0183. MQTT, REST, and custom cloud protocols on the egress side.
Gateway Application
Custom Linux application developed for the gateway with configurable data pipeline: acquisition interval, local aggregation, threshold-based alerting, offline buffering, and automatic resync on reconnection.
Dashboard Options
Integration into existing platforms (Grafana, Losant, Ignition, custom REST APIs) or deployment of a pre-configured Grafana instance with your data sources, panels, and alerting rules.
Deployment and Management
OTA firmware updates via alloy-it. Remote configuration and diagnostics. Deployment scope from single-unit proof-of-concept to multi-hundred-unit fleet rollout.
Applications
Use cases and industries
Machine OEMs Adding Connectivity to New Models
OEMs designing connectivity into a new machine model need a validated sensor and gateway stack that can be documented in the BOM and replicated across production volumes. Melqart Systems defines the architecture, develops the gateway application, and delivers the reference implementation.
Retrofit Connectivity for Existing Equipment
Assets already in the field can be retrofitted with sensors and a gateway without modifying the original equipment. Melqart Systems specifies what attaches where and develops the gateway application that reads it correctly.
Mixed-Connectivity Deployment Environments
Sites with variable coverage such as outdoor yards, mobile assets, tunnels, and remote installations require a gateway application that manages multiple interfaces intelligently. Melqart Systems develops and tests the failover behavior before deployment.
Integration into an Existing Platform
Companies that already have a SCADA system, IoT platform, or analytics tool need a field layer that feeds data in the right format. Melqart Systems develops the gateway application to handle protocol translation, schema mapping, and authentication on the device side.
Proof-of-Concept to Production Scaling
A validated single-unit deployment with the correct architecture can scale to hundreds of units without rework. Melqart Systems builds the gateway application and the PoC with production constraints in mind from the start.
Software Companies Building Field Data Products
Analytics platforms and AI applications need reliable, structured field data. Melqart Systems provides the hardware layer and develops the gateway application so software teams can focus on the product rather than field integration.
Results
Key outcomes
“Engineered to defined requirements, not to an average deployment profile.”
- Validated sensor selection for your measurement type and environment.
- Telematics gateway matched to your I/O count, protocol stack, and compute needs.
- Gateway application developed specifically for your gateway hardware with your data pipeline, local logic, and protocol handling.
- Multi-interface connectivity with intelligent failover and offline buffering.
- Dashboard integration into your existing platform or a deployed, pre-configured dashboard.
- OTA-capable and remotely manageable from day one.
Solution datasheet
Custom edge connectivity
Sensors, Owasys gateway, gateway application and platform integration engineered to your requirements, and tested in a pilot before scaling.
MS-DS-CEC-2026-57 · PDF · 6 pages · English
Frequently asked questions
01Which telematics gateway should I choose for my project?
The gateway is selected and sized by I/O count, processing needs, connectivity and environmental constraints. Compact units suit deployments with few sensors, while higher-I/O models handle complex edge logic. Melqart Systems specifies the gateway as part of the engagement.
02Which protocols can a custom gateway application handle?
On the field side: CAN bus, Modbus RTU/TCP, RS232, RS485, I2C, SPI, analog 4 to 20 mA, digital I/O and NMEA 0183. On the egress side: MQTT, REST and custom cloud protocols.
03Can the gateway fail over between WiFi, LTE and Ethernet?
Yes. Any combination is supported, such as WiFi primary with LTE fallback, Ethernet primary with LTE failover, or all three for maximum resilience. Data is buffered offline and resynchronized automatically on reconnection.
04Can the data go into our existing dashboard?
Yes. Data can be integrated into Grafana, Losant, Ignition or custom REST APIs, or Melqart Systems can deploy a pre-configured Grafana instance with your data sources, panels and alerting rules.
05What are the steps of a custom edge connectivity project?
Assess the measurement requirements, environment, protocols and target platform; specify the sensors, gateway model and connectivity; develop the gateway application; then integrate with your dashboard. Scope ranges from a single-unit proof of concept to a multi-hundred-unit fleet rollout.
Define what needs to be measured and where the data must go.
Melqart Systems scopes the sensor, gateway, application, connectivity stack, and integration in a single architecture session, then defines the path to production.