RS-485 Data Logging with the Neousys POC-610
How an automation specialist uses a compact box PC to capture serial machine data, forward it to the cloud via MQTT, and lay the foundation for predictive maintenance.
The Challenge
A mid-sized special-purpose machine manufacturer operates 24 CNC milling machines and lathes of various ages in its production hall. The older machines (built between 2005 and 2015) have no Ethernet interface — only RS-485 ports for serial communication.
The problem: Machine downtimes were only noticed when an operator reported the fault. Operating data such as spindle speed, feed rate, and temperature could only be read locally at the machine. No central monitoring existed.
The Solution: POC-610 as Protocol Bridge
The integrator chose the Neousys POC-610 — a compact, fanless box PC with a native RS-232/422/485 port and three 2.5 GbE Ethernet interfaces. The system runs a lean Linux with Node-RED and Mosquitto MQTT broker.
Data Flow Overview
↓
POC-610 — Node-RED: Modbus-Read → JSON Mapping → MQTT Publish
↓
Factory LAN (2.5 GbE) → MQTT Broker → Cloud Dashboard (Grafana)
Why the POC-610?
Native RS-485 Port
Software-switchable between RS-232, RS-422, and RS-485 — no USB adapter needed, reliable in continuous operation.
Compact & DIN-Rail
Fits in any control cabinet next to the machine controller — DIN-rail or wall mount installation.
3× 2.5 GbE Ethernet
Three network ports enable network segmentation: one for the machine VLAN, one for the office network, one for management.
Fanless, -25 to +70 °C
No dust, no wear — maintenance-free 24/7 operation in dusty manufacturing environments.
Results & Key Metrics
After three months of operation, the benefits of centralized machine data acquisition are clearly visible:
Each POC-610 reads up to 8 Modbus RTU slaves via the RS-485 bus at 5-second intervals. The data is buffered locally and forwarded via MQTT to a Grafana dashboard. When thresholds are exceeded (e.g., spindle temperature > 85 °C), an automatic notification is sent to the shift supervisor.
The next step: integrating the newer Ethernet-capable machines via OPC UA — also on the POC-610, which provides sufficient computing power and network ports for this task.
Does your project have similar requirements?
Whether RS-485, CAN bus, Modbus TCP, or OPC UA — we will find the right industrial PC for your data acquisition. Our experts provide vendor-independent advice and configure your system ready for operation.
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