Patlite AirGRID

Patlite “AirGRID” × TAKEBISHI OPC Solution

In manufacturing sites, it is essential to visualize OEE by monitoring equipment operating status and to detect abnormalities in real time in order to respond quickly. However, many existing machines are not IoT‑ready, making data collection and analysis difficult in numerous cases.

This article introduces how to easily and cost‑effectively implement IoT for factory equipment by combining Patlite’s “AirGRID” with Takebishi’s industrial communication software "DeviceXPlorer OPC Server" and the IoT Gateway "DeviceGateway".

What Is AirGRID?

AirGRID is a system that adds wireless communication capabilities to Patlite signal towers, which are widely used in manufacturing sites, enabling operating status data to be collected over a network.

By attaching a transmitter (WDT series) to a Patlite signal tower, it can wirelessly communicate with the receiver "WDR‑PRO", allowing equipment status to be easily integrated with upper‑level systems.

Features

• Easy installation via wireless communication:Can be retrofitted onto existing signal towers.
• Acquisition of operating data:Lighting colors and patterns can be converted into digital data.
• Modbus support:Enables easy integration with external systems using a general‑purpose protocol.
   

Figure 1:AirGRID WD PRO System Image

However, to understand the operational status of not only equipment equipped with Patlite signal towers but the entire production line, it is also necessary to collect data from all devices, controllers, and sensors from various manufacturers on the shop floor. Supporting each manufacturer’s proprietary communication specifications requires significant time and cost—from understanding the specifications to implementing the communication programs.

Benefits of Integrating DeviceXPlorer OPC Server / DeviceGateway

AirGRID supports Modbus communication, allowing easy connection with our OPC Server and DeviceGateway. This integration provides the following advantages:

Data Visualization and Analysis
Operating information from signal towers can be aggregated into upper‑level systems via OPC UA or MQTT and visualized through dashboards and analytics tools.

Comprehensive Equipment Data Collection
In addition to signal tower data collected through AirGRID, the system can communicate with more than 400 types of devices—including PLCs, NC controllers, and robots.

Retrofit IoT Enablement for Legacy Systems
By attaching AirGRID to existing equipment and connecting through the OPC Server to MES or cloud systems, even legacy machines can be easily IoT‑enabled.

Application to Anomaly Detection and Predictive Maintenance
By analyzing historical operating data, abnormal trends can be identified at an early stage, helping reduce downtime.

Integration Architecture

Configuration Image:

AirGRID WDR PRO → Modbus communication → DeviceXPlorer OPC Server / DeviceGateway → OPC UA/MQTT/HTTP → SCADA, Cloud, BI tools

Figure 2:Configuration of AirGRID Integration with DeviceXPlorer OPC Server or DeviceGateway

Overview of Each Product

Industrial Data Integration Platform “DeviceXPlorer OPC Server”

• Software that converts data from control devices into OPC or MQTT formats and links it with upper‑level systems.
• Provides access to more than 400 series and over 100 vendors of control devices used in manufacturing sites (major PLCs: Mitsubishi Electric, Omron, Keyence, Yokogawa, Fuji Electric, etc.).
• Holds the No.1 market share in Japan with over 40,000 licenses sold; widely adopted both domestically and internationally.

IoT‑ready Data Access Unit “DeviceGateway”

• A unit that collects equipment information and bridges it to IoT services such as cloud platforms.
• Supports OPC UA, MQTT, HTTP, FTP, SNMP, and other protocols, enabling integration with a wide variety of IoT services.
• Provides access to more than 320 series of control devices used in manufacturing sites.

Configuration Details of Each Product

Please refer to the documentationhere.

Summary

By combining Patlite’s AirGRID with Takebishi’s OPC solutions, you can easily digitalize on‑site operational data and accelerate IoT implementation. The system can be retrofitted onto existing equipment and seamlessly integrated with cloud services, making it an ideal first step toward realizing a smart factory.

Products and Services Used

TAKEBISHI:  DeviceXPlorer OPC Server  DeviceGateway
Patlite: Wireless Data Collection System AirGRID WD (external link)

Configuration Details for Each Product: Please refer to the documentation here.